Modernizing production-critical motion control without interrupting production.
A global aerospace manufacturer needed to replace obsolete motion technology supporting two aircraft wing assembly systems. Across four phased installations, Concept Systems modernized more than 170 coordinated servo axes while working within five-day production shutdowns. The result was a more reliable, maintainable motion platform designed to support increased production demands.
Challenge: Modernizing Obsolete Motion Control Technology
A large aerospace manufacturer needed to replace obsolete motion control technology on two systems supporting aircraft wing assembly. The existing systems relied on Allen-Bradley Kinetix 6000 servo drives and SERCOS technology. With Kinetix 6000 discontinued by Rockwell Automation and no longer available for sale, modernizing the platform had become increasingly important for long-term reliability, serviceability, and access to replacement hardware.
On the surface, the objective was straightforward: migrate the aging technology to a modern platform. In practice, the retrofit involved more than 170 coordinated servo axes and years of existing software and field infrastructure that had to continue working together seamlessly.
Drawing on its knowledge of the customer’s manufacturing environment, Concept Systems developed a migration strategy that went far beyond hardware replacement. Thousands of software tags, motion parameters, HMI interfaces, and network communications had to be evaluated and validated before installation.
With production demands increasing, system reliability was critical. The new platform needed to reduce the risk of unplanned downtime while providing the confidence and maintainability needed to support a higher production cadence.
Solution: Kinetix 5700 Motion Control Migration
Concept Systems partnered closely with Rockwell Automation and NorthCoast Distribution to execute the modernization across four phases, upgrading the legacy Kinetix 6000 platform to a Kinetix 5700 architecture supporting more than 170 coordinated axes of motion.
Each installation had to be completed within a five-day holiday production shutdown, leaving little margin for unexpected issues in the field. Concept Systems invested heavily in pre-engineering, validating software conversions, motion configurations, HMI updates, network communications, and hardware integration before each shutdown. This preparation allowed potential issues to be identified early and minimized commissioning risk while production was offline.
The solution incorporated Allen-Bradley Kinetix 5700 servo drive axis modules, CompactLogix 5380 Safety Controllers, ControlLogix 5580 Safety Controllers, EtherNet/IP communication modules, and Feedback Converter Kits.
Close collaboration between Concept Systems, Rockwell Automation, and NorthCoast Distribution brought together the engineering, automation, and hardware expertise needed to execute each complex migration within the customer’s limited installation window.
Results: Improved Reliability and Long-Term Maintainability
All four retrofit phases were completed within their scheduled five-day holiday shutdowns, modernizing production-critical motion systems without extending planned downtime or disrupting production schedules.
Replacing the discontinued Kinetix 6000 platform with the actively supported Kinetix 5700 architecture extended the useful lifecycle of these critical systems while reducing the maintenance and sourcing risks associated with obsolete hardware. Standardizing the platform also allows the manufacturer to maintain readily available spare components, improving long-term serviceability and reducing the risk of extended downtime.
The modernization improved diagnostics and maintainability while increasing confidence in system reliability. With downtime presenting less production risk, the manufacturer is better positioned to support a substantially higher production cadence and pursue more aggressive throughput targets.
At the scale of this operation, the impact extends beyond individual equipment uptime. Reliable positioning systems help keep major aircraft assemblies moving through production, where avoiding even a single day of unplanned downtime can represent significant manufacturing value.
The project also established a proven approach for modernizing complex legacy motion systems, demonstrating how experienced engineering, careful pre-planning, and close technology partnerships can provide a repeatable path forward for critical aerospace manufacturing infrastructure.
Technology Used
- Allen-Bradley Kinetix 5700 servo drive axis modules
- CompactLogix 5380 Safety Controllers
- ControlLogix 5580 Safety Controllers
- EtherNet/IP communication modules
- Feedback Converter Kits
Is obsolete motion control hardware putting your production at risk?
Aging or discontinued technology like Kinetix 6000 can create challenges with reliability, replacement parts, and long-term support. Concept Systems can help develop and execute a modernization strategy that minimizes downtime while moving your critical systems to actively supported technology.