Success Story – Retrofit einer Abpackanlage mit einem 3 Achsen Portal

Success Story

Retro­fit of a pack­ing plant with a 3 axes portal

Complete technical plant maintenance of an existing plant of the automobile industry.
Com­par­i­son before and after the modification

Scope of work

The tar­get was to exe­cute a mod­erni­sa­tion and opti­ma­tion of an exist­ing plant that packs dri­ve shafts regard­ing hard- and soft­ware. The tech­nol­o­gy of the plant was quite obso­lete and it has to be updat­ed to the today´s state of the art. The chal­lenge of this project was main­ly the short time for com­mis­sion­ing. After mechan­i­cal and elec­tri­cal com­plete retro­fit in 4 days and 2 addi­tion­al days soft­ware set up pro­duc­tion can be restart­ed with a part of the plant. The start-up of the com­plete plant was done after two weeks. This was only pos­si­ble by a good prepa­ra­tion and sim­u­la­tion process­es previously.

Oper­a­tion of the plant

Regard­ing the oper­a­tion of the plant it must be men­tioned that there are two plant parts. On the first part the dri­ve shafts are con­veyed to a lift­ing table by means of a chain con­vey­or. After fetch­ing the shafts out of the sec­ond plant part by a por­tal the emp­ty pal­let on which the shafts are stored is con­veyed to the next plant by anoth­er chain con­vey­or. The sec­ond plant part has a 3 axes por­tal that is posi­tioned by ser­vo dri­ves. By means of that por­tal the dif­fer­ent shafts are con­veyed in a box espe­cial­ly pro­vid­ed for it. The logis­tics is done ful­ly automated.


The plant was dis­as­sem­bled mechan­i­cal­ly and all wear parts are mod­ernised. In the course of that the pneu­mat­ic com­po­nents are also replaced. Regard­ing the elec­tri­cal instal­la­tion the switch­board cab­i­net includ­ing oper­a­tor pan­el was replaced. For safe­ty func­tions a safe­ty con­trol with cor­re­spond­ing safe­ty com­po­nents (safe­ty door switch­es, safe­ty brake) was insert­ed. By using an oper­at­ing inter­face espe­cial­ly made for the plant it becomes pos­si­ble to mon­i­tor all process con­di­tions of the entire plant.

CE and documentation

On the basis of the new dec­la­ra­tion of con­for­mi­ty of the plant an exten­sive doc­u­men­ta­tion includ­ing risk eval­u­a­tion accord­ing to appen­dix VII of the EC machin­ery direc­tive has to be made.

Contact Person
Adrian Majewski
Adrian Majewski, M.Eng.
Software Engineer
Specializations: Control Engineering, Standard developments in TIA Portal and Step 7
Our philosophy

Only if our systems are integrated at the customer completely they develop their entire performance potential. Therefore it is important for us that our customers are integrated in the process from the very first day of the project carry out. Communication is about it the most important connecting part between us and our customers.

Customer targets
  • Maximum production efficiency and quality
  • Stable industrial processes
  • Well trained personal
  • Low service costs
  • Most favourable conditions