Control System Rebuild for Tyre Manufacturing Machine: Siemens S7-1500T Platform Migration
Sector:
Tyre Manufacturing & Processing
Type:
New Build - Control System, Software, Obsolecence Upgrade
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl designed, built, and commissioned a replacement control system for a tyre manufacturing machine, migrating the control platform from obsolete legacy Siemens equipment to a modern Siemens S7-1500T CPU with SINAMICS S120 servo drives and ET 200SP distributed I/O. The project included a fully engineered new control panel, bespoke PLC and motion control software, a full documentation package, factory acceptance testing, and site installation and commissioning.
Challenge
A tyre manufacturing facility needed to address obsolescence in the control system of one of its production machines. The existing equipment — comprising a SINUMERIK 840DI CNC module, Simodrive 611 drive rack, and S7-300 ET200 remote I/O — was no longer supportable and required replacement.
The customer required a complete rebuild of the machine's control panel, with the control architecture redesigned around a current Siemens platform. Safety control, previously handled separately, was also to be integrated into the new PLC. Existing field devices, motors, and cabling were to be retained wherever possible.
Solution
DelaControl designed and built an entirely new control panel, migrating the machine's control architecture to a Siemens S7-1500TF CPU with SINAMICS S120 servo drive system and ET 200SP distributed I/O over ProfiNET — replacing the legacy RS485 communications bus. A notable engineering decision was the selection of the S7-1500T platform in place of a direct SINUMERIK ONE equivalent: following investigation into the machine's control philosophy, DelaControl determined that the same motion control capabilities could be achieved with the S7-1500T CPU, simplifying the architecture and reducing cost.
The panel was built at DelaControl's Bristol facility in a Rittal VX enclosure suite. Weidmuller terminals, Siemens protective devices and contactors, and WAGO interface relays were used throughout. Six equivalent Siemens 1FK7 servo motors (across three frame sizes) were also supplied as part of the project. A SIMATIC IPC427E industrial PC and a Siemens MTP1900 Unified Comfort Panel HMI were included in the delivered system.
DelaControl developed new PLC and motion control software based on ghost images of the existing controller code, recreating like-for-like control logic on the new platform. A full documentation package was produced, including electrical schematics, general arrangement drawings, a Declaration of Conformity, inspection and test schedule, thermal calculations, and a SISTEMA report (ISO 13849-1 safety performance level assessment).
Prior to delivery, the panel was tested at DelaControl's facility using I/O simulation and test motors, with the customer invited to a formal factory acceptance test. DelaControl then attended site to disconnect the existing panel, reconnect field cables to the new panel, and commission the system.
Key Facts
Siemens S7-1500TF CPU selected as main controller, with SINAMICS S120 Active Line Module and servo drive system
ET 200SP distributed I/O: 11 digital input modules, 3 digital output modules, 4 relay output modules, 2 analogue input modules, 1 RTD/TC analogue input module, 2 analogue output modules, 3 fail-safe digital input modules, 2 fail-safe digital output modules
Six Siemens 1FK7 servo motors supplied: 2x 1.5 kW, 3x 2.3 kW, 1x 3.3 kW
ProfiNET communications replacing legacy RS485 bus
Three-enclosure Rittal VX panel suite (800 W, 1000 W, and 1200 W bays)
Siemens MTP1900 Unified Comfort Panel HMI and SIMATIC IPC427E industrial PC included
SISTEMA report (ISO 13849-1) and full Declaration of Conformity produced
Site installation (field cable reconnection) and commissioning included in scope
400 A incomer with NH fuse switch-disconnector