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Option two carefully repairs the existing control system when failures occur using well stocked spare parts shelves, careful planning, and a little bit of luck.

This can often be the lowest cost path, but eventually the shelf will be empty and an upgrade or retrofit will be required.

FIGURE 1: BRADBURY DESIGNED AND BUILT THIS AUTOMATIC COIL PROCESSING LINE WHICH UNCOILS, LEVELS, CUTS TO LENGTH, AND STACKS THE CONVERTED PRODUCT.

THE PATENT PENDING E-DRIVE, USING A HYDRAULIC ROLLER LEVELER, PROVIDES COMPLETE CROSS-SECTIONAL STRESS ELIMINATION OF THE WEB.

Option three identifies critical hardware and then upgrades select devices while some existing and supportable equipment remains in place.

Careful engineering and integration can make this a cost-effective solution with minimal downtime.

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For example, in the article, the Bradbury Group ( builders of the metal processing equipment pictured in Figure 1 and other machines, keeps extensive program backups and obsolete hardware needed to keep its customers’ legacy equipment operating.Table 1 lists reasons to upgrade instead of replacing a control system.Many of these reasons are discussed in the real-world application examples below.“We first duplicated the controls, supported them through the life of the system, then re-programmed the machine with all new hardware, but with the identical look and feel,” says Lindley.The inspection system consisted to two cameras mounted perpendicular to each other.

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