Retrofit

Retrofit explained simply

Retrofit sounds technical, but it is actually quite simple: it means that you do not have to dispose of or replace an existing machine or plant, but instead lead it into the digital world through targeted upgrades – for example with modern sensors or control technology. You give the old machine an update to make it Industry 4.0 ready, increase its performance, extend its service life and bring smart networking into play – and all this without major new investments.

Background information

In the industrial context, retrofit refers to the targeted modernisation of existing plants by retrofitting them with technology components such as sensors, controllers or digital interfaces. The aim is to make machines more efficient, flexible and future-proof – at significantly lower cost than with complete overhauls or replacements.

A particularly forward-looking form is the digital retrofit: here machines are connected with IoT gateways, sensors or software platforms in order to collect and analyse real-time data on their operation. This makes technologies such as condition monitoring, predictive maintenance or intelligent data analytics possible – all without a complete replacement of the machine.

Process and practice of a retrofit project

A retrofit project typically proceeds in several clearly defined steps:

  1. As-is analysis and requirements definition: First, the current condition of the machine is analysed – such as existing signals or control interfaces, logistical framework conditions and technical constraints. From this, it is determined which retrofit goals (e.g. sensor data, IoT connectivity) are realistic.
  2. Cost-benefit analysis: Comparing the investment and benefit of a retrofit versus a new purchase often shows that retrofit is more economical – especially where there is a high risk of downtime or high effort for spare parts procurement.
  3. Decision for components and technologies: Based on the defined requirements, suitable sensors, IoT gateways or communication modules are selected – taking into account compatibility, environmental conditions and security requirements.
  4. Implementation and integration: The selected components are technically integrated – for example sensors placed in the control cabinet, IT network checked, IIoT gateways set up, signal paths secured. Implementation often takes place step by step in order to minimise downtimes.
  5. Testing, commissioning and monitoring: After installation comes validation – does data acquisition work, are interfaces secure, is communication stable? Pilot runs are often started in order to collect data and optimise the system.
  6. Evaluation & further development: The data obtained is visualised, analysed and purposefully used for operational improvements – e.g. for maintenance planning, efficiency increase or integration into higher-level systems such as MES or ERP.

Technologies in retrofit: sensors, IoT gateways, image processing

Retrofit solutions rely on a combination of innovative technologies:

  • Sensors: Retrofitting includes sensors for temperature, vibration, structure-borne sound or electricity, which can also be attached without existing interfaces – for example for maintenance automation or condition monitoring.
  • IoT gateways / IIoT units: These connect the sensors with digital platforms. They convert analogue data into digital signals and handle protocol conversion, security filtering, possibly data aggregation or local pre-processing.
  • Image processing (optional): Systems such as cameras or optical sensors allow visual inspections, pattern recognition or quality checks – for example for intelligent modernisation of packaging plants.
  • Edge and cloud connectivity: Retrofitted data is transmitted to local or cloud-based platforms – for dashboards, analyses or AI-based diagnostics. Stable communication, data security and easy access are important here.

Further information and links

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