Retrofit of a hardening machine including converter technology

Plant general view before modernization.

Definition of a project
The tech­nol­o­gy of the plant was obso­lete and the spare parts are not avail­able. The tar­get was the com­plete mod­ern­iza­tion of the total plant for hard­en­ing of dri­ve shafts in short­est downtimes.

Mechanical mod­ern­iza­tion
The equip­ment was decon­struct­ed in all sin­gle parts and all wear parts of the plant (jour­nals, con­nec­tors, seal­ing gas­kets, gear rings and guid­ing shafts) were replaced. By using new cylin­ders, valves and sup­ply units the pneu­mat­ic and hydraulic sys­tems were mod­ern­ized all around. A high­er plant dynam­ic was achieved by using ser­vo drives.

High volt­age and converter
The high volt­age trans­former as well as the con­vert­er plant of the hard­en­ing proces­sor in tran­sis­tor tech­nol­o­gy were replaced. The exist­ing sup­ply racks were revised, the water cool­ing sys­tem was modernized.

Electrical mod­ern­iza­tion
It becomes nec­es­sary to replace the elec­tri­cal plant instal­la­tion includ­ing switch­board cab­i­net, oper­at­ing, sen­sor tech­nol­o­gy and cabling com­plete­ly. All safe­ty func­tions were real­ized by the use of safe­ty con­trol and cor­re­spond­ing dri­ve con­trollers. Via indus­tri­al PC as well as and mobile pan­els oper­at­ing was realized.

Process opti­miza­tion and Visualization
Via visu­al­iza­tion tai­lored to the plant an oper­a­tor guid­ed con­trol as well as an opti­mal process super­vi­sion of all plant con­di­tions were realized.

CE and documentation
Based on the new con­for­mi­ty dec­la­ra­tion of the plant it becomes nec­es­sary to pre­pare an exten­sive doc­u­men­ta­tion includ­ing risk eval­u­a­tion accord­ing to appen­dix VII of the EC machin­ery directive.