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Client: Aluminium Manufacturer
Industry: Metals / Aluminium Processing
Location: Belgium
Scope: Control system upgrade – medium performance servo application
Obsolete Reliance Electric control system replaced with a modern, fully supported platform.
Enhanced shear performance delivering smoother, more consistent cuts.
Reduced maintenance requirements and improved long-term reliability.
Minimal disruption to production during upgrade implementation.
Cost-effective approach leveraging existing equipment where possible.
“iconsys did a great job optimising the shear cycles and improving the system beyond the original specification.”
— Engineering Manager, Aluminium Manufacturer
A leading aluminium manufacturer in Belgium had been progressively modernising its colour coat line control systems, replacing ageing Reliance Electric AutoMax PLCs with modern Allen-Bradley ControlLogix platforms.
However, one crucial section, the exit rotary shear, still relied on its original Reliance Electric AutoMax control system. Over time, this legacy system had become increasingly difficult to maintain. Spare parts were scarce and costly, and the obsolete software could no longer be modified or optimised.
The client required a reliable, cost-effective upgrade that would be compatible with the rest of the line, while ensuring minimal downtime and production risk.
iconsys was commissioned to deliver a modern, compatible, and efficient control solution for the rotary shear system. Leveraging the Allen-Bradley ControlLogix platform, which offers integral motion control capabilities, iconsys implemented an M02AE dual-axis control card to deliver precise, high-performance motion control.
Within the RSLogix 5000 environment, iconsys developed a custom rotary knife cam generator Add-On Instruction (AOI), forming the core of the new shear control system.
To address specific operator challenges and improve performance, several advanced motion control features were incorporated, including:
Where feasible, existing equipment was retained, including the analogue variable speed drive and DC motor, supported by a stock of spares.
This approach minimised project costs and avoided introducing unnecessary risks associated with replacing proven components.
The project successfully replaced the obsolete Reliance Electric control system with a modern, integrated ControlLogix solution.
Key outcomes included:
Reliable operation with fully supported, up-to-date hardware and software.
Smoother, more consistent shear performance.
Reduced maintenance effort and improved long-term serviceability.
Minimal disruption to production during the upgrade.
iconsys was selected for its proven expertise in control system migration and motion control solutions.
By combining in-depth knowledge of both legacy Reliance systems and modern Rockwell Automation technology, iconsys delivered a low-risk, cost-effective upgrade that aligned with the client’s broader digital modernisation programme.
The project demonstrates iconsys’ ability to enhance performance and reliability while maintaining production continuity; a scalable approach that can be replicated across similar process line upgrades.
“The PLC and software upgrade of our rotary shear was very successful – on time and to specification. iconsys did a great job. They put a lot of effort into optimising the shear cycles and even went beyond specification by not just translating the existing software into the new PLC, but improving it at the same time. The result was, and still is, that the shear is working much better and smoother than before the upgrade.”
— Engineering Manager, Aluminium Manufacturer
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