Over the years new and better ways of automation have been implemented every day in the industry. This has originated gigantic steps which outdate technology so often that obsolescence has become a problem into the industry. Whole machinery systems are falling rapidly in this condition leaving designers and processes improvers with a limited scope of options. Perfectly good machines cannot be repaired without modifying the system significantly due to the lack of parts that are no longer available in the market.

Additionally, safety regulations have changed within time. Many old equipment does not meet the regulations of a modern world. This in turn, increases the cost and complexity of the improvement by the addition of safety items such light curtains, safety cages, safety scanners, etc.

A benefit of the rapid advancement of technology that might not be so obvious, is the wider range of possibilities regarding to the solution of a specific problem and to the different applications of such solution. For instance, adding a servomotor to a specific system that originally required more precision, can provide also more information and more control over variables like speed, positioning and acceleration. Subsequent information like amperage usage of the motor, revolutions and torque can be used for generating safety features for protecting the equipment and the operator. This provides the machinery with new capabilities that it did not have originally.

Rebuilding or retrofitting a piece of equipment has become a common task in the industry. It is a good low-cost option for having access to newer technology. It requires careful planning and expertise on several areas that include mechanical, electrical, and electronic systems. It is technically a complete research that encompasses different types of analysis, search of different types of information, electrical design, programming and an overall integration of all the systems. The result is a multidisciplinary project of Automation congruent with the emergent field of Mechatronics.

The purpose of this research is to develop a new control built upon new technology that manages all the functioning of OMCG 1-580, a wire bending machine.