The differences among overhauling, retrofitting, and reverse engineering of processing machines and how to use them
Machine tools that have been used for a long time in manufacturing sites tend to wear out and deteriorate over the years, resulting in a decline in accuracy and an increase in breakdowns, making it difficult to maintain productivity. This is where the improvement methods of "overhaul," "retrofit," and "reverse engineering" come into focus. Each method has its own characteristics, and it is important to use them appropriately depending on the current issues and objectives.
In this article, we will explain in detail the characteristics of each method and how to use them, as well as what points you should keep in mind when making a request.
1. Definitions and characteristics of each method
Overhaul
An overhaul is a method of disassembling a processing machine and inspecting, cleaning, and replacing parts to restore the same precision and performance as a new machine. The aim is to eliminate causes of deterioration, wear, looseness, etc., and return the machine to stable operation. The advantage of an overhaul is that it can be done at a lower cost and in a shorter delivery time than purchasing a new machine. It is particularly suitable for extending the life of overseas-made machines, large machines, and machines that are no longer supported.
Retrofit
Retrofitting is a method of improving performance and operability by adding or replacing the latest functions and new control systems to existing processing machines. For example, by converting old machine tools to NC or introducing PLCs and touch panels, productivity and ease of operation can be improved.
The benefits of retrofitting include the ability to achieve functionality equivalent to that of a new machine at a low cost, as well as the ability to further improve the functionality of existing machines, such as by shortening setup time by updating and modifying control devices to the latest specifications.
Reverse Engineering
Reverse engineering is a technology that uses 3D scanning to acquire the shape of existing parts and equipment, and then restores and redesigns them as CAD data. It can also handle situations where there are no blueprints, the existing equipment has been discontinued, or the shape is unknown due to wear. The benefits of reverse engineering include the ability to reproduce products with no blueprints or parts that are difficult to obtain, corrective design for high-precision parts, and secure digital assets that can be used for future maintenance and modifications.
▼Check the basic information of reverse engineering▼
2. How should you use them? Points to check before making a request
Point 1: Organize current issues and goals
You need to decide what to do depending on the issues and objectives of the processing machine you are currently using. Below are some examples of what method to choose for each issue and objective.
Table 1. Examples of selection methods by issue/purpose
| Task/purpose | Which method should you choose? | Reasons and benefits |
| The precision of the machine has decreased, and there is a lot of wear and rattle. | Overhaul | By replacing and adjusting parts, precision close to that of a new product can be restored. It can be returned to the field at a relatively low cost and in a short delivery time. |
| Sudden breakdowns and production stoppages are increasing | Overhaul | Preventive maintenance is highly effective and can reduce unexpected downtime. |
| Want to improve operability/increase productivity | Retrofit | By updating the control device and NC device, you can reduce setup time and improve processing efficiency. |
| Parts are difficult to procure/manufacturer support has ended | Reverse Engineering | Discontinued parts can be reproduced using 3D scanning, etc. This will also help secure future parts. |
| I want to secure the same performance as a new product at a low price. | Retrofit + Overhaul | This offers excellent cost performance as it extends the life of the machine while also adding the latest features. |
| No blueprints make modifications and future maintenance difficult | Reverse Engineering | By saving the design assets as CAD data, they can be used for modifications and parts restoration. |
| We can't stop the production line, but we want to improve performance | Phased overhaul + retrofit | Work can be divided and carried out systematically, improving performance while minimizing the impact on operations. |
Point 2: Be mindful of return on investment (cost, delivery time, and results)
As mentioned above, the method to be applied and the return on investment will differ depending on the issue and the objective. Generally, overhauling can restore the current state at a relatively low cost and in a short delivery time. While retrofitting increases investment costs slightly, it aims to dramatically improve functionality and productivity. Reverse engineering can accumulate non-digitized products such as drawings as data assets, which can be applied to future part reproduction and modification. It can be said to be particularly effective in cases where drawings have been lost.
3. Introducing our achievements
We have a wealth of experience in retrofitting and reverse engineering of processing machines. Below are some examples of our work.
Case 1: Retrofitting and reverse engineering of mold processing machines
Before improvement
After improvement
This is an example of retrofitting and reverse engineering a multi-purpose lathe whose machining accuracy had deteriorated after years of use. The machine was disassembled, and all parts were drawn up and checked. After that, deformed or difficult-to-obtain parts were newly manufactured, and the control system was updated to the latest Mitsubishi model. The hydraulic drive was converted to electric, the dedicated conveyors and robots were replaced with general-purpose articulated robots, and the LM guide was also changed to a high-rigidity type. This resulted in improved machining accuracy and ease of maintenance, while also reducing costs. Furthermore, by preparing the drawing data, future maintenance and modifications will be easier.
Case 2: Overhaul and reverse engineering of reducer in processing machine
This is an example of an overhaul that was performed after a reduction gear installed in one of our processing machines started making an abnormal noise. After disassembling the reduction gear and inspecting each part in detail for wear, it was discovered that the noise was caused by worn bearings. Therefore, we replaced the bearings with new ones of the same specifications, and cleaned and inspected the other parts as well. When reassembling, we carefully referenced the drawings to ensure the correct positioning of each part and the tightening torque to ensure precision. As a result, the reduction gear stopped making abnormal noise and resumed normal operation.
If you have any questions or concerns, please contact the "Equipment and Automatic Machine Parts Reverse Engineering Center."
"Overhaul" is the best method for improving precision and productivity, "retrofit" is the best method for enhancing functionality, and "reverse engineering" is the best method for regenerating parts and capitalizing data. By choosing the best method for each purpose, you can increase productivity and maintainability while keeping costs down.
We have the experience and technical capabilities to use these methods, and can provide optimal proposals tailored to the challenges faced by on-site personnel. If you are unsure which method to choose or would like to discuss specific improvement proposals, please feel free to contact us.
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