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Control Migration

Migrations and retrofits of control systems in existing production lines — replacement of obsolete PLCs, drives and communication networks without the need to purchase new machinery.

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Control system migration and retrofit

RCE Automatyka carries out migrations and retrofits of control systems in existing production lines. The service involves replacing obsolete PLCs, drives and communication networks with modern, supported solutions.

The goal is to eliminate the risk of production downtime and increase efficiency without the need to purchase new machinery. RCE integrates new systems with Industry 4.0 solutions, provides access to production data and prepares the installation for further expansion.

Full control system migration of a relocated machine

The Challenge

An automotive industry client was operating with end-of-life automation components. The machine had been relocated from another of the client's plants, and the lack of spare parts and manufacturer support threatened extended production downtime.

  • Old servo drives with low performance and difficult diagnostics
  • PLC forming a bottleneck on the line, with limited memory preventing further development and integration
  • Outdated or incomplete technical documentation

The Solution

RCE carried out a full control system migration of the relocated machine, from the drive layer through to the technical documentation.

  • 1.
    New servo drives and positioning modules: Replacement of end-of-life drive components with modern, supported solutions
  • 2.
    New communication network: Implementation of a newer-generation communication infrastructure supplied by the manufacturer
  • 3.
    New PLC controller: Installation of a control unit eliminating the previous line bottleneck
  • 4.
    PLC programme rewrite: Control logic optimised for the new platform
  • 5.
    New EPLAN documentation: Preparation of up-to-date, complete technical documentation
  • 6.
    Current safety standards: Implementation of solutions compliant with applicable norms including NIS2/CRA requirements

Client Benefits

The control system migration ensured production continuity and access to modern, supported components, together with readiness for integration with the Smart Factory environment.

Benefits achieved:

  • Production continuity — elimination of downtime risk through supported components and permanent access to spare parts and manufacturer service
  • Higher reliability — modern controllers and drives reduce failure frequency and ensure stable, predictable line operation
  • Easier maintenance and diagnostics — clear EPLAN documentation and optimised PLC programme
  • Energy savings — modern servo drives consume less energy than older solutions, reducing operating costs
  • Data access and integration — production data collection, online diagnostics and MES/SCADA integration
  • Compliance and security — conformity with current technical standards and NIS2/CRA cybersecurity requirements

No new machinery needed

Modern control with full EPLAN documentation compliant with NIS2/CRA

Control system migration of an industrial machine
New PLC control cabinet after migration
0

New machines needed

NIS2

Compliant

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