In the era of accelerated automation, many factories face the same dilemma: their robots work, but their control systems are outdated. The solution? Retrofitting. Modernising an obsolete industrial robot not only saves investment, it also prolongs its service life and improves its performance at a much lower cost than a new machine.
What is robotic retrofitting? Retrofitting involves updating the hardware and software of an existing robot — refurbishing its electronic components, sensors, or controllers — to restore full compatibility with current industrial standards. Instead of discarding a mechanically functional piece of equipment, control modules, safety systems, or secondary axes are replaced with more up-to-date versions.
Stages of the process:
- Technical diagnosis: checking the condition of servomotors, cables, controllers, and the accuracy of the axes.
- Replacement of controllers: switching to modern systems (such as KUKA KRC4 or ABB IRC5) compatible with Ethernet/IP, ProfiNet, or OPC-UA interfaces.
- Software update: integrating current programming systems (RoboStudio, KUKA WorkVisual, etc.) and ensuring compatibility with CAD/CAM environments.
- Integration of sensors or artificial vision: adding 3D cameras, laser scanners, or torque sensors to expand capabilities.
- Final testing and calibration: validating precision and repeatability according to ISO 9283 standards.
Advantages of retrofitting compared to purchasing a new robot
- Costs are reduced by up to 60% compared to acquiring a new machine.
- Structural and mechanical components are reused, preventing industrial waste.
- Compatibility with new applications is achieved without the need to alter the work cell.
- Downtime is minimised, as the refurbishment is carried out on the existing equipment.
Common Success Stories
Companies in the automotive, metalworking, and plastics sectors implement retrofits to integrate new safety systems, IoT connectivity, or even remote control via industrial software. In several cases, refurbished Eurobots robots have been delivered with complete upgrade kits, ready to be integrated into Industry 4.0 plants.
Sustainability and a Second Life
Retrofitting also contributes to the circular economy: it reuses materials and reduces the overall energy consumption of the sector. Every refurbished robot means less electronic waste and a smaller carbon footprint.
Upgrading a robot is not just a smart investment; it’s also a commitment to sustainability and efficiency.
URT offers refurbished robots and technical consultancy for industrial retrofit projects, helping companies to modernise without the need for replacement.