The project included the design, programming, testing, and commissioning of a new PLC and HMI software solution as part of the ongoing modernization of the rolling mill control system.
This phase represented the final step of a multi-stage upgrade initiative at the site, all implemented by AIC, and has fully replaced the existing ABB PLCs with Allen-Bradley ControlLogix-based systems. The scope of work included
• Full development and implementation of new PLC logic for the rolling mill, shears (CV70, CV30, CVM05), and auxiliary systems
• Seamless integration with existing systems such as RHF and WTP
• Conversion and optimization of all existing logic for improved troubleshooting
• Interface with profile gauge systems
In parallel, a new server-client HMI system has been deployed, offering high-resolution screens, enhanced troubleshooting capabilities, and central supervision via ThinClient architecture, using ThinManager. Existing HMI projects have been migrated into the new application to ensure continuity and operator familiarity.
AIC has also integrated the existing iba system into the upgraded mill control architecture, enabling advanced real-time and offline data analysis through ibaPDA and ibaAnalyzer tools. This has improved diagnostic and operational efficiency.
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