Controls Systems Upgrade for High-Volume Grease Metering System
January 22, 2021
Project Features:
Process Controls System Upgrade, Mitsubishi PLC, Grease Metering and Dispensing System, Grease Application
Streamlining Production with an Engineered Grease Dispensing System Solution
When component obsolescence threatens a high-volume production line, a precise controls systems upgrade is vital to maintaining operational continuity. For a leading transportation equipment manufacturer, a failing legacy control interface across three plants required an immediate, turnkey intervention. Discover how ACS utilized its custom equipment process to flawlessly modernize the manufacturer’s grease metering system, integrating new Mitsubishi PLCs with existing field infrastructure to deliver a standardized, reliable grease dispensing system without disrupting planned production schedules.
The Challenge
An industry leader in conventional and intermodal transportation equipment manufacturing faced a critical operational bottleneck due to component obsolescence. The company needed to replace the legacy control system components and enclosures for their existing grease metering systems across three of their primary manufacturing plants. The original PC-based control systems had reached the end of their lifecycle, threatening production continuity and critical grease application processes. The client’s objective was to transition to standardized Mitsubishi PLCs while requiring the new system’s operations and functionality to remain identical to their legacy setup. A primary constraint of the project was that all field instrumentation and equipment external to the control panel, including high-precision flowmeters, solenoid valves, drum level switches, and stack lights for each automatic grease dispenser, had to remain unchanged. This required the incoming solution to seamlessly interface with existing infrastructure without causing any disruptions to the tight plant production schedules.
The Solution
The first step of the ACS engineering team was to initiate a collaborative design phase utilizing our custom equipment process. This structured methodology was critical to uncovering the exact operational parameters required to accurately replicate the legacy system’s performance for every grease application on the line. To build the foundational framework for the controls systems upgrade, the ACS team worked closely with the client’s stakeholders to collect and validate critical technical data, including:
- Part numbers and technical specifications for existing flow meters to ensure the selection of appropriate input modules and accurate flow measurement programming
- A comprehensive control sequence to guarantee the identical functionality of the modernized grease metering system
- A complete breakdown of legacy Human-Machine Interface (HMI) screens to perfectly mirror user interaction and vital process data
- An exhaustive I/O list with precise wiring details to generate flawless schematic designs
- A detailed mapping of data exchange between the control platform and external databases or Mechanical, Electrical, and Plumbing (MES) systems
Leveraging this data, ACS engineered and manufactured three new process control systems to manage each plant’s automatic grease dispenser. Each system featured a robust NEMA 12 industrial control panel housing the Mitsubishi PLC, an intuitive HMI, and all necessary internal control components. To manage risks and ensure a rapid deployment, a complete Factory Acceptance Testing (FAT) runoff was conducted at the ACS manufacturing facility, where all external field equipment was dynamically simulated. Following a successful runoff, ACS managed the physical installation and commissioning at all three plants. The deployment was meticulously synchronized around the client’s production schedule to ensure the controls systems upgrade did not interfere with planned manufacturing operations. Furthermore, ACS provided dedicated, on-site engineering support during the critical first production day for each system to guarantee a seamless transition.
The Outcome
The ACS team delivered a fully integrated, turnkey controls systems upgrade that successfully modernized the manufacturer’s automated assembly lines without disrupting daily plant operations. By replacing the obsolete hardware and software with a standardized Mitsubishi PLC platform, ACS eliminated the risks associated with unsupportable components and extended the operational lifespan of the client’s capital equipment.
The three newly commissioned control panels provide identical functionality across all three plants, ensuring a consistent user experience for operators and a standardized architecture for maintenance teams. Through precise programming and meticulous integration with the existing field hardware, the new panels maintain absolute control over every automatic grease dispenser, ensuring accurate grease application and metering on the active production lines.
By utilizing the ACS custom equipment process, the client received comprehensive drawing packages and complete software documentation, leaving them fully equipped for long-term operational success. The engineered solution successfully optimized the client’s grease metering system, providing a stable, reliable foundation for their high-volume transportation equipment manufacturing lines.
Key Features
- Modernized process control system for automated axle grease application and metering on active production lines
- Comprehensive controls systems upgrade replacing obsolete PC-based hardware and software with Mitsubishi PLCs
- Seamless controls integration with legacy field instrumentation and mechanical systems
- Identical operational functionality deployed across three separate manufacturing plants
- Replicated HMI screens to maintain user familiarity and ease of operation
- Delivery of complete drawing schematics and software documentation for the upgraded automatic grease dispenser setup
ACS Services
- Controls engineering and design
- Control panel build and assembly
- Integration with client’s existing equipment
- Factory Acceptance Testing (FAT) via simulation
- Onsite commissioning and first-day production support
