Success Story – Retrofit eines Rundläufers in China

Success Story

Retro­fit of a rotary machine in China

Control exchange with complete electric and pneumatic system overhaul


The goal was to mod­ern­ize one exist­ing plant for the pro­duc­tion of halo­gen bulbs, which is in use in var­i­ous auto­mo­biles. The pro­duc­tion plant con­sist­ing of a sup­ply as well as a dis­charge con­vey­or belt, a rotary machine and var­i­ous qual­i­ty assur­ance units is oper­at­ed in Songzi (Chi­na) and is part of an auto­mat­ed pro­duc­tion line. Because the life­time of the com­po­nents exceed­ed and the con­troller was dis­con­tin­ued, the sys­tem should be brought to the newest state of technology.

Engi­neer­ing and project management

The engi­neer­ing and pro­duc­tion of the com­po­nents was done in Ger­many. All fin­ished parts includ­ing acces­sories for mod­ern­iza­tion were trans­port­ed to Chi­na by air freight. The project man­age­ment in the prepara­to­ry phase was coor­di­nat­ed from Stol­berg and con­tin­ued with the imple­men­ta­tion in China.

Elec­tri­cal modernization

The com­plete machine instal­la­tion includ­ing con­trol cab­i­net group and user inter­faces should be exchanged. An exist­ing vision sys­tem was adapt­ed to the new con­cept and revised. The prod­uct track­ing and oper­a­tional data acqui­si­tion was mod­ern­ized and inte­grat­ed into the new con­trol cab­i­net group.

Mechan­i­cal modernization

Old pneu­mat­ic actu­a­tors were replaced by bus-con­nect­ed valve ter­mi­nals, the pneu­mat­ic instal­la­tion was renewed.


The new soft­ware was pre­pared in Ger­many and test­ed in a sim­u­la­tion. In addi­tion, the BDE sys­tem was revised, adapt­ed to the new con­trol sys­tem and inte­grat­ed in the infra­struc­ture of the cus­tomer. The user inter­faces were devel­oped in coop­er­a­tion with the customer.

Con­ver­sion and commissioning

One pri­or­i­ty was of course a pos­si­ble short down­time of the pro­duc­tion line. By opti­mal project plan­ning and prepa­ra­tion we were able to let recon­struc­tion and com­mis­sion­ing phase flow seam­less­ly into each oth­er, so that the pro­duc­tion loss dur­ing mod­ern­iza­tion was reduced to a minimum.

Doc­u­men­ta­tion /Training

On site an oper­a­tor train­ing was done and an oper­at­ing man­u­al was pre­pared. The elec­tri­cal cir­cuit dia­grams were new­ly made in EPLAN P8.

Contact Person
QA Mitarbeiter Dennis Paustenbach
Dennis Paustenbach
Electrical Designer
Specializations: Electrical Engineering, Project Management
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 favorable conditions