From Standalone to Networked: Calculating the Cost of Laser Marking System Upgrades

A detailed analysis of the core costs of upgrading a laser marking system from the single-machine model to the network model includes hardware modification, software adaptation, and operating and maintenance expenses.The book explains the key steps in retrofitting laser cutting machines to work in a network, helps small and medium-sized enterprises accurately calculate the costs of retrofitting, and provides practical advice for cutting costs.

Why upgrade to the Internet?

Many factories still use old-style single laser marking equipment, which requires manual operation of the machine each time parameters are adjusted. This is especially time-consuming when there is an urgent order.After upgrading its network system, the company can now control multiple machines remotely via a computer or cell phone, and production data can be collected in real-time. For a company that requires mass processing, this represents a big boost in efficiency.

The three main items of the hardware renovation budget.

The communication module is added.

Most old equipment lacks network ports, so industrial-grade communication modules must be added.The mainstream RS485-to-Ethernet modules on the market range in price from NT $ 800 to NT $ 1500 each. We recommend choosing a model that has isolation protection, even though it costs about NT $ 200 more. This will help prevent electromagnetic interference from causing communication failures.

Server configuration.

If you have more than 10 pieces of equipment to manage at once, it is best to set up a separate server.A second-hand Dell PowerEdge 5000-series machine should be sufficient. Don't let the sales people persuade you to buy a new machine--the money you save could be used to buy two copies of the control software.

Wiring installation costs.

Don't try to save money by using ordinary cabling in factories. Industrial-grade shielded twisted pair cable is three to five NT dollars more expensive per meter, but can withstand the high-frequency vibrations of industrial equipment.The wiring for a 20-machine workshop, including both materials and labor, costs about NT $ 12,000-18,000. Finding a local low-voltage electrician is 30 % cheaper than the equipment manufacturer's quote.

Hidden costs that are often overlooked.

Software licensing fees.

Many manufacturers didn't ask about this in advance, so they had to buy new software licenses.The difference in price between the single-user and the network version of the software is between NT $ 2000 and NT $ 5000. I suggest buying a three-year maintenance package, which will save you a lot of headaches down the road.

Costs of training employees.

Don't underestimate this! Last year we trained five operators. Just learning how to deal with alarms on the new system took three days.He suggested that the company prepare a manual with diagrams to help people solve common problems, so that the new employees could quickly get the hang of things, and the old hands wouldn't always have to be called in to put out fires.

That's the most economical way to upgrade.

(1) Upgrade in stages: First, upgrade the main equipment, then replace old machines.

2. Re-use old parts: Don't throw away the original guide rails or laser tubes if they're still usable.

3. Off-peak construction: Carry out renovations in December, when equipment utilization is low, to reduce losses from downtime.

Finally, if your equipment is over eight years old, it may be better to simply replace it with the latest networked models.We figured the cost of repairs and found that it was more than 60 % of the price of a new machine, so we decided to just get a new one.