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A digitally controlled pressure regulator that was critical to their process had failed, and a direct replacement was no longer available.

The failed unit was controlled via an 8 bit parallel data word, and a strobe bit, from a PLC. Although mechanically identical, the replacement unit required a 0-10v signal to operate correctly.

There was no option to modify the PLC hardware and software to accommodate this, as the system was both obsolete and read protected by a manufacturer who no longer existed!

Technique Services reverse engineered the existing control strategy, identified and supplied the required micro PLC components available from their stock, finally programming it to act as a transparent interface between the existing PLC and the replacement regulator valve.

All this was completed within 4 hours, performance was identical to the original unit.

Full production was reinstated, and all orders went out on time!