Retrofit and Modernization
In short
A retrofit keeps a mechanically sound machine in production by renewing its ageing control system (PLC, motion card, drives, motors, panel). ONX Control moves old DC/AC drive and PLC systems to a CODESYS-based PC control architecture with EtherCAT communication; the mechanics are usually kept.
Scope of service
- Survey of the existing system: electrical drawings, software, I/O list, motor and mechanical data
- Renewing DC drives (Mentor MP) or converting DC motors to AC or servo motors
- Moving PLC and motion card software to CODESYS and connecting the field over EtherCAT
- Panel modification or a new control panel
- Commissioning, comparative testing against the old system and documentation
How we work
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1
Site survey
The machine is inspected on site; existing hardware, software and faults are listed.
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2
Preliminary sizing and quote
Motors, drives and control architecture are selected; a quote is prepared together with a downtime plan.
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3
Engineering
Software and panel are prepared and tested in the workshop before the shutdown.
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4
Commissioning and handover
Removal, installation and commissioning are done during a planned stop; the system is handed over with documentation.
Frequently asked questions
Retrofit or a new machine?
If the mechanical structure (frame, slides, drive train) is sound and the process requirements have not changed, a retrofit brings the control system up to date at a lower cost than a new machine. If mechanical wear is significant or more capacity is needed, a new machine should be considered.
How long is the downtime?
It depends on scope and line layout. Software and panel preparation are completed before the shutdown to shorten the time on site; the exact plan is made after the survey.
Can the DC motor be kept?
Yes. If the mechanics and motor are sound, only the DC drive can be renewed. The efficiency and maintenance benefits of moving to AC can be compared with the DC to AC retrofit calculator.
Let's define the retrofit scope of your machine
Share details of the existing control system, drives and motors; we will get back to you for a survey and preliminary assessment.