Identified challenges
After the first meeting with the customer together with our technicians, the situation and the many critical points to be addressed were clear:
Retrofit of a robotic cell with Fanuc robot for Alumat
SECTOR:
Metalmechanical
Location:
Bergamo, Italy
CUSTOMER
Alumat, a company specializing in the manufacture of dies for aluminum extrusion
REQUIREMENT
To restore the operation of a robotic cell with Fanuc robots that had been in operation for over 15 years, solving different issues that were hindering the normal running of the production activity.
Objective
to modernize a robotic cell while maintaining the existing hardware, ensuring minimized downtime, and developing open, customizable software that complies with Industry 4.0 standards
- Lack of technical documentation, including wiring diagrams, which made maintenance work complex, even for trivial problems. For example, a small failure, such as a broken limit switch, could bring the system to a standstill for days.
- Lack of support from the original manufacturer, available only via email, causing long downtime.
- Closed and obsolete software: the operating system was old and vulnerable not compatible with modern 4.0 standards, lacked any integration with enterprise databases for production management. It also could not be updated for security reasons.
- Compromised security: substandard control units and failed components.
The solutions proposed
After a thorough analysis, we developed a structured intervention plan:
Replacement of safety circuits
with new standardized control units and complete refurbishment of the control cabinet.
Redesign of the software
aon board robot, making it more understandable and flexible.
Collaboration with the client's IT department
to integrate the new software with existing business systems, ensuring operational consistency
Backward compatibility:
the new system was designed to also work with the old supervisor, ensuring production continuity during the transition phases.
Interventions and Results
We reconstructed the missing wiring diagram and modernized the cell with advanced tools such as RoboGuide.
As a result, we focused on creating tailored software that could enable the planning of handling missions with greater accuracy and reliability.
The electrical cabinet refurbishment involved replacing obsolete components, improving reliability and reducing failures.
Thanks to these interventions and careful planning, unmanned production was interrupted for only one night, without compromising order delivery delays.
New documentation and software simplified interfacing, which was completed in only 3 days.
The robotic cell is now completely revamped and integrated into business processes.
Among the main benefits achieved:
- Reduced downtime: faults are resolved quickly thanks to documentation and a more intuitive system.
- Greater flexibility: open software allows the customer to make changes and optimizations independently.
- Guaranteed safety: intervention on the control units has eliminated any risk associated with non-standard components.
- Production 4.0: the system is now fully integrated with company databases, improving the planning and monitoring of production activities.
The customer can now operate autonomously and safely, with the peace of mind of having a documented and reliable system.
Thanks to Robo Feed's intervention, we were able to transform an obsolete cell into a strategic asset for our production. The technicians demonstrated competence and punctuality, ensuring continuity even during the work. We are extremely satisfied with the result.
Production manager
Project Conclusion
Concluding our intervention, the client was able to replace one of the machine tools connected to the cell in just three days, a task that would have been unthinkable before.
Production is now smooth, safe, and ready to meet future challenges with a documented and customizable system.
Do you have a robotic cell to upgrade? Contact us today to find out how we can transform your robotic plant into a modern, reliable asset that meets Industry 4.0 standards.
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