BEFORE
AFTER
The various components in automation systems age at different rates - while mechanical components are robust and made-to-last, control elements reach the end of their service lives considerably faster. Operators of automation systems have to react in good time, otherwise their entire plants are at the risk of stoppage. Liebherr therefore provides a particular service called Retrofit that enables old systems to operate with new controls - and provides all the benefits that go with state-of-the-art technology.
When production lines are in operation for one or two decades, it is often individual components that break down. Computers or other control units, which are no longer state-of-the-art and which are often no longer of any use, are usually affected. However, since the mechanical components generally still function properly, it makes sense both from a financial and a sustainability perspective to install new control technology in the existing system.
Two Possible Options
"Liebherr offers two alternative procedures here, both called Retrofit," said Uwe Radigk, Key Account Manager for Automation Systems. Option one involves the entire control cabinet, including operator controls, being replaced. "Option one works like plug & play on a computer. We simply replace the old control system in its entirety with a new one. We configure the technology in the factory and deliver it ready to use, meaning production can generally be resumed after a weekend break for installation. This solution is quick, but comparatively expensive."
In the somewhat cheaper second option the old control cabinet is not completely replaced, but is augmented by adding the new control system with the aid of a pre-configured hard drive. This can also be the best option if the control cabinet cannot be entirely replaced, given the existence of relay circuits. Since this approach involves significantly greater wiring time and effort, it takes correspondingly longer to complete. Both options involve the replacement of motors and gearing in addition to control systems.
Impact on Productivity and Quality
"The ramifications of such a course of rejuvenation are manifold," Radigk said. "These modern technological retrofits significantly increase the system's reliability, enable higher numbers of cycles to be achieved and subsequently deliver genuine value and quality to the customer. Updates provide a new level of operator convenience. Operators are trained and kitted out with up-to-date user interfaces offering a range of new opportunities and benefits such as improvements to system availability. This rejuvenation treatment also has an impact in data transfer terms. It facilitates data transfer and documentation that would not have been feasible 20 years ago. Furthermore, this rejuvenation brings the new standards of system and operator safety to the production system."
Liebherr is opting to provide a sustainable after-sales service, which combines automation longevity with customer care. For that reason the company offers an additional "Wellness Check" to go with retrofit. Roughly every second retrofit customer makes use of the this extra general overhaul service, which involves putting the entire system through its paces, replacing wear components and culminates in the issue of a new warranty certificate. "You almost have a system that is as good as new," is how Radigk describes the results of the check-up. This offering is often used in the vehicle manufacturing industry.
For more information contact:
Liebherr Automation Systems Co.
1465 Woodland Drive
Saline, MI 48176-1259
734-429-7225
info.lgt@liebherr.com
www.liebherr.us