In a world where sustainability and operational efficiency are essential, maximizing the lifespan of industrial machinery has become a strategic priority. With this in mind, ABB Robotics has introduced a comprehensive Robot Modernization Service designed to extend the life of its industrial robot arms through upgraded components, software, and controllers. The initiative not only cuts costs and reduces waste—it also gives manufacturers the flexibility to embrace new production requirements without replacing entire systems.
ABB’s modernization approach is built on four core pillars:
1. Workshop Reconditioning and Repair
ABB receives robots for evaluation and restores them in dedicated facilities, ensuring they regain original precision, speed, and performance.
2. Extensions, Upgrades, and Retrofits
Through hardware and software enhancements, legacy robots can unlock new capabilities such as
• artificial vision,
• advanced motion control,
• modern industrial network connectivity.
This allows older units to evolve alongside today’s AI-driven production environments.
3. Replacement and Buyback Programs
Customers can trade in older robots for new or refurbished ones, enabling a smooth transition while maintaining budget protection.
4. Installation and Commissioning
ABB manages the final implementation phase end‑to‑end, guaranteeing that every modernized robot is production‑ready from day one.
Powering Smart Automation with ABB Ability™ Connected Services
This modernization ecosystem is strengthened by ABB Ability™ Connected Services, a platform that monitors robot health in real time using operational data, usage history, and early-wear alerts.
The result:
- intelligent, predictive automation,
- improved uptime,
- reduced energy consumption,
- more sustainable production lines.
A Flagship Example: The Modernized ABB IRB 1200
A standout beneficiary of this modernization strategy is the ABB IRB 1200, a compact and versatile robot widely used for handling, light palletizing, and packaging tasks. With upgraded components—including OmniCore controllers, screws, servomotors, and software—the IRB 1200 can restore or even exceed its original performance, extending its useful life without the cost of purchasing a new robot.
In facilities operating large fleets of IRB 1200 units, modernization enables seamless adaptation to new production demands:
- integration with AI-based automation,
- support for modern communication standards like Profinet and MQTT,
—all without full hardware replacement.
Many companies report operational cost reductions of 40% or more compared to acquiring new robots with equivalent capabilities.
A Strategic, Sustainable Path Forward
ABB’s modernization service is more than a technical upgrade—it is a strategic move toward the circular economy, reducing environmental impact while preserving and enhancing the productivity of existing production lines. By enabling models like the IRB 1200 to continue operating with state‑of‑the‑art technology, ABB delivers a competitive and sustainable answer to the challenges of staying up-to-date in a rapidly evolving automation landscape.