Retrofit and modernisation

A machine's frame, ways and mechanics last twenty years; its electronics and software age far sooner. Retrofit means replacing what has aged and keeping what has lasted.

When to consider a retrofit

• Spare parts for the control board or drive are no longer available
• Faults have become frequent and downtime is disrupting production
• The programming software runs on an obsolete operating system
• The machine runs but cannot hold the precision new products require
• No production data can be extracted; the machine runs blind
• The operator interface is an undocumented system nobody understands

What gets replaced

Scope depends on the machine. Sometimes only the controller and operator panel are renewed; sometimes drives and motors as well. A PC layer can be added to give the machine capabilities it never had — generating programs from drawings, or calculating a cutting plan.

• PLC, controller and operator panel replacement
• Servo motor and drive renewal; analogue systems moved to digital
• Panel rebuild, rewiring and safety chain update
• Adding a PC-based software layer
• Adding production data collection and reporting

How we proceed

The machine must first be inspected on site: mechanical condition, existing hardware, remaining documentation. A price given without that inspection is not realistic. After the inspection we state in writing what stays, what is replaced and how long the machine will be down.

Downtime is usually the most critical item. We prepare the panel and the software in advance so the on-site changeover takes as little time as possible.

Retrofit or a new machine?

Not every machine is a retrofit candidate. Fitting new controls to a worn machine whose geometry is gone is money wasted. We give that verdict honestly — if it is not suitable, we say so.