What can you do when essential machine components are no longer available or when the machine in general needs to be modernised in order to maintain its productivity and thus increase the machine’s service life? Purchasing a new machine is often very costly and time-consuming. That’s why, in most cases, a retrofit is the better and more sustainable alternative.
There are many reasons for a retrofit: in addition to the general desire to modernise the machine, there are often external reasons that initiate conversion measures. For example, important components are no longer available, safety devices are manipulated because they are no longer state of the art and thus affect the availability of the machine, or the efficiency of the machine is to be increased.
The steps for a successful retrofit follow a general process, which can be influenced by the extent of the retrofit and the type of plant or machine.
Click on the steps to find out more:
1. Analyse status quo and proposed measure
The first step is to analyse the existing plant or machine and evaluate the proposed retrofit measure. This includes determining the type of retrofit that should be carried out: e.g. just replacing a component in the existing automation or safety concept or converting the existing control system.
The following questions must be clarified:
Which safety and control concepts are currently in place and what should they look like in the future? Which framework conditions, legal requirements, technical and logistical factors need to be taken into account? How must the process workflow be organised so that measures can be bundled sensibly and, if necessary, carried out in parallel with ongoing operations in order to keep plant downtimes to a minimum?
2. Check for a substantial modification
Once the objective of the retrofit has been determined, the next step should be to review the measure for any substantial modification. If the conversion creates new hazards and a substantial modification is identified, the machine legally becomes a new machine and must be fully adapted to the current state of the art. The operator becomes the manufacturer and must carry out a (renewed) EC conformity assessment procedure. The assessment of whether a proposed conversion represents a substantial modification, or whether the aim of the retrofit can also be achieved through another measure, must be considered on an individual basis.
The new Machinery Regulation synchronises this subject for the entire EU and details what exactly is meant by a substantial modification.
An overview of the new Machinery Regulation
3. Planning and implementation
In the planning phase, depending on the chosen conversion measure, the appropriate control and safety concept is created in accordance with applicable directives and standards, along with the design plans for the electronics, pneumatics, etc. The technical conversion of the machine is then carried out in accordance with these specifications and in coordination with the customer. The implementation can be flexible. This means that the system’s available downtimes can be taken into account right from the planning phase.
4. Validation and documentation
After the conversion, if the safety devices have been renewed then they are validated, and the documentation is compiled. The circuit diagram and operating instructions are updated, for example. This step is often followed by staff training.
Implementation of retrofits is very individual, depending on the machine, and must bear in mind the processes for the entire plant. Pilz supports all steps of the implementation and ensures that the current Safety and Security standards are taken into account.
Specifically, Pilz offers safety and automation technology services and comprehensive support for all phases of the machine life cycle – from risk assessment to CE marking. The company also provides support in carrying out safety-related inspections, training employees and producing the necessary technical documentation, in the role of partner.
At the end of a retrofit, the client has a plant that meets the latest technological requirements. By updating the automation and safety technology, both the manufacturing quality and the safety of existing machinery can often be guaranteed for years to come – Safety and Security included.
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