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Industrial PCs, virtual machines and machine retrofits
Industrial PCs, IPCs, and panel PCs are central components in many production facilities. They control machine functions, visualize processes, connect PLC controllers to user interfaces, or run specialized machine software. If an industrial PC fails, a simple replacement with modern standard hardware is often not possible.
Especially with existing systems, older machines and discontinued IPC systems, the problem often arises that the existing machine software is tied to a specific operating system, old drivers, special interface cards, fieldbus cards or a specific hardware generation.
Retrofit GmbH supports industrial companies in Germany with retrofitting industrial PCs, replacing industrial PCs, IPC migration, repair, replacement devices, software transfer and – if technically possible – using a virtual machine for industrial PCs.
The goal is to maintain existing machine functions, reduce downtime, and avoid unnecessary plant modifications or complete reprogramming.
SOLVING COMPATIBILITY ISSUES TARGETEDLY
Old machine software on new or suitable replacement hardware
Many older production plants operate with specially adapted machine software. This software is often closely integrated with the plant and was originally developed for specific hardware, a particular operating system, or specific interfaces.
Retrofit GmbH has expertise in making existing machine software usable on new or suitable replacement hardware. This can include software migration, reinstallation, image backup, operating system migration, driver testing, and hardware compatibility testing.
Important: Technical feasibility must always be assessed on a case-by-case basis. Not every older software can be run on every new hardware without modification.
Typical technical challenges during the exchange
- Old software does not run on new hardware
- New chipsets no longer support old operating systems.
- Drivers for older interface cards are missing.
- Fieldbus cards are no longer compatible
- Serial interfaces or parallel ports are required.
- License dongles only work with certain hardware.
- Hard disk images cannot be transferred directly.
- Machine software is no longer documented
- Original installation media are missing
- Reprogramming would be costly or risky.
Relevant test points for legacy systems
- Which operating system and machine software is installed?
- Is there a full backup or image?
- Which drivers and interface cards are installed?
- Are there dongles or license restrictions?
- Which fieldbus or communication systems are connected?
- Is a direct hardware replacement via a virtual machine advisable?
FROM MS-DOS TO WINDOWS 11
Industrial PC retrofit for existing systems
Many machines have been running reliably for years, even though their industrial PCs, operating systems, or interfaces are technically outdated. The situation becomes critical when the IPC fails, the hard drive is defective, the motherboard no longer boots, or a suitable replacement device is no longer available.
In this context, an industrial PC retrofit does not automatically mean a complete machine overhaul. Often, it involves specifically repairing, replacing, or technically migrating the existing machine PC. Retrofit GmbH analyzes the architecture without unnecessarily modifying the existing system.
Virtual machine for industrial PCs
Running legacy machine software in a virtual machine. The existing software environment is technically encapsulated or "enclosed" to reduce dependencies on old physical hardware.
Operating systems from MS-DOS to Windows 11
Thorough testing of legacy systems (MS-DOS, Windows 95, XP, 7). Adaptation of chipset, drivers, and BIOS/UEFI settings for modern hardware compatibility.
Examine the limits of virtualization
Realistic and case-specific evaluation of real-time requirements, interface cards (Profibus, CAN bus) and license dongles prior to encapsulation.
Machine Retrofit: Definition and Understanding
Classical understanding of retrofit
In a classic retrofit, the machine’s mechanics often remain largely unchanged. At the same time, the entire electrical system is replaced with a new generation of electronics. This can include new controllers, new drive technology, new HMI systems, new cabling, and new programming. Such a complete retrofit can require significant investment, depending on the machine and its scope. As a general guideline, costs in practice are sometimes cited as being in the range of approximately 60–80% of the cost of a new machine. However, this figure is project-dependent. It is important to note that if the mechanics remain unchanged, the machine’s output does not automatically increase. The economic benefits must be evaluated in relation to costs, software dependencies, and production requirements.
Retrofit GmbH's understanding of retrofitting
Retrofit GmbH understands retrofitting in a practical, targeted, and economical way. Not every machine requires a complete overhaul. Often, it makes more sense to retain the mechanical components of the existing machine and selectively repair, replace, or procure critical electrical or electronic components. These include: industrial PCs, IPCs, panel PCs, HMI PCs, PLCs, frequency converters, servo controllers, HMI panels, control boards, power supplies, interface cards, and electronic assemblies. For industrial PCs, this approach means that the defective or at-risk IPC is not considered in isolation. The crucial factor is whether the existing machine software, operating system, interfaces, and machine functionality can continue to be used. The focus is on ensuring the machine’s continued economic viability.
Possible process for an industrial PC migration
The exact process depends on the hardware, software, operating system, and machine connection. Generally, a project can be carried out in several steps.
Recording of the existing industrial PC
The following information is recorded: type, serial number, operating system, hard drive, interfaces, cards, software, error pattern and machine connection.
Data and software environment backup
If possible, hard drives, images, or software versions are backed up. A check is then performed to ensure the existing environment is still readable and usable.
Hardware compatibility check
Mainboard, chipset, interfaces, drivers, dongles and fieldbus cards are evaluated with regard to a possible migration.
Selecting a suitable solution
Depending on the outcome, repair, replacement device, hardware migration, software transfer or a virtual machine may be considered.
Implementation and functional testing
The chosen solution will be implemented and tested within the scope of technical possibilities. Additional on-site testing may be required for machine integration.
Key information at a glance
FAQ: Frequently asked questions about industrial PCs and virtual machines
Can old machine software still be used on new hardware?
In many cases, a technical solution can be explored. Whether the old machine software can continue to be used on new or suitable replacement hardware depends on the operating system, drivers, interfaces, chipset, dongles, and machine connection.
What is a virtual machine in industrial PCs?
A virtual machine is an encapsulated software environment in which an operating system and applications can run independently of the direct physical hardware. In industrial settings, this can help to make older machine software usable for the long term.
Is virtualization possible on every machine?
No. Virtualization always requires technical evaluation. Real-time requirements, fieldbus cards, special drivers, dongles, and interfaces, in particular, can affect feasibility.
Which operating systems can be considered?
Depending on the starting point, systems ranging from MS-DOS to older Windows versions such as Windows 95, Windows 98, Windows NT, Windows 2000, Windows XP and Windows 7, up to Windows 10 or Windows 11, can be considered.
What happens if an industrial PC breaks down and no replacement is available?
Then various options can be considered: repairing the existing IPC, procuring a replacement device, transferring the software environment, hardware migration, or virtualization. The most suitable solution depends on the specific circumstances.
Can an industrial PC be replaced without reprogramming the machine?
This may be possible if the existing software environment can be preserved, transferred, or virtualized. However, a guarantee cannot be reliably given without a technical examination.
Do you have a defective industrial PC, outdated machine software, or a discontinued IPC system in an existing plant? Get your industrial PC retrofit and virtualization options assessed now!