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3.10 Retrofitting a traditional forming equipment to a digital one

When retrofitting a traditional forming machine to a digital system, several components may
need to be changed, upgraded, or added to enable the transition to a more advanced and
automated process. The specific components to be modified or upgraded will depend on the
type of forming machine, the goals of the retrofit, and the desired level of automation. Here are
some key components to consider:
1. Control System and Automation

• Programmable Logic Controller (PLC): Upgrade or replace the existing PLC with a modern
and capable unit to control and monitor machine functions.
• Human-Machine Interface (HMI): Install a user-friendly digital interface for operators to
interact with the machine, monitor processes, and input commands.
• Sensors and Feedback Devices: Add or upgrade sensors to provide real-time data on
variables such as pressure, temperature, speed, and position.
• Data Acquisition System: Integrate a system to collect and analyze process data for quality
control and optimization.

2. Drive and Motion Control

• Motor Drives: Upgrade motor drives to modern variable frequency drives (VFDs) for precise
control of motor speed and torque.
• Servo Systems: Implement servo motors and drives for accurate and programmable motion
control.

3. Actuators and Mechanisms
• Replace or retrofit mechanical actuators with more advanced options, such as hydraulic or
pneumatic cylinders, linear actuators, or electric actuators.

4. Tooling and Fixtures

• Modify or redesign tooling and fixtures to accommodate automation features and ensure
compatibility with the digital control system.
5. Safety Systems

• Install modern safety components such as emergency stops, light curtains, interlocks, and
safety relays to ensure compliance with safety regulations.

6. Communication and Connectivity
• Networking: Integrate Ethernet or other communication protocols for seamless connectivity
with other machines or central control systems.
• IIoT Integration: Implement Industrial Internet of Things (IIoT) capabilities to enable remote
monitoring, data analytics, and predictive maintenance.
7. Power Distribution

• Upgrade power distribution components as needed to support the new digital control
system and automation components.

8. Software and Programming

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