CONTROL SYSTEM RETROFITS

Common Point can extend the life of problematic custom in-place machine tools by providing a control system retrofit. This can be an attractive alternative to replacement if your equipment is mechanically sound and is still capable of production. The questions and answers below should further clarify what we mean by in-place machine tool control system retrofit.

Q1. What is meant by the term "in-place machine tool"?

First we will define what we mean by "machine tool", then our term "in-place". Just like a carpenter who uses a power saw, electric drill, or sander, a factory has to have "tools" to make its products. These "tools" are the large mechanical devices that perform the molding, cutting, bending, shaping, and assembly of the materials used to produce the factory's final product.

In some cases multiple operations can be performed by one "tool". When designed in this capacity, the "tool" is usually referred to as a machining center. Other "tools" are used to move material from one machine tool to the next for further processing. These "tools" are generally referred to as material handling equipment. Examples are conveyors, lifts, robots, and transporters.

Machine tools can be divided into two broad categories. These are production and custom. Production machine tools are usually produced in large quantities with features driven by overall market demand. Custom machine tools are produced in very low quantities (even a quantity of one) with features driven by the end users specifications. Our retrofits apply primarily to custom machine tools.

Our term "in-place" refers to that group of machine tools that are being used in the production process or are still considered by the end user to be production worthy.

Q2. What is a control system?

Machine tools consist of mechanical and electrical components. Mechanical components are the bearings, lever arms, gears, pulleys, etc that perform the physical acts of the machine. The electrical components consisting of such parts as relays, sensors, pushbuttons, switches, etc. provide the power and manages process of the mechanical parts.

The operator of a machine tool can be a person or another machine. A sub group of mechanical and electrical components provide connection from the machine tool to the operator. These components allow the operator to "tell" the machine tool what to do. The control system is all those electrical and mechanical components that translate the operators requests into predictable mechanical action. Our control system retrofit upgrades the electrical part of the control system.

Q3. What is a control system retrofit?

A control system retrofit consist of removing the old out-dated electrical components and installing operationally comparable components based on modern technology. Further these comparable components are selected to minimize there custom nature, provide for cost effective long term obsolescence management, while maintaining the original operational process.

Q4. When is a retrofit needed?

A control system retrofit applies to custom machine tools that can be mechanically maintained and are having operational problems that can not be solved through normal means. This usually means that spare parts are scarce, the original manufacturer is out of business, and / or maintenance talent is no longer available affect the repair.

Q5. How can I tell if a retrofit applies to my equipment?

If the answer to the following questions is "yes", a control system retrofit should be explored.

1. Can you maintain it mechanically?
2. If the operational problems could be eliminated, would you still use it?

Q6. What does a Control System Retrofit consist of?

A control system retro fit generally consists of the following.

1. Review end user intentions for the machine.
2. Review operational requirements.
3. Develop a general retrofit plan.
4. Design the new control system.
5. Acquire all hardware.
6. Schedule down time based on current production requirements.
7. Remove the old control system.
8. Install new control system.
9. Test and debug new system.
10. Perform end user acceptance test.
11. Return machine tool to service.

Q7. How long does a typical Control System Retrofit take?

We do all of our concept, design, and development work off site. This means you are still up and running during this time. Installation, test, and acceptance require the down time. We are very well aware that any down time means lost revenue to the end user. Therefore every effort using good strategy and planning is made to minimize this.

We have successfully performed the installation and test phase of the retrofit on machines with a replacement costs between 1 to 4 million with one to two weeks of actual down time. Actual down time for your machine would be determined during retrofit planning. Again, down time is a function of your production requirement and the machines retrofit requirements.

Q8. What does it cost?

Generally a control system retrofit can cost between 1/20th and 1/5th the replacement cost of the machine tool itself.

Q9. What about support?

Common Point offers a wide range of long term support contracts. These contracts are based on the needs of the end user. It is possible to arrange 24/7 support covering 100% parts and labor.

Q10. If I am interested, what is the next step?

Call or email us for a no-obligation initial consultation at the phone number or email address below.

Common Point Technologies, Inc.
P.O. Box 290
Sugar Grove, Illinois 60554-0290
(800)357-2784

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information@cpti.com