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RS Components
Siemens PLC Upgrade
In February 2008 MCS Control Systems were contracted by RS Components in Nuneaton to upgrade one of their Siemens PLC's in the One-Liner area from the S5 range to the current S7-300 range. The S5 PLC Rack included an interface to their Dematic Warehouse Management System to alert FLT drivers that they are required to collect an order from the area. This functionality was to be replicated in the S7 PLC.
On the initial site survey, the existing S5 PLC code was uploaded and the system functionality was verified and recorded. The software was then converted to S7 and internally tested using simulation software against an agreed set of testing requirements.
The One-Liner PLC is critical to the warehouse operation and this transplant had to be approached with each phase planned in detail along with contingency plans in place to minimise any downtime.
During commissioning, our first step on site was prove the WMS interface by using data logging software to capture and analyse Dematic's bespoke message telegrams and the interface was proven without the need for expensive WMS changes. Rigorous functionality and exception handing tests were carried out to validate the robustness of the PLC software prior to launching into production
Working closely with the End User the new S7 PLC was tested and installed over a 3 weekend period with no down time and disruption to production.