Spain · Europe
When it is time to replace
- Spare parts. The manufacturer no longer supplies spares for the controller or motors, and every breakdown means a long stoppage.
- Cycle time. The line needs to run faster and the current robot cannot keep up, in speed or in payload.
- New parts. A larger or heavier part number comes in that the current robot cannot handle.
- Know-how. Nobody at the plant still knows the language or software of the old controller.
What is reused and what is replaced
| Element | Usually | What to check |
|---|---|---|
| Mechanics and bases | Reused | Whether the new robot base fits or an adapter plate is needed. |
| Grippers and tooling | Reused | Weight of the gripper plus part against the new robot's payload, and the mounting flange. |
| Guarding and safety | Reused and reviewed | That the new robot's reach stays inside the guarded area. |
| Robot and controller | Replaced | Model chosen by payload, reach and cycle time. |
| Programs | Rewritten | Robot paths and logic in the new brand's language. |
| Signals with PLC and press | Adapted | Signal list and fieldbus. |
If only the controller is failing, it is sometimes enough to replace it and keep the arm. We decide after seeing the robot and its programs.
How it is prepared to fit into the shutdown
- Site visit and a backup of everything. Robot and controller model, programs, signal list and photos of the cell.
- The cell in 3D. We place the new robot in the cell model and check reach, interference and cycle time.
- Programs before the shutdown. Programs and signals are prepared offline, and whatever can be assembled is tested in our workshop.
- Shutdown plan. Removal, installation, connection and testing, with who does what each day.
- Start-up. On a press line, first in ghost mode: the full cycle without sheet metal to check paths and synchronisation with every stroke.
- Afterwards. Program backups handed over and maintenance staff trained on their own cell.
Experience in robot replacement
The partners have carried out complete robot replacements on press lines already in production, within planned shutdowns: programming and commissioning of the new robots and their vision system.
What we need to propose the changeover
- Current robot and controller models.
- Program backups, if you have them.
- Photos of the cell and of the robot's rating plate.
- When your planned shutdown is.
- The plant's robot and PLC standard.
With that information we send you a first proposal, free of charge.
Frequently asked questions
Do we have to change robot brand?
No. We can install a new robot of the same brand, or a different one if the plant is changing its standard. We program ABB, KUKA and FANUC.
Can the robot be replaced without replacing the whole cell?
Yes. We reuse the mechanics, guarding and tooling that work, and replace the robot, controller or vision.
How long does the on-site work take?
As long as your planned shutdown. We prepare and test everything possible beforehand so that on site it only needs installing and tuning.
What if something does not work on start-up day?
That is why everything that can be tested offline is tested beforehand. We stay on site until the line is producing at rate, and afterwards we provide remote and on-site support.