Long life machinery is always engaged in very high undesirable stops. It will cause inconstancy and unreliability on production rate of a workpiece by machinery, in a period of time.
Moreover, the high costs for preparation and change in defective electronic boards because of very old electronic and electric parts in these machines result in loss of guarantee to continue to supply their spare.
To solve the mentioned above problem, the low cost method is now proposed in order to implement the technique of Retrofitting. It is a method to reach the high quality and more reliability compared to production process, through modernization and machinery upgrading.
The technique is suggested for four types of machinery:
1. The inactivated machines due to failure in replacement or repairing of the defective parts;
2. The machines that have the capacity to operate, but seeming unreliable and uneconomic because of much more reparations and long-time stops in the productions;
3. The time-consuming machines due to controller structure and programming process, or because of low capacity of system memory, the complex machine programs need to perform in several stages;
4. The machines of ability to precisely and suitable quality machining, due to weakness in measuring and controlling systems;
Control Afzar Company, succeeded to renovate many machine tools and return them into production line by its own skilled and experienced engineers, and offering the modern methods based on Retrofitting from Siemens, bringing the following benefits for industries owners:
• Increase in readiness coefficient of machine;
• More simplicity and comfort of operating and programming;
• Decrease in time and increase in care in machining;
• High efficiency of machine;
• Ensuring to support the spare parts for more period of time;
• Secure availability of programs and data;
• Increase in capacity of controller’s memory;
• Providing the network and ability for DNC;
• Simplicity and fall in repair and maintenance;
To compare it with replacement and purchasing the new machinery, the followings are to be considered:
Cost savings of roughly 40%-60%
compared to buy a new machine with the same performance
Special end customer demands can be taken into account during
configuration and converting
Existing tools can be re-used
Due to the maintenance and reparation personnel familiar with the mechanic of recovered machine, it will facilitate to the future services of machine;
In this method, the procedure usually includes: replacement of controller, motors, drivers, measuring systems, rewiring, construction of electric panel and the mechanical recovery of machine.