Why modernization can be worthwhile in some cases instead of purchasing a new grinding machine.

The potential benefits of retrofit also lie beyond the direct cost comparison.

Over 2,000 DISKUS WERKE machines are located around the world. As a rule, they are operated for many decades because they grind reliably.

At some point - often only after decades - the question arises whether it is time to replace a grinding machine. Of course, a new acquisition is associated with considerable costs. But for other reasons, too, investing in a new machine is not always the best solution:

• The mechanics used are usually hardly outdated and could continue to be used without any problems.
• Employees are experienced in handling and would first have to be retrained for a new machine.
• The spatial conditions are often optimally adapted to the existing machine and can only be changed with great effort.

So there is a whole range of reasons why it may be better to give the old machine a thorough modernization. This is precisely where Retrofit comes in.

Retrofit involves bringing an existing grinding machine up to today's technical standard by completely overhauling it and adding new components. This applies in particular to the control, drive and automation systems, as these are often outdated after decades of use and replacement is extremely expensive and difficult.

In addition, however, there is one of the most important aspects of all: operator safety. Today, completely different safety regulations apply than when an existing machine was first put into operation. Within the scope of a risk assessment, it can even be determined that such a machine must be retrofitted according to the law. With retrofitting, the company and the operator are literally on the safe side.

The basis for Industry 4.0 is data and the networking of machines via the Internet of Things. To implement manufacturing with the help of Industry 4.0, it is not necessarily necessary to invest in new grinding machines.

A cost-effective solution can be to upgrade existing grinding machines with the help of retrofitting. For this purpose, existing machines must be equipped with additional sensors and communication interfaces. In this way, it is possible to record and analyze production data as well as network and communicate between the machines, which form the basis for manufacturing in the sense of Industry 4.0.

Technology optimization can also be made possible through retrofitting, if necessary. By integrating new components from the areas of control, drive and automation, it is possible, for example, to implement force-controlled grinding or a post-process measuring system for cyclical checking of the features to be measured and/or automatic compensation of grinding wheel wear.

So is it better to modernize than to buy new?

This cannot be said so sweepingly. Retrofitting is certainly a sensible alternative in many cases - but not in all. Which solution is rather to be recommended can be decided only in the concrete individual case and depends on many, complexly connected factors. The experts of DISKUS WERKE can give a well-founded recommendation with experience and analytical view and in each case create a concept for the concrete implementation.
 

Retrofit in der Praxis
Ausgangspunkt: eine DDS600CL, Baujahr 1967 ohne Sicherheitseinrichtung