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Control Migration — Automotive Headlamp Reflector Vacuum Metallizer

Automation Allen-Bradley Controls Migration Automotive Lighting

A vacuum-metallizing machine that aluminizes plastic headlamp reflectors for a leading automotive lighting manufacturer was running on an obsolete Siemens TI 545 PLC with an aging UniOP HMI. I migrated control to Allen-Bradley CompactLogix with a larger PanelView Plus 6 touchscreen, replicating the full multi-stage vacuum sequence with a 5-day commissioning window and no throughput loss.

Scope of Work

  • Migrated the Siemens TI500 PLC to a CompactLogix L3ER.
  • Migrated the UniOP HMI to a 15" PanelView Plus 6.
  • Replicated the multi-stage vacuum-metallizing sequence: rough vacuum → crossover → fine vacuum → preheat → flashing → plasil coat → vent.
  • Commissioned within 5 days without reducing throughput.

Architecture

The vacuum-chamber sequence — rough/fine vacuum, glow discharge, filament preheat, aluminum flashing/evaporation, plasil top-coat, and chamber vent — is monitored from a single PanelView screen showing live vacuum gauges and pump/valve states.

Technology

  • Allen-Bradley CompactLogix L3ER
  • PanelView Plus 6 (15")
  • EtherNet/IP