The machine, built in 1998, was equipped with a functional but outdated contactor-based control system.
Because the press is part of an automated production line and loaded by a robot, a safe and clearly defined interface between robot and press was required – something the existing control system could not provide.
The primary goal of the retrofit was to transform the outdated press into a modern, safe and reliable machine that meets current safety standards and can be operated and controlled consistently by the robot – including safe release logic, controlled handshaking and achieving Performance Level e at all relevant safety functions.
Scope of Work
- Complete replacement of the existing control system
The old contactor logic was replaced by a modern safety control system. The retrofit achieves the required Performance Level PL e for presses. - Operating modes
Two operating modes are available:
Setup · Robot operation - Protection in setup mode
Setup operation is protected by a two-hand control device. - Safety control system
All logic and safety-related functions are handled by a Pilz PNOZmulti (MB0 + expansion modules). - Fault display and operator messages
Error messages and operator information are displayed on a 4.3″ touchscreen
(optionally 7″ upon request). - Control cabinet & wiring
The existing control cabinet and the two-hand desk were completely replaced, and all relevant wiring was renewed. - Door monitoring
Two position switches are implemented for safety-related door monitoring tasks. - Prepared for future expansion
The new control system is designed with reserve capacity for potential future extensions. - Electrical schematics
Schematics were created in EPLAN P8. - Initial inspection & stop-time measurement
Before handover to production, a documented initial safety inspection and a stop-time measurement were carried out. - Declaration of Conformity
A Declaration of Conformity was issued for all modifications performed. - No photos
At the operator’s request, no photos of the actual machine can be published.
Additional project note
For the same customer, an EBU stamping press (160 t) in another production cell is being retrofitted.
Commissioning: 09/2025.