Siemens S5 to S7 conversion

Timing Belt Manufacturing Machine

The Scenario :
The customer was running a plant with obsolete Automation which led him into production crisis in terms of quality and productivity. Then customer approached Cotmac for a solution.
Cotmac representative visited the facility to understand the pain points from the customer, and to study the existing running system.
Cotmac’s Findings:
  • The system was running on an obsolete S5 -115U CPU.
  • The Turn Table was running on Stepper motor which was not providing the desired accuracy.
  • The wiring from the control panel to the turn table motor was through Drag chain which was reducing the communication speed.
Cotmac’s Solution:
  • The PLC system was upgraded from Existing S5 to S7 CPU.
  • The Turn Table was running on Stepper motor which was not providing the desired accuracy.
  • The wiring from the control panel to the turn table motor was through Drag chain which was reducing the communication speed.
  • The communication between the main control panel and turntable was upgraded from physical connection to wireless.
  • The Profibus communication protocol was replaced with Profinet.
  • Cotmac converted the old S5 PLC Program to the new S7 with new Functionality.
Benefits to Customer:
  • Reduced production downtime due to use of Latest Hardware.
  • Increased accuracy with the use of Servo motor.
  • Increased Productivity.
  • More access to the system statistics with the help of advanced UI.
  • Increased reliability.

Automatic Storage and Retrieval System

What was once upon a time considered to be a state of art plant, had gone through the normal action of getting phased out by newer technologies.
Here was an opportunity for Cotmac to step in and offer their knowledge and expertise in aiding the customer to enhance his production capabilities.
In the above scenario, expertise in S5 as well as S7 systems was a crucial requirement – specific to the solution and upgradation strategy required for successful execution of the project. Local presence was vital as well.
And Cotmac fulfilled all these expectations.
Cotmac’s Solution:
  • Phase wise upgradation of the S5-115U system at the Coil Cars, Cranes and Master System
  • Conversion of S5 to S7 and upgrading to the S7 400 system
  • Up-gradation from S5-115U to S7-400 system for 2 Cranes
  • Application S5 software converted to S7
  • Replacement of the serial communication with Ethernet communication.
Client’s Success:
Our clients were delighted with the smooth execution of the entire project, with minimum shutdown time, and strong support services round the clock. They were highly impressed with the statistical data that was now being presented to their team, thus enabling them to take better and proactive decisions.

Integration made Easy