Control System Upgrades & Replacement

AAA offers control system upgrades for existing machine controls of all ages. Normally, an existing control system is evaluated to determine what (if any) existing components can be utilized in the new system. A proposal is then submitted listing the work to be completed and the cost of the project.

AAA then designs a replacement system, incorporating all of the features requested by the customer. When the design is complete, AAA obtains the necessary components and completes all required shop work for the project.

AAA personnel then travel to the customers location and remove the existing system and associated wiring. New wiring and components are installed as necessary to complete the project.

AAA remains on site once the installation is complete to provide start up support and training for the new system.

AAA then delivers a complete documentation package for the new system.



Existing control cabinet and several existing components were incorporated into the new design to substantially reduce the project cost

Material Handling  Control System at Plastics Manufacturing Plant

Customer wanted to add two more stations to existing material handling control system.

  • Extremely disheveled installation made troubleshooting very difficult.
  • No electrical drawings existed.
  • Control program locked by OEM – customer has no access for expansion / troubleshooting.
  • Existing spare I/O was not useable
  • Removed old system, identified, and labeled all existing wiring.
  • Provided new control panel with sufficient I/O for current and future anticipated needs.
  • NEATLY installed all wiring.
  • Provided customer access to PLC and HMI programs for troubleshooting and future expansion.
  • Provided complete “as installed” documentation package.

Batching and Mixing System Upgrade at Pipe Manufacturing Plant

  • Outdated mostly manual system required extensive operator intervention and highly trained operators.
  • No electrical drawings existed.
  • Only manual record keeping for batch parameters.
  • Removed old control system.
  • Designed, built, and installed new control panels.
  • Developed PLC and HMI programs for batching and mixing operations.
  • Automated system requires minimal operator training and delivers consistent results.
  • Complete “as installed” documentation package provided.
  • Customer has access to all programs for future troubleshooting or system expansion.
  • Remote access possible for troubleshooting assistance.
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