Customer Highlights Client with Three Legacy Controlled Casting Pits

Client with Three Legacy Controlled Casting Pits

Methodical Casting Pit Systems Upgrade

Industry Metals

Product/Material Handled Casting pit materials

System Deliverables

Legacy System Reverse Engineering

Working from aging GE 9030 PLCs and HMIs, the team reconstructed control narratives and drawings-building a clear modernization roadmap for all three casting pits.

Advanced CompactLogix Implementation

Rockwell CompactLogix controllers and PanelView Plus HMIs brought predictive speed algorithms and tighter PID control to every area of the operation.

Segmented Ethernet Network

Each casting pit got its own Stratix switches and segmented networks, keeping communication clean and reliable between PLCs, HMIs, and remote I/O.

Results in Action

Enhanced Process Control

Predictive and PID-based algorithms took a lot of guesswork out of casting, keeping operations consistent and product quality steady.

Efficient Installation and Changeover

Comprehensive documentation and on-site supervision made installation fast, and the system switchover nearly seamless-with minimal downtime.

Future Scalability

The updated platform sets the stage for ongoing modernization and a potential plant-wide Ignition rollout for better visibility across the board.

  • Perhaps most importantly, this satisfied client has already engaged the team to continue their modernization efforts elsewhere in the plant and to investigate an area or facility-wide Ignition solution for enhanced supervisory control in the future.

    — Magnum’s Controls & Process Automation Group Case Study Narrative
  • Magnum’s Controls & Process Automation Groups’ methodical approach to systems upgrades was exactly what the revised solution required. Their team worked onsite to reverse-engineer the existing systems by interviewing the client’s staff, reviewing the physical connections inside the panels and in the field, and conducting a detailed review of the data code. Based on this investigation, they developed controls narratives and plans for the eventual equipment installation.

    — Magnum’s Controls & Process Automation Group Case Study Narrative
  • It was a simple yet elegant solution that leveraged all the strengths of the Rockwell Automation platform in a powerful yet small form factor that fit the needs of the application both logically and physically.

    — Magnum’s Controls & Process Automation Group Case Study Narrative
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