Machine retrofit – even when the manufacturer no longer exists
Retrofit of control systems, software and mechanics of industrial and CNC machines. I bring machines without manufacturer support back to work.
The manufacturer has gone out of business, service does not answer, there is no documentation – and the machine is still needed in production? This is the situation I deal with most often. Instead of buying a new machine, it is often cheaper and faster to retrofit the one you have.
For me, retrofit is mainly about control and software: analysing the existing program, corrections, new functions or a completely new control system. Mechanical changes too, when needed.
I always inspect the machine on site first. Only after checking the control, drives and mechanics do I tell you what makes sense and what it may cost.
Scope of retrofit
From a small program change to a new control system for the whole machine.
Control system retrofit
Replacing an obsolete PLC or operator panel with a new one, migrating and cleaning up the program.
Program changes
New functions, shorter cycle time, additional safety and diagnostics – on the existing control.
New HMI
Clear visualisation, recipes and alarm history instead of an old text display.
Drives and servo drives
Diagnosis and replacement of drives, inverters and servo drives, sourcing replacements for unavailable parts.
Safety
Upgrading safety circuits: light curtains, scanners, safety relays, guard locking.
Mechanical changes
Mechanical modifications needed for a new function or a new part – when control changes alone are not enough.
When the manufacturer no longer exists
No service, no spare parts and no documentation does not have to mean scrapping the machine. I reconstruct how it works from the control cabinet and the program, and then we choose one of two paths:
- the same control – repair, program backup, corrections and documentation,
- rebuild – new control and program, often with functions the machine never had.
CNC machines and machines from China
I also retrofit CNC machines and machines from China that lack support, documentation or parts. Results vary here – for some machines a retrofit pays off, for others buying a new one is the better choice.
That is why I always start with a cost-effectiveness assessment, with no promises made blindly.
How I work
1. On-site assessment
Inspection of the machine, control, drives and mechanics, plus a backup of the existing program.
2. Proposal and quote
An honest assessment: repair on the current control, rebuild, or a recommendation to replace the machine.
3. Implementation and documentation
Retrofit, commissioning in production, operator training, schematics and a program backup for you.
Service area
South-east Poland: Dębica, Rzeszów, Tarnów, Mielec, Ropczyce, Kraków. For larger retrofits I travel throughout Poland.
Frequently asked questions
Often yes – especially when the mechanics are in good condition and the problem is the control, unavailable electronic parts or lack of manufacturer support. A retrofit is then usually much cheaper than a new machine. I assess cost-effectiveness after an inspection.
Secure a backup of the program and any documentation that exists, then have the machine assessed. It can be maintained on its current control or rebuilt with new, available components.
Yes, but not every retrofit is worth doing. The quality of mechanics in machines from China varies a lot, so I always start with a cost-effectiveness assessment.
Yes. I reconstruct how the machine works from the control cabinet, wiring and program. After the retrofit you receive the documentation that was missing.
It depends on the scope. A program change is usually a short job; replacing the control takes more time for preparation and commissioning. I plan the work to keep downtime as short as possible and give you a schedule together with the quote.
South-east Poland: Dębica, Rzeszów, Tarnów, Mielec, Kraków. For larger retrofits I travel throughout Poland.
Have a machine without manufacturer support?
Send photos of the rating plate, control cabinet and operator panel with a short description of the problem. Call: +48 663 300 959 or write: info@airobotic.pl