Case Study: Coil Setting and Testing Station


Setting and Testing Station 

Servo Upgrade


An automotive parts manufacturing plant produces shock absorber springs for the automotive industry. It’s Setting and Testing machine used outdated servos and amplifiers that were major contributors of downtime. Something had to be done to resolve downtime on the machine and improve replacement part availability issues. ONYX was contacted to modernize the servo drives and motors for the system.







[Inset Descriptive Title]


[Inset Descriptive Title]

The Problem

Obsolete motion control equipment was identified as a frequent point of failure on the heavily utilized Setting and Testing station. Availability of spare parts and vendor support was also limited due to obsolescence. This led to significant downtime when failures did occur. The operation reliability and testing accuracy of the system was questioned with all of the issues as it was important to maintain the quality standards of their product.

The Solution

Onyx Engineering upgraded the servo system and motors with latest state-of-the-art Servo drive system. The 4 existing servo motors, and their 75-foot cables were replaced with new servos, amplifiers, and cables. The PLC program was updated with new motion logic routines and the existing HMI was updated with servo controls and additional diagnostic screens for quick troubleshooting.


The Results

The Setting and Testing System upgrade significantly improved the performance and reliability of the existing equipment. With a user-friendly HMI in place it is easier to troubleshoot PLC and Servo drive issues.  The overall system uptime and OEE was increased.

Project Details



About 24 months




                   Client: 1 PM                                                    

Onyx: 1PM, 1 S Engineer,  1  Controls Engineer







Services Provided

Control Engineering and design

Control panel modifications

PLC/HMI/Motion programming 

AutoCAD Electrical documentation 

 Installation, Start-up and commissioning




Allen-Bradley ControlLogix 5580PLC

Allen Bradley Kinetix 5700 Servo Drives

Rockwell FactoryTalkView ME

Allen Bradley PanelView Plus 1250 HMI