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Client: Aerospace Prime
Client Type: End user
Industry: Commercial Aerospace
Location: UK
Scope: Crane control system retrofit and communication upgrade
Improved communication reliability across all crane operations
Removal of obsolete Mauell units and bus bar communication systems
Reduced production downtime and maintenance requirements
Streamlined signal flow via modern wireless I/O architecture
Simplified system design ensuring long-term reliability and scalability
The client operated a complex creep crane system comprising two gantry cranes in a master-slave configuration, each equipped with two cross-travel hoist crabs. All crane movements were controlled via a radio hand-held operator panel, which interfaced with a PLC on the master crane through relay logic.
Originally, communication between the master crane and the cross-travel crabs relied on Mauell I/O units transmitting signals across a bus bar and collector system. This legacy bus bar communication system had become increasingly unreliable, frequently causing unplanned downtime and maintenance interruptions.
The master crane also communicated with the slave crane via a radio link, which in turn connected to its own cross-travel hoist crabs through a second set of Mauell I/O units. This layered communication structure introduced multiple potential failure points, limiting overall system performance and reliability.
The client sought a complete modernisation of the crane communication and control network to improve reliability, eliminate obsolete components, and reduce downtime without requiring extensive physical rewiring or long production halts.
Leveraging iconsys’s extensive experience in automation modernisation and wireless industrial communication, we proposed a simplified and more reliable control architecture that eliminated the root causes of system instability.
All Mauell I/O units and associated bus bar communication systems were removed, making the existing bus-based infrastructure redundant. In their place, iconsys installed Siemens remote I/O modules at each key location, connected to the central PLC via a robust industrial wireless network.
This approach provided direct, high-speed communication between the master crane PLC and all remote I/O points across both cranes—eliminating the need for intermediary relay signals or radio links between cranes.
With each crane and hoist crab equipped with its own wireless connection, the traditional radio communication between the master and slave cranes was also removed. This significantly simplified system architecture and reduced the amount of hardwired I/O.
The new system enabled seamless signal flow from the slave hoist crab I/O directly to the master crane PLC, improving responsiveness and reducing latency while also cutting down on hardware complexity.
iconsys worked closely with the client’s operations and maintenance teams to deliver a smooth transition. The upgrade was planned and executed within the scheduled shutdown period, ensuring minimal disruption to production. All systems were fully commissioned and tested prior to handover.
The modernised crane control system has delivered significant improvements in communication reliability, operational uptime and overall system simplicity.
Improved communication reliability throughout the factory
Reduced downtime thanks to the elimination of obsolete hardware and failure-prone bus systems
Simplified maintenance and diagnostics, reducing operational costs
Enhanced scalability, providing a foundation for future system expansion and digital integration
“We’re extremely pleased with the results. The new system is far more reliable and efficient. iconsys completed the design, installation and commissioning well within the shutdown window, enabling production to resume ahead of schedule.”
– Maintenance Manager
The client chose iconsys for our proven expertise in control system modernisation and multi-vendor automation integration. Our deep understanding of complex communication networks, combined with our ability to deliver turnkey retrofit projects, made us the ideal partner for this challenge.
By combining engineering excellence with flexible project management, iconsys ensured that the full upgrade was completed within the limited shutdown window—without compromising on quality, reliability, or performance.
This successful project further demonstrates iconsys’s ability to help manufacturers transition from obsolete, failure-prone systems to robust, future-ready automation solutions that improve uptime, safety, and long-term operational efficiency.
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