Finding and integrating modern control and safety systems to upgrade a legacy steel coil processing line
To modernize a legacy inspection and repair line for steel coils, Contec was entrusted with a full electrical revamp for a steel manufacturer located in the Liège region. The client’s original setup was controlled by two console-mounted cabinets and a third relay-based electrical cabinet operating two DC motors via DC drives. This outdated setup posed both operational limitations and safety concerns.
Our solution focused on engineering a safe and efficient system using modern control platforms and automation standards.
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Reverse engineering of legacy machine functionality
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Field check of electrical cabinets, motors, and sensors
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Functional and safety analysis
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Integration of Siemens safety PLCs and DC drives
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Development of electrical schematics using EPLAN P8
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Specification and delivery of safety components (light curtains, safety locks)
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Electrical installation and commissioning
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Training for client personnel
The challenge
Helping our customer ensure safety and reliability on a legacy production line
The legacy system was built around DC drive technology, which is increasingly rare in modern industry. The goal was to implement a safer, more reliable system without impacting the existing mechanical setup.
Moreover, integrating functional safety, including safe speed monitoring and modern operator protection, was vital to comply with current standards and ensure personnel safety during line operations.
Our approach
From legacy complexity to modern precision
Our team began with a detailed technical audit of the existing system, including reverse engineering of undocumented machine functions and field checks of all critical components. This insight guided the design of a new electrical control system using Siemens safety PLCs and modern DC drives.
Cable calculations, functional safety development, and EPLAN P8 schematics formed the backbone of our engineering documentation. We provided a complete construction package to the contractor and oversaw the on-site installation in partnership with a local contractor.
New safety locks and light curtains were installed to protect operators, while our team commissioned the system and trained the client’s staff for a seamless handover.
All electrical cabinets were built, tested, and validated at the cabinet builder’s site before delivery, ensuring smooth on-site integration.
