When a leading aerospace composites manufacturer faced the challenge of modernizing a late-1980s coating line equipped with obsolete DC motors and a CompactLogix PLC, they turned to EDC for a comprehensive retrofit and upgrade. The aging system, with components nearly 35 years old, posed significant risks of failure and operational inefficiencies. To address these challenges, EDC replaced the DC motors with modern AC equivalents, upgraded to a Safety CompactLogix PLC, and installed a new HMI to streamline operations. Through a phased turnkey approach, including pre-installation preparation and a tightly coordinated one-week shutdown, EDC delivered a safer, more reliable, and efficient system—completing the project two days ahead of schedule.

Problem

The client’s coating line faced critical challenges stemming from outdated technology and limited operational flexibility. Six legacy Parker SSD DC drives formed the backbone of the system but had become increasingly prone to failure. Replacement parts for these drives, which were four or five generations old, were no longer manufactured, forcing the client to rely on costly repairs or aftermarket solutions. The operator interface consisted of manual knobs, dials, and meters, requiring operators to input up to 30 parameters manually for each recipe change—a time-consuming process prone to error.

The existing CompactLogix PLC (Allen-Bradley/Rockwell Automation) was functional but not safety-rated, limiting the line’s compliance with modern aerospace standards and preventing advanced diagnostics. The lack of an Ethernet-based control network made it difficult to capture real-time manufacturing intelligence. The drives’ outdated connectivity further compounded the problem, requiring serial cable programming instead of high-speed Ethernet protocols.

Solution

EDC executed a comprehensive, staged approach to modernization that addressed the client’s challenges while ensuring minimal disruption to operations. The project began with extensive planning, including collaboration with a local mechanical design firm for mechanical updates and careful pre-installation work during an initial visit. The final retrofit was completed during a one-week shutdown just three months later. Key elements of the solution included:

Key Upgrades

Results

The modernization of the coating line delivered significant improvements in safety, reliability, and operational efficiency. By converting the outdated DC motors to AC and introducing modern controls, EDC eliminated the risks associated with legacy technology and enhanced the line’s functionality. The new Safety CompactLogix PLC provided advanced diagnostics and safety zoning, allowing operators to isolate specific areas of the line without interrupting production.

The updated HMI replaced a cumbersome manual interface, reducing operator errors and providing repeatable operation with recipe functionality. Previously, operators had to manually set up to 30 parameters; with the new system, they could simply select a recipe from the HMI, saving time and improving quality. Additionally, the Ethernet-based network enabled real-time process monitoring, providing the client with valuable manufacturing intelligence.

Despite the challenges of limited access to the line and a strict deadline, EDC completed the project two days ahead of schedule. The client was so impressed with the results that they awarded EDC three additional projects at the same facility, and a fourth at another facility, further cementing the partnership.

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