S.A.B.C.A. relies on a Jobs LinX Duo machine to do the work. This powerhouse turns out large workpieces, but in dual mode it had limited functionalities. S.A.B.C.A. teamed up with Siemens to ramp up the quality. One retrofit project later, the machine is far more reliable and safer. 

Business Challenges:

• S.A.B.C.A.'s production environment was already quite advanced, but the Jobs LinX Duo machine could still get quite a few improvements. With this optimization process, S.A.B.C.A. aimed to bring the whole factory up to the same high standard.
• The machine delivers its best performance when the two portals are working on two of the same workpieces. But the duo mode wasn't running completely smoothly yet.
• Because of the older technology, the machine no longer complied with the latest machinery directive. Also the different operating modes of the machine made the safety concept particularly complex.

Technical challenges:

• The Jobs LinX Duo machine had limited diagnostics functionality. For instance, it did not have a tool break detection system installed.
• There was no RFID scanner, which meant the device could not identify tools in the most optimal way yet.
• To bring about a smoother dual mode, S.A.B.C.A. wanted more options such as a new synchronized program. This allows the portals to cooperate better and produce two workpieces.

Solution:

• S.A.B.C.A. opted for the Siemens Retrofit process. It involved three phases. In the first two phases, Siemens tackled each of the machine's portals one at a time. This meant that the machine could continue with production. In the third phase the two portals were linked up.
• The new SINUMERIK 840D Solution Line control with SINAMICS S120 frequency inverters replaced the 840D Powerline.
• Siemens carried out a risk analysis in collaboration with a specialist partner. As part of the process, the machine was tested against the latest machinery directive. The old and way too complex safety concept was amended to align with the Siemens safety integrated concept, which significantly ramped up safety.
• The dual mode got a new synchronized program, which allows each portal to work with its own tool compensation or rotation of the workpiece.
• The machine was equipped with a number of new functions: a tool break detection system and a tool identification system based on RFID tags.

SABCA is one of the main aerospace companies in Belgium. SABCA Brussels is the headquarter of the company. Besides its corporate, commercial and financial functions, the Brussels plant is home of the structural and mechatronics engineering offices, responsible for most new programs at SABCA.