Intralogistics · Existing-plant modernization
regiolux Königsberg
Existing control system fully replaced by SiMonThe intralogistics system, first commissioned in 1993 and last updated in 2012, was modernized with SiMon within a few months in 2025. Proven conveyor equipment was retained, the server architecture could be updated, and the actual changeover was completed in one day.
The starting point
A stable plant on a software foundation that was no longer future-ready.
The existing control system operated reliably but could no longer support the required Windows Server architecture update. Replacing the connected PLC and conveyor technology would have been technically complex and economically unreasonable.
The task was therefore to completely modernize the software layer while continuing to use the installed equipment and its established interface.
Material flow
Pallets between goods receipt, storage, production and dispatch.
The high-bay warehouse stores and buffers raw materials, work in progress and finished goods.
Goods receiptIncoming production materials
High-bay warehouseRaw materials and buffers
ProductionWork in progress and finished goods
DispatchFinished outgoing goods
Clear system boundaries
SiMon complements SAP and the existing PLC exactly where it is needed.
ERP
SAP
Manages inventory and storage locations and controls higher-level material flow outside active transport.
Control system
SiMon
Manages and monitors pallets during transport, communicates with ERP and PLC, and provides operation, visualization and logging.
Plant level
Existing PLC
Controls the installed conveyors. Its proprietary interface was reproduced compatibly in SiMon.
The migration
Simulated in advance, changed over under control.
The greatest project risk was communication with the legacy PLC. The relevant systems were therefore reproduced and tested in a simulation environment before commissioning.
- Source code analyzedThe available legacy source revealed the existing logic and interfaces.
- Interface reproducedSiMon received a compatible connection to the installed PLC and conveyors.
- System simulatedxNet reproduced the participating systems in a simulation environment.
- Functions testedTransport processes, special cases and operator workflows were checked in advance.
- Fallback securedA prepared fallback concept was available for the changeover.
- Changed over in one dayThe actual migration took place as planned during production-free time.
Operational value
Current IT, better operation and new freedom for extensions.
Updated servers
The Windows Server architecture could be modernized without replacing the functional conveyor equipment.
Modernized operation
New dialogs and screens support daily work and perform plausibility checks on user input.
Transparent faults
A visualization created specifically for administrators makes plant states and faults easier to understand.
Logging and statistics
User actions and transport data are recorded and can be statistically evaluated.
Flexible changes
The open SiMon architecture makes it easier to integrate new requirements.
Ready for the next step
Future extensions may include operating and information functions for mobile devices.
Modernize instead of replacing everything
Is your plant reliable while its control system reaches the end of its lifecycle?
xNet reviews existing software, interfaces and server environments and develops a realistic migration path with SiMon.
RetainContinue using proven plant and control equipment
ReplaceRetire outdated software in a controlled manner
ExtendImplement new functions flexibly
Arrange a migration call