Smart retrofitting of machine tools in the context of industry 4.0

Al-Maeeni, Sara Salman Hassan; Kuhnhen, Christopher; Engel, Bernd; Schiller, Michael

doi:10.1016/j.procir.2020.05.064

Cited by 40 publications

(32 citation statements)

References 12 publications

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“…Other works aim to improve performance, such as Guerreriro et al [21] which, through the smart retrofit of a drilling process and using augmented reality, improve the quality and reduce the cycle time of the process. Still using augmented reality, Hassan Al-Maeeni et al [13] propose the retrofitting of a bending machine through which it helps operators follow the right sequence of work to improve times and costs. Some authors suggest retrofitting case studies with an approach aimed at adaptive manufacturing; for instance, Lass and Gronau [22] apply it on a roller conveyor to speed up the reconfiguration.…”

Section: Literature Reviewmentioning

confidence: 99%

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Retrofitting a Process Plant in an Industry 4.0 Perspective for Improving Safety and Maintenance Performance

2021

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The transformation from traditional industry to Industry 4.0 can bring many benefits in various spheres, from efficiency to safety. However, this transition involves adopting technologically advanced machinery with a high level of digitization and communication. The costs and time to replace obsolete machines could be unsustainable for many companies while retrofitting the old machinery. To make them ready to the Industry 4.0 context, they may represent an alternative to the replacement. Even if there are many studies related to retrofitting applied to machinery, there are very few studies related to the literature process industry sector. In this work, we propose a case study of a two-phase mixing plant that needed to be enhanced in the safety and maintainability conditions with reasonable times and costs. In this regard, the Digital Twin techniques and Deep Learning algorithms will be tested to predict and detect future faults, not only already visible and existing malfunctions. This approach strength is that, with limited investments and reasonable times, it allows the transformation of an old plant into a smart plant capable of communicating quickly with operators to increase its safety and maintainability.

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Section: Literature Reviewmentioning

confidence: 99%

“…In the context of Industry 4.0, we talk about smart retrofitting. In addition to the classical retrofitting features, smart retrofitting involves implementing all necessary tools and technology provided by Industry 4.0 [13]. Retrofitting is related to the need for sustainability, productivity and increased technological level.…”

Section: Introductionmentioning

confidence: 99%

Retrofitting a Process Plant in an Industry 4.0 Perspective for Improving Safety and Maintenance Performance

2021

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“…They often constitute a high proportion of a company's capital. For this reason, a work life of 20-30 years is common for such machines [5]. Due to the paradigm shift in the course of Industry 4.0, older machine tools may no longer meet the requirements for quality or connection ability.…”

Section: Introductionmentioning

confidence: 99%

“…Retrofitting can be divided into two categories, namely: traditional and smart retrofitting. Traditional retrofitting is the replacement of components to optimise accuracy, speed, maintainability and ease of use [5]. Upgrading the drive and control elements of an old machine is one way to extend work life.…”

Section: Introductionmentioning

confidence: 99%

“…Both the historical and real-time data can be used to access status and condition of the system. The data can be, for example, further processed into a cloud service and also provides a decision-making basis for the plant control [5]. It should be noted that, for successful modernisation according to the idea of Industry 4.0, both types of retrofitting are necessary.…”

Section: Introductionmentioning

confidence: 99%

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Implementation of a Machine Tool Retrofit System

Dietrich

Sand

Reiff-Stephan

2021

TH Wildau Eng. Nat. Sci. Proc.

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Small and medium-sized companies increasingly turning their attention towards the fourth industrial revolution. In order to increase their own long-term competitiveness, there is a growing desire to make production smarter, more efficient, safer and more sustainable through new technologies. Often, however, existing plants cannot be easily replaced by modern equipment. The reasons for this can be high investment costs, excessive downtimes or the unavailability of an equivalent machine. An alternative solution to the purchase of new equipment is the modernisation or expansion of existing systems, also called retrofitting. Thus, this paper deals with the retrofit process of a machine tool, whereby the software architecture of the control unit is the primary concern of this work.

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Machine Retrofitting for Tissue Paper Industry—INTERFOLDER Case

Milivojevic

Bojović

Babic

et al. 2022

Machine and Industrial Design in Mechanical Engineering

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This paper is a presentation of applied design knowledge as well as practical experience in mechanical engineering and industrial automation in order to retrofit machines. The main goal is to offer affordable solution for automated log transfer and at the same time extend the life of those tissue paper converting machines that are already in operation. We exhibit practically tested solutions for a module for sheet counting and log separation that can be mounted onto existing semi-automated machine. The digital prototype e.g. CAD model is generated for a preliminary module design. Rapid prototyping is used to refine delicate geometry of moving segment before tangible manufacturing. By machine retrofitting we attain a fully automated production that consequently increased efficiency of the line by elimination of the log manual transfer operation. Also, data collection from built-in sensors and analysis provide optimization of the overall equipment effectiveness. Additionally, retrofitting includes repairs, replacements and adjustments of electrical and pneumatic systems, implementation of software for controlling that adapts machine for conformity marking and for regulations.

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Smart retrofitting of machine tools in the context of industry 4.0

Cited by 40 publications

References 12 publications

Retrofitting a Process Plant in an Industry 4.0 Perspective for Improving Safety and Maintenance Performance

Retrofitting a Process Plant in an Industry 4.0 Perspective for Improving Safety and Maintenance Performance

Implementation of a Machine Tool Retrofit System

Machine Retrofitting for Tissue Paper Industry—INTERFOLDER Case

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