Electrical control systems are the heart and soul of your manufacturing and assembly line equipment. They are the central point of command and control. Using buttons, switches, and screens, control panels help operators safely and efficiently run equipment.
But what happens throughout the years as repairs come and go? Are the wires tucked back into place, or are they left to hang all over? Did you begin with a defined schematic, but now you must guess how everything connects? Does your outdated control panel system impede technological compatibility? How does that help efficiency in your business?
Throughout the years, there have been many technological advancements in industrial control panel systems. What started as rudimentary in the 1800s has evolved to incorporate greater safety features, touchscreen control, and human-machine interfacing. Processes have become more streamlined as the technology has advanced, but not every industry has kept up to date. What is the overall cost of out-of-date processes to your business?
Control Systems Through the Ages
Mid-20th-century control panel systems consisted of large arrays of electromechanical relays, timers, and switches to handle large loads of current. While being a marvel of engineering, these control systems were bulky and could be difficult to troubleshoot and modify. Modifications often required complete rewiring, making upgrades expensive and time-consuming.
With the rise of digitization starting in the mid-to-late 1900s, programmable logic controllers (PLCs) revolutionized industrial control panel systems. PLCs helped to solve the challenge of needing to use several relays to control one machine. PLCs also had the memory capacity to preserve loaded programs during power outages and were built to handle tougher industrial environments.
Supervisory Control and Data Acquisition (SCADA) systems were also created around the same time, used to gather data from industrial equipment and optimize production. Employees no longer needed to be attached to their stations at the machines to supervise processes, helping to reduce overhead costs.
Stepping into the 21st century, Human-Machine Interfacing (HMI) became a key aspect of modern control panel systems. User-friendly touchscreens and graphics improved how operators monitor and control industrial processes using real-time data. This change improved machine control and enabled remote monitoring and data collection, leading to Industry 4.0 systems.
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Modernizing Control Systems
Technological shifts have progressed rapidly during a relatively short period of time. Machines have evolved, and components within control panel systems have been modified or repaired. The result? Control panel systems that are hard to navigate, difficult to troubleshoot, and are prone to failure.
The more repairs a control panel receives, the weaker the entire system can become. If the control panel even had a plain-language schematic to begin with, it can easily become outdated. This could lead to safety problems, lower efficiency, increased maintenance costs, and plant closures while troubleshooting. Modernized control panels offer remote access and control. Predictive maintenance can find issues early and diminish downtime.
A Company That Builds Relationships
Regardless of industry, it is important to find a reputable company that can help you determine the right course of action to ensure that your systems run as smoothly as possible. Since starting their company in 2005, Control Works, Inc. has been helping customers to clean up the clutter and revitalize their control panel systems.
The specialists at Control Works work closely with clients to understand their specific needs, offering responsive support and tailored solutions that larger companies often can’t match. From a simple motor starter to a fully integrated automation system, the specialists have you covered. All control panel systems are built to the highest industry standards, UL508A Certified, ensuring safety, compliance, and reliability.
Control Works specializes in developing PLC programs that are powerful, intuitive, and easy to understand. Their code is structured, well-documented, and designed for long-term maintainability, so your company can manage the systems for years down the road.
Control Works Bring Order to Chaos
The journey from relay logic to modern PLC-based control panel systems is a testament to the progress of industrial automation. Often, with progress comes complexity, and complexity needs smart, reliable solutions. Control Works is here to help whether you’re upgrading aging equipment, building new systems, or tidying a messy panel. And they will provide you with comprehensive, easy-to-understand schematics for future use.
Take control of the chaos with a company that is committed to excellence in panel design, fabrication, and programming. Control Works excels in control panel systems and press brakes, earning customer trust through reliable service. When Control Works does the job, you get more than just a service, you get a comprehensive solution that is clean, compliant, and built to last.
Contact Control Works today to find out more of what they can do for your control panel needs.
