“For example, our customer purchased a rewinding system with a measuring section (diameter and length measurement, knot control, and insulation fault detection) from us in 2002,” explains Kurre retrofit expert Joachim Lukassen. “The system has run almost continuously and reliably for the past 22 years. However, like all systems, after numerous operating hours, it is no longer ‘up to date’, and the risk of permanent failures and costly repairs increases.”

 Especially the electronic components such as drive units, control systems and electronics age quickly because development is progressing ever faster. Mechanical components, on the other hand, remain in good condition in most cases - often for decades.

 “That’s why a retrofit often pays off when a machine or system becomes an economic risk. The key factor here is usually the ratio of electronic to mechanical components,” explains Lukassen. “For a fair assessment, it is therefore essential to take a close look at the system in advance. ”During an on-site inspection, Kurre employees critically examine the potential retrofit machine and provide an evaluation.

 If a retrofit is profitable, the system is modified either at Kurre’s facilities or directly on-site. “Then the real work begins,” says Lukassen. “All parts, especially the mechanical ones, are thoroughly inspected once again. Wear parts such as bearings and dimensional accuracy are especially checked – if in doubt, they are either adjusted or replaced. The majority of electronic components are replaced.”

 In this rewinding machine, the motors and the entire mechanical system have been retained with a few exeptions. In addition to a comprehensive new electrical installation, a new control system with HMI enables significantly more intuitive operation of the system. Additionally, further interfaces for data management and remote maintenance were implemented. After this complete overhaul, the system can be used effectively in production for many more years.

 “It is important to know that retrofitted systems continue to operate within their previously defined parameters. Extensive improvements (e.g., higher speeds) must be evaluated separately, as the mechanics are specifically designed for the original configuration,” Lukassen concludes.

The advantages of a retrofit at a glance
Often, refurbishing a system is more cost-efficient than a completely new acquisition. Thanks to new electronic components, the system can often operate more energy-efficiently and time-effectively, as new control technology, for example, can significantly reduce setup times. Additionally, new interfaces can be implemented, making process management, documentation, and data archiving much more efficient. Production downtime due to aging system failures is also prevented.

In addition to retrofitting entire systems, Kurre Systems also covers the area of spare parts. “This actually goes hand in hand,” explains Lukassen. As an expert in special machine construction, the manufacture of custom-fit spare parts to keep machines in operation for many more years is not a challenge.

wire India 2024, hall 1 booth M 69

Kurre Spezialmaschinenbau GmbH
Industriestrasse 5, 26683 Saterland/Germany
Contact person is Thorsten Wilde
Tel.: +49 4498 9250-120
thorsten.wilde@kurre-systems.de
www.kurre-systems.de