Allen Bradley System Integrator: Connecting Industrial Equipment for Better Performance 

In order for your industrial machinery to run effectively they also needs to work in conjunction with each other. Having multiple control systems means that you can easily manage and monitor your production processes. An Allen Bradley system integrator will have the knowledge to set up your automation components.

Often within manufacturing environments, there will be situations where you will need to add more equipment, upgrade automation components, or change production processes. If you do not have the relevant experience, you may encounter problems regarding control integration. The aim of these projects is to bring everything together to streamline your production.

Overview of Industrial System Integration

The concept of industrial system integration is to connect and have all of your machines, controllers, sensors, devices and more work together to communicate.

Allen-Bradley system integrators will use compatible automation components and technologies to create the control system. They will look at what is currently being used for production, program, interface, network and test the system to give you a final product.

As an illustration, if a production line comprises multiple machines that must operate in a particular sequence for the process to function, integration makes it possible for them to interface and pass signals to each other concerning operating parameters. The resulting configuration is a control system that is intuitive, easier to oversee and operate, and easier to troubleshoot and has potential for growth.

Challenges with Industrial Automation

A number of facilities encounter difficulties with automation because their production activities do not lend themselves to seamless interaction and operation.

Equipment that Operates in Isolation

When machines operate in isolation, it may become difficult for human operators and automated systems to monitor the production process with ease, determine when a given machine is in standby, or identify possible production line bottlenecks. By contrast, integration installs connections that tie related equipment together, putting relevant information right at the operator’s fingertips.

Outdated Technology and Limitations

Control equipment and software that do not have the capacity to communicate with other automation components can limit the production potential of a given facility. In addition, replacement parts and components may also be unavailable due to the system being outdated.

A qualified system integrator can evaluate the existing setup and identify whether modifications, upgrades, or a complete overhaul would be a more viable option.

Restrictions in Production Monitoring

Lack of suitable monitoring equipment can make it hard for a manufacturing supervisor to identify developing malfunctions and stop production processes, resulting in waste and reduced yield. By installing suitable monitoring and recording applications, control engineers can gain greater insight into the ways production processes unfold.

Troubleshooting Production Flaws

Automation systems and equipment that are poorly programmed, with confusing alarm set-ups and difficult to troubleshoot will slow down the process of getting equipment repaired and replaced. Good programming, documentation, and alarm set-ups will make it easier and faster to get equipment repaired.

Automation Services that are Worth Considering

Depending on a given facility’s infrastructure and production needs, system integration can comprise a number of services.

Programmable Logic Controller Programming

Programmable logic controllers (PLCs) are devices that employ customized programming to control a broad range of automation equipment. Through them, machines and sensors can relay and process information and react depending on given parameters, thus establishing a production sequence of sorts. An Allen-Bradley system integrator is able to program and configure PLCs as well as perform troubleshooting and maintenance tasks.

Well-documented programming can further enable system operators to troubleshoot production issues and react accordingly. Considerations should also be built in for emergency stops, interlocks, alerts, and troubleshooting activities.

Operator Interface Configurations

At its most basic level, an operator interface (HMI) is a device that enables an operator to manipulate a machine. A well-designed interface makes it easy for operators to view data about machine functionality without having to sift through irrelevant information.

By comparison, a poor interface design can limit production and add to general process delays. Screens should be developed using best practices, including consistent layouts, recognizable symbols, informative prompts, appropriate screen organization, and intuitive navigation.

Network Infrastructure

The industrial network provides a single point of control and monitoring for operators and engineers. It enables communication between PLCs, drives, sensors, operator interface, and monitoring stations. We may need to understand what our requirements are for the network, including security/safety requirements. How large is our capacity? How much can we expand?

Automation Reports & Data Analysis

Supervisory Control and Data Acquisition (SCADA) systems allow information to be presented to industrial plants/facilities in a graphical format, whilst also providing reports. When set up correctly, it allows operators, engineers, and supervisors to gain as much information as possible about irregularities and trends within the process.

Therefore, depending on the nature of the project, networked monitoring applications can allow facilities to analyze trends, address alarm signals, and detect recurring operational problems.

Modernization of Control Systems

When control systems need to be modernized, a number of considerations come into play, including cost and time. Instead of replacing equipment, a system integrator can identify specific areas that can be upgraded. In short, the goal is to identify specific limitations as well as opportunities. Therefore, modernization projects encompass a range of aspects: replacing programmable logic controllers, programming upgrades, interface replacements, and network infrastructure.

In considering a control system modernization project, there will be a number of factors to consider. These include compatibility, project timelines, cost-benefit analysis, and maintenance expectations. In general, modernization projects are broken down into specific areas depending on a given business’s needs.

The Benefits of Integration Projects

In practical terms, a good integration project can ensure there is more consistent production, greater clarity regarding the status of production, less time spent maintaining equipment, better production coordination, and potential for growth. However, these advantages are ultimately dictated by the specific integration solutions that apply to a given situation, the nature and integrity of the equipment, and the extent to which it fits the specified needs of the host enterprise.

Planning Activities for an Integration Project

An experienced Allen-Bradley system integrator has the knowledge to develop a system that meets a given company’s objectives within the constraints of the existing production environment. This includes:

Reviewing Existing Equipment Capabilities

The initial review process involves determining the compatibility parameters between different equipment as well as the overall scope of improvement, including any production goals the project intends to achieve. In a real-world application, an experienced professional would be able to identify the gaps and limitations between PLC programming, drives, interface requirements, networking, and the general suitability of existing components. For instance, an engineer will be able to recommend interface and networking components based on a production line’s communication capabilities.

Establish a Plan

The next phase entails establishing the main aspects of the project, including the anticipated behavior of existing equipment. Furthermore, system specifications, testing and implementation procedures, and timelines should be stipulated. It is at this stage that appropriate safety considerations are factored into the project.

Configure and Program

The next step is to configure and program the various components in line with the established parameters. Existing programs, for instance, may need to be modified or expanded to allow for new equipment additions. During this phase, operators and maintainers should be given training regarding the system’s features.

Test Programming

Programming and configuration will be tested to make sure the system behaves the way you expect it to, devices can talk to each other, and things like alarms work. A qualified designer should have included the correct safety aspects when programming.

Commissioning and Documentation

The newly configured system can be commissioned according to the planned schedule. Technical documentation, programming and commissioning should be taken into account so that maintainers can make the most of the new system, identify problems and change it.

Finding the Right Kind of Partner

There are a number of considerations when searching for potential engineering partners. An ideal partner will have the appropriate experience with regard to the planned project and general industrial expertise. In short, they should recognize the intricacies and technical requirements involved, as well as the practical aspects and limitations that may exist within the equipment or production framework. As such, an initial assessment regarding past experience concerning similar equipment, control configurations, and infrastructure constraints should be taken into account. During the evaluation stage, questions concerning project planning, programming, testing and commissioning activities, documentation, and general maintenance considerations should also be taken into account.

Beyond experience, it is important to establish the extent to which integration will disrupt the production process when installing a new system. For some facilities, installation work can only be carried out when production activities are at a standstill. Other projects, on the other hand, may require that equipment be modified or adjusted incrementally depending on production schedules. Finally, it is also essential to consider post-commissioning support since the process of testing, troubleshooting, configuring applications, or additional integration in the future may be necessary.

Final Thoughts

An Allen-Bradley system integrator utilizes different facets of automation equipment specification and programming to help streamline industrial production processes. In short, system integration projects can span a broad range of requirements depending on the needs of the host facility. Through careful planning and implementation, system integrators can help organizations achieve seamless production and stay ahead of potential maintenance and expansion needs.

Frequently Asked Questions

1. What does an Allen Bradley system integrator do?

They are experts in programming and configuring different facets of automation equipment so that they are compatible with each other and achieve a company’s objectives.

2. Can system integration help a facility minimize production halts?

Although good system maintenance can minimize occurrences of production issues, system integration has limited ability in this regard.

3. Can a facility integrate new automation elements into an old system?

Depending on the suitability of existing equipment, it may be possible to make additions or modifications without having to scrap the entire infrastructure.

4. What is the benefit of industrial communications?

Networked infrastructure ensures that PLCs, machinery, computers, and other applications share and receive data about the production process,

5. What information does a system integrator need to perform their job?

Existing equipment capabilities, including drive type, operator interface requirements, safety necessities, and the anticipated improvements, should be highlighted.