Industrial Controls Upgrades
Automation | Process | Motion | Building Management | Safety | Machine
At Rise Automation, we specialise in upgrading existing control systems often improving performance and reliability. Whether you require a full system overhaul or targeted upgrades to key components, our team is ready to deliver solutions that are reliable and robust. We collaborate closely with you to ensure each upgrade integrates seamlessly with your existing setup, providing improved functionality and longevity.
Electrical Drawings
Our electrical designers will review your existing drawings and create new schematics that incorporate all upgrade work ensuring your machine is ready to be maintained for the next phase of its operational life.
Software
Upgraded operating and diagnostic interfaces significantly increases machine usability by minimising the time needed to identify stoppages and providing access to historical performance supporting proactive maintenance.
Integration
Modern controllers allow for greater system integration, simplifying machine complexity while enhancing the reliability, durability, and overall robustness of the control system. reducing the risk of operational disruptions.
Before
After
When a servo system with an integrated PLC failed, we took the opportunity to modernise the entire control and operator interface. The solution involved replacing the obsolete unit with a Siemens S7‑1200F CPU paired with a CU250S Position Controller. This upgrade significantly improved the machine’s control precision and diagnostic capabilities, while also laying the groundwork for future expansion and integration. The S7‑1200F’s safety features enabled full monitoring of safety circuits and allowed isolation of the remaining variable frequency drives (VFDs) in line with current industry standards, ensuring both compliance and operational reliability.
Our blog explores the pros and cons of upgrading controls versus purchasing new machinery, offering guidance on how to make the best decision for your business. > Read
Siemens Control Systems
Trusted across global industries for advanced PLC, HMI, and SCADA solutions, ideal for complex, high performance applications.
Omron Automation
Compact, flexible systems with excellent motion, safety, and vision capabilities, perfect for fast paced production environments.
Allen Bradley (Rockwell)
Heavy duty PLCs and intuitive HMIs, widely used in large scale manufacturing and process automation.
Mitsubishi Electric Controls
Reliable, cost effective systems with strong motion control, well suited to UK and European production standards.
Custom PLC & HMI Programming
From basic control panels to full production line integration, we build bespoke systems around your process and equipment.
Retrofit & System Upgrades
Breathe new life into legacy machinery with modern controls, improving reliability, efficiency and data visibility.
SCADA & Remote Monitoring
Gain full control and visibility of your system, view diagnostics, trends, and alarms in real time from anywhere.
Servo & Motion Control
Achieve precise movement and synchronisation, essential for robotics, pick & place, labelling and packaging tasks.
Profinet
An industrial Ethernet standard developed by Siemens, offering fast, deterministic communication ideal for high speed automation and real time data exchange in complex production environments.
Profibus
A widely used fieldbus protocol for reliable serial communication between devices, ideal for connecting PLCs, sensors, actuators, and drives in established or retrofit systems.
EtherNet/IP
Developed by Rockwell Automation, this protocol enables real time control and device level communication, commonly used in Allen Bradley systems.
EtherCAT
An ultra fast, low latency Ethernet protocol ideal for motion control and time critical applications, popular in robotics, CNC systems, and high speed packaging lines.
Modbus (RTU & TCP/IP)
A simple, robust protocol for connecting industrial devices, ideal for SCADA systems, HMIs, and interfacing between third party equipment and control panels.
CANopen
A reliable fieldbus used in embedded control systems and motion networks, often found in machinery where compact, distributed control is needed.
DeviceNet
A low cost network used mainly for sensor and actuator communication in Allen Bradley systems, supports easy integration in standard factory automation tasks.
Conveyors
Cobot Palletising
Control Cabinets