Revitalizing Lifecycle Support for Heavy Forging Equipment – Modernization and Upgrade Strategies for Existing Manipulator Systems

Abstract

Heavy-duty forging manipulators and handling systems are typically designed for operational lifetimes extending over several decades. Many systems installed worldwide continue to operate successfully after more than 25 years of service. However, forge shop operators increasingly face challenges related to changing production requirements, higher load demands, outdated automation systems, spare part obsolescence and evolving safety standards. At the same time, complete machine replacement is often associated with significant investment costs and resource consumption. This contribution presents DANGO & DIENENTHAL’s approach to modernization, upgrade and lifecycle extension of existing forging manipulator systems. The objective is to adapt long-life equipment to current and future production requirements while maintaining the robustness, precision and high availability required in demanding forging environments. The paper discusses practical engineering approaches including retrofit concepts, control system modernization, component replacement strategies and structural evaluations for performance enhancement. Particular attention is given to engineering-driven upgrade solutions that enable increased load capacities and operational improvements within the existing machine structure. In addition, the integration of existing equipment into modern digital production environments is addressed. Based on selected project examples and OEM experience, the contribution demonstrates how phased modernization concepts can extend operational lifetime, reduce operational risks and improve production flexibility without complete machine replacement. Furthermore, lifecycle extension represents a sustainable approach regarding resource utilization, investment protection and long-term industrial productivity. The presented approaches highlight the growing importance of modernization and technological partnership concepts for the future operation of heavy forging equipment in the global forging industry.