Industrial Automation increases efficiency and reduces costs in production. However, many control systems are outdated and need to be updated to remain competitive. This is where the Migration of automation systems takes place.

In addition, the Migration also allows the integration of new electrical control elements and drives, which contributes to increasing the energy efficiency of the plant and reducing operating costs.

Migrating an automation system does not have to intervene directly in the facilities and processes that are in use. That is to say, the company continues to operate while the entire improvement and updating process is developed.

In this article, we will talk about the different aspects involved in migrating an automation system, from the basic concepts to the specific steps to migrate a STEP 7 project to TIA Portal.

What is an automation systems migration?? 

Automation Systems Migration is the process of modernizing an obsolete automation system. This can be done through a retrofit, which is updating the system components and software, or through a complete migration to a new system. 

The objective of Migration is increase efficiency, reduce operating costs, improve process quality and accuracy, and increase plant safety. 

Instead of investing in a completely new system, Migration allows you to take advantage of existing infrastructure while updating and integrating it with new control elements. 

It is a detailed process that includes the design and integration of PLC programming, the electrical integration of new control elements and drives, the installation and integration into the industrial network, the migration of HMI screens, the factory commissioning, the migration of OT architecture, industrial communication protocols... 

This strategy, in addition to being profitable, minimizes the impact on production and reduces plant downtime. 

What is a PLC migration?

A PLC (Programmable Logic Controller) is a programmable electronic device used in industrial automation systems to control processes and machinery. 

PLCs are an essential part of industrial automation, and many automation systems depend on them for their operation. 

PLC Migration is a process that involves changing an obsolete programmable controller for a more updated model. 

It is necessary when old models are no longer compatible with new systems and have been discontinued or simply cannot handle the current workload. Next-generation technologies such as wireless communication or the integration of intelligent systems or IIoT can also be implemented.

How is a PLC migration performed?

The PLC Migration process involves several phases: 

1. Previous analysis: It is necessary to carry out a detailed study of the system that you want to migrate, analyzing the system architecture, the devices and components that are used, the software that is being used and the communication protocols. 
2. Planning: Deadlines, necessary resources, work team must be established and the migration procedure defined. 
3. Design: of the new system architecture by selecting the new components and devices to be used and establishing the new communications. 
4. Unwiring and hardware wiring- Unwiring the old hardware and rewiring the new hardware. 
5. PLC software conversion: You must carry out the conversion from the old to the new and check that it has been done correctly and that the new software meets the system requirements. 
6. Commissioning and testing- Testing is necessary to verify that everything is working correctly.  
7. Documentary writing: All steps carried out in the migration must be documented for future reference of the system, including: plans, diagrams, diagrams and manuals. 

How to migrate a project from STEP 7 to TIA portal?

It is the conversion of the existing STEP 7 project to TIA portal, the latest automation platform. Siemens that offers a greater efficiency and flexibility. Below are the steps to follow in the migration: 

1. Make a backup copy of the original project in STEP 7. 
2. Create a new project in TIA Portal and select the “import” option in the file menu. 
3. Select the project file generated by STEP 7 and follow the instructions of the import wizard. 
4. Verify that all project elements, such as function blocks, programs, and configurations, have been imported correctly. 
5. Perform a complete review of the project in TIA Portal to verify that everything is working correctly. 
6. Perform necessary testing and adjustments to ensure that the project works optimally. 

It is important to note that migration can be complex and requires advanced knowledge in PLC programming and the use of TIA Portal software.  For this reason, it is advisable to have the help of industrial automation specialists to guarantee the success of the migration project. 

Advantages of migrating your automation system

• Improvement in efficiency and productivity.  
• Reduces operating costs. 
• Optimization of production processes. 
• Improving the energy efficiency of the plant.  
• Less downtime, thanks to the new automatons.  
• More consistent, precise and higher quality production. 
• Increases plant safety. 

Téciman and Industrial Automation 

In Teciman We provide our clients with tools to manage their facilities in a close and friendly way. 

We customize control systems to improve productivity and efficiency in industrial environments, automating all types of processes. 

Thanks to the latest generation technologies we can control and monitor industrial processes, using tools from leading brands such as Siemens, Rockwell, Omron, Schneider Electric…. Through own developments Our engineers implement programs that guarantee optimal operation. 

Can digitize any line phase and represent the most important variables of the process through visual tools such as HMI, SCADA Systems and DCS. 

We design and implement industrial communication networks under different communication protocols such as Ethernet/IP, PROFINET, DeviceNet, PROFIBUS, CANOpen, EtherCat, MODBUS… 

We have extensive experience in updating and optimizing obsolete automata, making modifications to any type of automated systems, adapting them to the client's needs.   

Consult in detail our capabilities in the Web and contact us by phone 947 20 91 41 and mail teciman@teciman.com . We tell you about our projects on LinkedIn: Teciman International