In modern manufacturing automation is a key driver in that it supports unmanned operation and reduces labor costs. The capabilities of older CNC machines can be greatly improved by retrofitting them with automation systems.
There are three types of automation systems.
- Robotic Loading/Unloading: The CNC machines can operate continuously, without human intervention, robots can be integrated to load and unload parts.
- Conveyor Systems: Machining stations can be automated so that parts can be transported between them by automated conveyor systems.
- Tool Changers: Automatic tool changers allow quick, on the fly, accurate tool change, reducing setup time and increasing productivity.
KUKA and ABB are two companies that offer a variety of robotic solutions which can easily be integrated with any existing CNC setup. Halter does offer a more all-in-one plug and play robotic system for CNC Machines.
Industry 4.0 Technologies
Industry 4.0 is defined as the process of integrating digital technologies into manufacturing process. Older CNC machines can have Industry 4.0 edge retrofitted to them.
Key Technologies
- IoT Sensors: Installing IoT sensors can deliver real time machine performance data, allowing predictive maintenance and operation optimization.
- Cloud Connectivity: CNC machines that are connected to the cloud can be remotely monitored, the data analyzed and software updated.
- Machine Learning: Machining process optimization, maintenance prediction, as well as enhanced overall efficiency.
For example, Siemens is using its MindSphere platform to provide a set of tools for connecting machines to the cloud, enabling in real time the analysis of data and predicting machine maintenance.
Retrofitting Practical Steps
Retrofitting a CNC machine is a very complex process, and must be planned and executed carefully. Here are some practical steps to consider:
Step 1: Consultation and Planning
Contact a qualified retrofitting service provider or obtain an authorized representative of the machine’s manufacturer to see the machine and come up with a retrofit plan. This is an important step to make sure that your retrofit is customised to your needs.
Step 2: Component Selection
Select components that are to work with your existing machine. Make sure that the new parts are nice and covered properly with support and warranties.
Step 3: Installation
Installation should only be performed by experienced technicians to ensure no risk to your machines or downtime. Subsequently, I create new controllers, automation systems, and other technologies, as appropriate.
Step 4: Training and Support
Change out the new systems to include comprehensive training to operators on the new systems, and adequate support post installation. It comprises manuals, technical support and online resources.
Cost Considerations
However, retrofitting is often a less costly alternative to buying new machinery, but the long term cost implications should be considered.
- Initial Investment: Retrofitting cost includes the cost of new components, installation and training.
- Long-Term Savings: Retrofitting can result in long term savings due to improved efficiency, reduction in maintenance costs and an extension of machine life.
- Return on Investment (ROI): Well planned retrofit can give a large ROI by enhancing productivity and reducing operational costs.
Conclusion
The strategy of retrofitting used CNC machines with cutting edge technology can make a big impact on manufacturing operations. Upgrading CNC controllers, automation systems integration, and Industry 4.0 technologies will help manufacturers extend equipment life, improve efficiency, and remain competitive in a fast changing industry.
For further information on retrofitting and modernizing CNC machines, you can refer to resources such as the National Institute of Standards and Technology (NIST) and industry publications such as Modern Machine Shop.
Finally, retrofitting is more than just a way to prolong the life of old machines; it’s a way to modernize them into state of the art production tools that lead the way to innovation and excellence in manufacturing.
