Retrofitting involves updating or modifying the existing machinery to meet the requirements of a new industry. For example, we recently retrofitted roll-to-roll coating machine for the rechargeable battery manufacturing industry.
Turning Old into New
The rechargeable battery manufacturer wanted to modify an existing roll-to-roll coating machine to apply coatings with specific properties and highly accurate thicknesses for their lithium batteries. They came to us when their current approach that could not achieve the quality and accuracy they needed.
What We Did for Them
We retrofitted with high-end feedback tools (interferometers and precision scanners) that measured the coating thickness and quality after application. The machine was updated to measure and log critical performance data as feedback.
The retrofitting project produced several positive results for the company. Our customer is getting better performance and material usage and can measure the quality of their processes. Retrofitting significantly improved operations and performance quality at a reasonable cost.
Steps Involved in Retrofitting Old Machines
These are the steps we follow:
Assessment: The first step in retrofitting is to assess the existing machinery to determine its suitability for modification. Engineers and technicians will evaluate the machine's age, condition, and functionality to identify potential areas for improvement. Many existing coating machines do not offer CAD data of their system for this purpose so we laser scan the areas of interest and create our own interface features and clearance limitations.
Planning: Once the assessment is complete, a retrofitting plan is developed. The plan includes a detailed list of modifications required to bring the machine to the desired standard, including upgrades to the control system, sensors, and other components.
Modification: The next step is to modify the machine according to the retrofitting plan. The plan may involve replacing old components with new ones, adding sensors and control systems, or upgrading software.
Testing: After modifications are complete, the machine is tested to ensure it meets the desired functionality and performance standards. The testing phase is crucial to identify any issues and make necessary adjustments.
Implementation: The retrofitted machine is ready for implementation once the testing phase is complete. Operation and maintenance documentation is created and Operators are trained on the modified machine. Any associated changes are made to the production process.
Conclusion
If you are considering retrofitting an old machine for a new industry, it is essential to work with experienced engineers and technicians who can evaluate the machine's suitability for retrofitting and recommend the best course of action.
