Case Study: INTERNATIONAL BORDER CROSSING GETS A CRITICAL SYSTEMS REFRESH

The Challenge

Borderlink manages a sophisticated air management system that continuously monitors and ventilates the 1.5 km tunnel, ensuring the removal of vehicle exhaust and maintaining air quality. However, the existing variable frequency drives (VFDs) and the legacy Modbus RTU communication infrastructure were becoming unreliable, with spare parts increasingly difficult to source. Borderlink recognized the risk to operational continuity and sought a proactive upgrade to modernize this critical infrastructure. 

The Solution

ONYX Engineering partnered with Borderlink’s team to deliver a seamless upgrade. The strategy involved:

• Replacing legacy drives with Rockwell PowerFlex 755T and 525 series VFDs, tailored for robust industrial applications.

• Integrating with the existing SCADA and redundant controls processor architecture while minimizing disruption.

• Upgrading from Modbus RTU to Ethernet/IP for significantly improved communication speed, bandwidth, and diagnostics.

• Implementing AI-based predictive maintenance models to monitor drive and motor health— for the large 100 HP and 200 HP motors.

The Results

Borderlink now operates its tunnel ventilation system using a modern, scalable, and reliable control architecture. The upgrade not only improves real-time monitoring and diagnostics but also lays the foundation for long-term operational support and efficiency.

The integration of AI-based predictive maintenance provides a forward-looking approach to asset management, reinforcing Borderlink’s commitment to safe, uninterrupted service at one of North America’s most critical infrastructure links.