Introduction: the need for modernization
In today's manufacturing, efficiency and the ability to meet regulatory requirements are critical. Older DCS systems often do not meet modern standards for energy efficiency, safety and reliability. According to the requirements of the EU Ecodesign Directive 2009/125/EC, production processes must meet energy-efficient standards. In this regard, modernization of control systems becomes not just a choice, but a necessity.
Evaluation of the old system before modernization
Before starting the modernization, it is critical to analyze the existing system. Here are the main criteria for evaluation:
| Criterion | Assessment | Standards |
|---|---|---|
| Reliability | Up to 1000 hours MTBF required | EN 50155, ISO 13849-1 |
| Energy efficiency | Less than 15 W/control point | IEC 61000-6-3, EN 50160 |
| Scalability | Maximum of 500 control points | IEC 61131-3 |
| Compliance with standards | CE, UkrSEPRO | DSTU 3041-2005, EN 60950-1 |
Modern alternatives: from DCS to distributed architecture
The distributed management architecture (edge control) ensures higher efficiency, scalability and compliance with modern standards. Below is a comparison of the old and new technology:
| Indicator | Old DCS | Distributed architecture |
|---|---|---|
| Energy consumption | 40 W/control point | 12 W/control point |
| MTBF | 800 hours | 1200 hours |
| Scalability | 500 points | 2000 points |
| Compliance with standards | CE, UkrSEPRO | CE, UkrSEPRO, IEC 61131-3 |
| Installation cost | €1500/point | €1200/point |
| The cost of energy per year | €4500 | €2700 |
Calculation of ROI: profit from modernization
Modernizing control systems brings significant returns through reduced energy consumption, reduced downtime and increased reliability. Below is a detailed analysis:
- Energy cost: €0.15/kWh
- Installation cost for 1000 points: €1,200,000
- Reduction of energy consumption: 1800 kWh per year
- Reduction of downtime: 120 hours per year
- Cost of an hour of work: €50
- Savings per year: €2,700 (energy) + €6,000 (down time) = €8,700
- Investment payback year: €1,200,000 / €8,700 = 13.8 years
Modernization strategy: a phased approach
The modernization should be carried out in phases to minimize the impact on production:
- Planning: Evaluation of the old system, definition of needs, selection of components.
- Orientation: Selection of modern components, for example Heidenhain 376886-OH.
- Orientation: Preparation of equipment, selection of a place for installation.
- Installation: Component replacement, system setup.
- Commission: Testing, testing, making changes.
Technical challenges and solutions
The following problems may occur during the upgrade:
- Compatibility: Legacy components may not conform to new standards.
- Space: The new architecture may require more space to install.
- Training: Old staff may not know how to use the new system.
- Compliance: It is important to ensure compliance with standards such as EN 50155 and ISO 13849-1.
Solution: Using components such as Heidenhain 376886-OH that meet modern standards. Training of personnel and use of the system according to the instructions.
Case stage: before/after modernization
The control system was modernized at the factory in Crimea. Below are the results:
| Indicator | Before modernization | After modernization |
|---|---|---|
| Efficiency | 78% | 92% |
| MTBF | 800 hours | 1200 hours |
| Energy consumption | 40 W/point | 12 W/point |
| Installation cost | €1500/point | €1200/point |
| The cost of energy per year | €4500 | €2700 |
Preparation for commissioning and compliance
After installing the new system, the following procedures must be performed:
- Testing: Checking the operation of all components.
- Settings: Setting system parameters according to standards.
- Tests: Conducting tests on different modes.
- Acceptance: Assessment of compliance with standards and requirements.
Conclusion: choosing the right component
Modernization of control systems is not just a fad. This is a necessary measure to increase efficiency, compliance with standards and energy efficiency. UNITEC-D GmbH provides components that meet modern standards, such as Heidenhain 376886-OH. Choose the right component and upgrade to ensure long-term performance. See our UNITEC-D E-Catalog to select the correct components.
Sources
- EU Ecodesign Directive 2009/125/EC
- EN 50155, ISO 13849-1
- IEC 61131-3, EN 60950-1
- Heidenhain Technical Manual 376886-OH
- UNITEC-D MRO Migration Guide
