Modernizing Vehicle Lifter Systems with Advanced Controls and Safety

July 9, 2026  •  3 min read

Industry: Automotive OEM  |  Application: Controls & Safety Upgrade  |  Platform: Allen-Bradley GuardLogix

The legacy PLC5 and PanelMate components were no longer supported. Troubleshooting was slow, safety was non-compliant, and the risk of extended downtime was growing.

A leading automotive assembly facility needed to address the growing risk posed by its aging vehicle lifter control systems. Originally built on Allen-Bradley PLC5 controllers and PanelMate HMIs, the systems had reached end of life. Parts were difficult to source, support was unavailable, and the safety architecture no longer met current industrial safeguarding standards.

Three challenges were driving the decision to act:

• Obsolete Hardware: PLC5 and PanelMate components were no longer supported, creating real exposure to extended downtime and costly emergency repairs
• Limited Diagnostics: The legacy HMI provided minimal system feedback, making troubleshooting slow and dependent on experienced personnel who could interpret obscure fault behaviour
• Non-Compliant Safety Systems: Safety components were outdated and did not meet current standards for industrial machine safeguarding, creating potential hazards for operators and maintenance personnel

A turnkey modernization package was designed and implemented to address all three areas simultaneously.

The legacy PLC5 was replaced with an Allen-Bradley GuardLogix controller. GuardLogix provides high-speed processing, built-in safety control, and seamless integration with modern Rockwell software platforms, including Studio 5000 and FactoryTalk. The upgrade eliminated the single largest source of hardware risk on the system.

The PanelMate interface was replaced with a PanelView Plus HMI. The new interface provides a clear, structured operator experience, enhanced fault diagnostics, and greater overall system visibility. Maintenance teams can now navigate to fault information directly rather than relying on interpretation of legacy fault codes.

A full suite of modern PLC-based safety features was installed, including:

• Light curtains for perimeter guarding
• Area scanners to detect unauthorized entry into hazardous zones
• Emergency stop buttons strategically placed around the lifter
• Safe Torque Off (STO) functionality to safely disable motor power during fault or emergency conditions

• Improved Safety: The system now meets or exceeds applicable safety standards including ISO 13849-1 and ANSI/RIA R15.06, significantly reducing risk to personnel
• Enhanced System Visibility: Maintenance teams can now quickly diagnose issues using the modern HMI, reducing mean time to repair (MTTR) by over 40%
• Increased Uptime: The GuardLogix platform, combined with modern networking and diagnostics, has improved system reliability and simplified future expansions
• Future-Ready Platform: The new controls architecture supports remote monitoring, data logging, and integration with Industry 4.0 initiatives

Legacy system upgrades are often deferred because they feel disruptive. But the risk profile of running unsupported hardware with non-compliant safety systems compounds over time.

This project shows what is possible when a controls and safety upgrade is planned and executed as a single, coordinated scope. The result is not just a compliant system. It is a more capable, more reliable, and more maintainable one.