Your existing automation equipment represents a significant investment. AMD Automation helps you extend equipment life, improve performance, and add new capabilities through strategic upgrades and retrofits. Often, upgrading existing systems delivers better ROI than complete replacement.
Why Upgrade vs. Replace?
Upgrading your existing automation offers significant advantages:
- Lower Capital Cost - Upgrade critical components while reusing mechanical infrastructure
- Reduced Downtime - Faster implementation than full system replacement
- Preserved Training - Operators maintain familiarity with equipment
- Incremental Improvement - Spread investment over time
- Extended Asset Life - Get 10+ more years from upgraded equipment
Robot Upgrades & Refurbishment
Robot Controller Upgrades
Upgrade to the latest controller technology while keeping your existing robot arm:
FANUC Upgrades - R-J2 to R-30iB Plus controller upgrade - R-30iA to R-30iB conversion - Add iRVision or force sensing capabilities - Upgrade teach pendant to iPendant
ABB Upgrades - S4C+ to IRC5 controller upgrade - Add SafeMove Pro safety functions - Integrate vision and force control - Upgrade to OmniCore controller
KUKA Upgrades - KRC2 to KRC4 controller migration - Add Safe Operation functions - Integrate KUKA.PLC mxAutomation - Upgrade SmartPAD interface
Robot Refurbishment
Restore older robots to like-new condition:
- Complete mechanical overhaul
- Replace worn gearboxes and reducers
- Recalibrate all axes
- Test and validate performance
- Provide warranty on refurbished units
Add Capabilities to Existing Robots
Enhance your current robots with new features:
- Vision Systems - Add 2D/3D vision for guidance and inspection
- Force/Torque Sensing - Enable sensitive assembly operations
- Welding Packages - Convert handling robots to welding
- Additional Axes - Add servo positioners and tracks
- Collaborative Features - Speed and separation monitoring
Control System Modernization
PLC Migration
Upgrade obsolete PLCs to current platforms:
Allen-Bradley Migrations - PLC-5 to ControlLogix - SLC 500 to CompactLogix - MicroLogix to Micro800/CompactLogix
Siemens Migrations - S5 to S7-1500 - S7-300/400 to S7-1500 - Classic to TIA Portal
Other Platforms - GE Series 90 to various modern platforms - Modicon to current Schneider Electric - Omron migrations and consolidation
HMI Upgrades
Replace aging operator interfaces:
- CRT to modern touchscreen displays
- Proprietary systems to standard HMI platforms
- Add remote monitoring capabilities
- Implement mobile HMI access
- Standardize across equipment
Drive System Upgrades
Modernize motor control:
- Replace obsolete servo drives
- Upgrade to energy-efficient VFDs
- Add regenerative braking
- Implement predictive maintenance monitoring
- Improve motion performance
Safety System Upgrades
Meet current safety standards and improve protection:
Safety Assessment
- Risk assessment per ISO 12100
- Gap analysis vs. current standards (ISO 13849, IEC 62443)
- Recommendations prioritized by risk level
Safety Upgrades
- Safety PLCs and controllers (Allen-Bradley GuardLogix, Siemens F-CPU)
- Light curtains and safety scanners
- Safety-rated sensors and interlocks
- E-stop upgrades and validation
- Guard systems and access control
Compliance Documentation
- Safety circuit validation
- Performance Level verification
- Updated risk assessments
- Training documentation
Production Line Improvements
Throughput Enhancement
Increase production without major capital investment:
- Cycle time optimization
- Bottleneck identification and resolution
- Parallel processing improvements
- Quick changeover implementation
Quality Improvements
Add inspection and traceability:
- Vision inspection stations
- Measurement and gauging systems
- Barcode/RFID traceability
- SPC data collection
- Error-proofing (poka-yoke)
Flexibility Upgrades
Support more product variants:
- Quick-change tooling systems
- Flexible fixturing
- Recipe-based programming
- Product identification systems
Upgrade Process
Assessment Phase
- Equipment Evaluation - Assess current condition and capabilities
- Requirements Definition - Define upgrade goals and constraints
- Feasibility Analysis - Evaluate technical and economic viability
- Proposal Development - Detailed scope, schedule, and investment
Implementation Phase
- Engineering - Design upgrade solution using digital twin simulation
- Procurement - Source components and equipment
- Build & Test - Fabricate and validate at our facility
- Installation - On-site implementation with minimal disruption
- Commissioning - Validate performance and train personnel
Support Phase
- Warranty on upgraded components
- Spare parts availability
- Technical support
- Preventive maintenance programs
Industries We Support
Our upgrade services support manufacturers across automotive, medical devices, aerospace, electronics, consumer products, and food & beverage industries.
Case Study: Robot Controller Upgrade
A Tier 1 automotive supplier upgraded 12 FANUC robots from R-J3 to R-30iB Plus controllers:
- Investment: 40% less than robot replacement
- Downtime: 3-day weekend installation per robot
- Result: 15% cycle time improvement, integrated vision capability, 10+ year extended life
Ready to upgrade your automation? Contact us for a free assessment of your upgrade opportunities.