Here, everything revolves around a topic that is very close to our hearts— retrofit.
Here at ROTH, we’ve been passionate about and committed to the concept of retrofitting for over 35 years. This applies not only to our customers’ automation systems but also to our own machines.
A retrofit is sustainable: It saves time, money, and resources.
And, by the way, it feels good to give an old system a second life.
Control System Retrofit of a CNC Milling Machine
It happens time and time again: a machine that was once state-of-the-art slowly becomes obsolete and gathers dust in the corner. But has it really reached the end of its useful life?
As part of his student research project, our student Bastian upgraded the control system of a non-functional CNC milling machine. The mechanics and drives of the existing system are still in use. Since the retrofit, the machine has been back in regular use, milling protective covers for our control cabinet construction—a task that previously had to be completed laboriously in several steps.
Control System Upgrade for a Machine Tool
Just recently, we were on site at a commercial vehicle OEM. Although a machine tool used for machining crankshafts was still operational, it was experiencing an increasing number of malfunctions, and sourcing replacement parts was becoming increasingly difficult.
The solution: Upgrading the CNC control system to a SINUMERIK 840d sl.
ROTH handled all aspects of hardware and software engineering: the control system, control cabinet, and decentralized peripherals were replaced, and the safety technology was brought up to the latest standards. The well-maintained mechanical components were inspected and could be reused in their entirety.
Small investment, big impact: The retrofit has made the system less prone to malfunctions and ensured the availability of replacement parts for control and drive components.
The maintenance staff are also pleased, as the system is now much easier to operate.
Worried about production downtime? No need to be. Since we implemented the project during the customer’s company vacation, production was able to continue as usual.
Where others recommend a new system, we make your existing system ready for the future with a sustainable retrofit.
Retrofit of a high-bay warehouse
Sometimes we aim high. This was recently the case with an international machinery manufacturer. An existing high-bay warehouse was showing its age but was to remain in use.
The challenge: The high-bay warehouse must operate around the clock to ensure a smooth supply to the customer’s assembly line. Therefore, the entire retrofit could only take place during the three weeks when the customer was closed for vacation.
How does that work? After taking measurements, ROTH created a virtual simulation and analysis of the existing system. This allowed us to assemble all the components in advance and commission the system virtually. The on-site retrofit was carried out without any risk during the plant’s shutdown period.
As part of the retrofit, individual mechanical components and control cabinets were replaced. The entire control system was upgraded to SIMATIC S7-1500, and the master control computer was replaced by the ROTH Process Control System (RPCS). And all this for a fraction of the cost of a new plant.
When they returned from their summer vacation, the employees found a fully operational high-bay warehouse that, thanks to the retrofit, was more efficient and less prone to malfunctions than before.
Customers also benefit financially: Thanks to modern control and drive technology, energy costs can be minimized and the availability of replacement parts ensured.
Retrofit of a machine loading system
A classic example of a retrofit at ROTH? A machine tool’s loader becomes redundant but can be used on another machine.
This was the case for one of our customers in the automotive supply industry. To reconfigure the loading of a machine for new workpieces, extensive work was required on the loading gantry, the stacking cell, and the safety zone. As part of the retrofit, the loader’s functionalities were also expanded and the software was adapted.
The effort paid off: By utilizing the existing automation, investment costs were minimized, and the machine loading capacity—which was originally no longer needed—could continue to be put to good use.
It’s important to note that using existing equipment on a new machine requires a new safety assessment. ROTH offers the entire automation technology workflow from a single source. As a result, we were able to provide the customer with a complete solution, including a CE Declaration of Conformity.
