Upgrading a PCS7 Conveyor System
As part of a comprehensive modernization project, gefeba was commissioned to completely overhaul the existing control system of a main transport line at the steel mill. The existing PLCs, which dated back to 2006, were to be replaced with a current version of Siemens PCS7 without disrupting the proven process flows. A particular challenge was migrating numerous functions—which had evolved over time and were individually programmed—into modern standard APL blocks. At the same time, the entire functional safety system had to be updated and fully integrated into the new control architecture.
gefeba analyzed all existing functions of the conveyor system and migrated them to modern, maintainable, and expandable PCS7 standard structures. In the process, all relevant central and communication modules were modernized, and the entire functional safety system was reimplemented based on modern F-System technology. In addition, gefeba integrated the existing weighing technology to bring it up to the current technical standard and completely rewrote the PCS7 application program. At the same time, all WinCC visualization screens were thoroughly revised and converted to a modern 16:9 format. The entire process control system was integrated into a virtualized server structure. This resulted in a sustainable improvement in the operational reliability, flexibility, and scalability of the IT architecture. Close coordination with the functional departments, as well as the iterative development of the functions, ensured that existing processes were maintained while simultaneously implementing the highest technical standards.
The comprehensive modernization resulted in a high-performance, future-proof automation platform for the main transport system at the steel mill. The new PCS7 architecture improves maintainability, increases system availability, and provides a stable foundation for future expansions. Thanks to modern F-System technology, virtualized server structures, and standardized software modules, operational reliability has been sustainably increased and the system’s long-term scalability has been ensured.
Why Customers
Choose to Work with Us
We develop customized solutions—from analysis through the engineering phase to commissioning and support. Our focus is on maximum functionality, on-time delivery, and durability.
Our project work is supported by collaborations with leading technology partners such as Siemens, Rittal, B&R, and Proxmox, which provide the technological foundation for our project results and help expand them.
