More efficient through retrofitting: CNC machine retrofitting for modern Industry 4.0

Introduction: Why retrofitting is becoming increasingly important

Many manufacturing companies have high-precision machines that are in perfect mechanical condition – but their CNC controls, electronics or software are outdated. This is where retrofitting comes in: the economical alternative to purchasing new equipment.

Instead of investing millions in new equipment, companies are modernising their existing machines – technically, electronically and in terms of software – and adapting them to the requirements of Industry 4.0Fourth industrial revolution through digitalization and intelligent networking of production facilities..

What does retrofit mean?

Definition

RetrofitModernization and upgrading of existing machines with new technology for digitalization without complete replacement. refers to the modernisation of existing machines or production systems, in which old components such as controllers, relays, electronics, drives or software are replaced with modern components.

The aim is to

• increase performance,
• reduce downtime,
• simplify maintenance and support, and
• bring the machine back up to the current technical standard.

Mechanical basis remains unchanged

The mechanical assemblies – i.e. spindles, axes and base frame – remain unchanged. This saves resources and ensures that proven mechanics continue to be used, while only the technological infrastructure is renewed.

Why renovation is worthwhile

1. Cost savings

A retrofit typically costs 30–50% of a new purchase, but offers almost the same range of services – with significantly shorter conversion times.

2. Higher efficiency and accuracy

Modern control systems improve repeat accuracy and reduce energy consumption.
This is a decisive competitive factor, especially for lathes and milling machines.

3. Sustainability & resource conservation

The continued use of existing machine components minimises the ecological footprint – an important argument in the context of Industry 5.0Human-centered production with collaboration between humans and intelligent machines for sustainable manufacturing..

4. Spare parts & support

New systems enable ISO-compliant interfaces, remote support and standardised maintenance via Windows-based CNC software solutions.

Typical industrial applications

Retrofitting is particularly suitable for:

• Milling machines and lathes – replacement of outdated control systems, improvement of accuracy
• Flame cutting machines – integration of modern control hardware with touch panel
• Machine tools – renewal of electronics, drives and sensor technology
• Special-purpose machinery – tailor-made retrofit systems for specific production requirements

Companies such as HDC Hüttelmaier, Wabeco and medium-sized manufacturing companies use retrofit measures to achieve efficiency and precision on a par with modern new machines.

Modernisation step by step

1. Analysis of the existing production system

The machine is evaluated from a technical perspective: mechanics, electronics, control system and software. This involves checking which components can be retained.

2. Concept development

Based on the requirements, new CNC control systems, operating elements and electronic components are specified – for example, based on modern platforms from Siemens, Beckhoff or ProCom Automation.

3. Conversion and integration

Old components are removed, and the new systems are installed, wired and tested.

4. Software configuration

The control software is tailored to the specific application – e.g. tool parameters, machining cycles and cutting strategies.

5. Commissioning and training

After a successful test phase, machine operators are trained and the final handover takes place, including documentation and a support concept.

Advantages and disadvantages

Advantages

• Retrofitting offers numerous economic and technical advantages for manufacturing companies. The most important ones are:
• Cost efficiency: Only 30–50% of the cost of a new purchase
• Fast implementation: Implementation usually within a few weeks
• Resource conservation: Reuse of existing assemblies and mechanics
• Higher precision: New controls improve accuracy and repeatability
• Flexibility: Individually adaptable to machine model and production requirements
• Availability: Spare parts and support for modern systems are guaranteed in the long term
• Sustainability: Reduced energy consumption and lower CO₂ emissions

Disadvantages and challenges

Despite the advantages, there are also factors that should be taken into account when making a decision:

• Mechanical dependency: Retrofitting is only worthwhile if the basic mechanics are in good condition.
• Planning effort: Detailed analysis and concept phase required.
• Compatibility risks: Old sensors, relays or drives often need to be individually adapted.
• Short downtimes: Production may be interrupted during the conversion and testing phases.
• Limited scope for modernisation: Mechanical limitations remain – no substitute for a completely new development.

Overview: Comparison of advantages and disadvantages

This objective comparison helps you to realistically assess the economic and technical benefits of CNC retrofitting in relation to potential costs.

Practical example: Retrofit of a laser fine cutting system

Initial situation

A laser fine cutting system that was over 20 years old was equipped with a ProCom CNC control system that had worked reliably but was no longer technologically up to date with current systems.
The aim of the retrofit project was to keep the machine running productively and efficiently for at least another five years – with modern operation and high accuracy.

Technical challenges

• Integration of a current Windows operating system (Windows 10 IoT LTSC)
• Retention of all existing processing programmes
• Ensuring the usual precision (< 10 µm tolerance range)
• Integration of a new control panel with touchscreen, speed potentiometer and function keys
• Implementation of customised retrofit hardware for compatibility with the old system

Procedure

1. Documentation and analysis phase:
2. All existing control data, relay diagrams and software functions were recorded.
3. Test system & simulation:
4. A separate test system was set up to initially test the retrofit hardware virtually.
5. Hardware integration:
6. Replacement of electronic assemblies, adaptation of the front panel, installation of the new control panel.
7. Software development:
8. Creation of a new user interface, optimised for touch and visual process control.

Result

The modernised laser system now operates with a control cycle time of 80 µs, significantly improved ease of use and reduced maintenance intervals.
Thanks to the new control system, the machine could continue to be used in continuous operation – with increased process stability, data connectivity and remote support functionality.

Costs, efficiency and ROI of a retrofit project

Conclusion: Sustainable modernisation with a future

CNC retrofitting is the smart alternative to purchasing new equipment.
You modernise your old CNC machine, increase productivity and efficiency – and bring your system up to the current Industry 4.0 standard.
Retrofitting is a tailor-made, reliable and economical solution, especially for small and medium-sized manufacturing companies.

FAQ – CNC retrofitting explained simply

The retrofit with our ProCom CNC300-PX control system demonstrates the importance of modernising existing systems to ensure efficiency, precision, and competitiveness. With tailored solutions, we help you unlock the full potential of your machines and secure your production capacity in the long term.Sparked Your Interest?

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