Skip to content
At Atlas Robots , we have an advantage that is rare in the used industrial robot market: We dismantle the robots ourselves, right at the automotive plant, where they have been in full production right up until the very last day. We don't buy lots at auctions or accept equipment that has been sitting in a warehouse for years. We know exactly where each arm comes from, how it has been used, and how it has been maintained.
This article explains, step by step, the process REFIT we use to refurbish each robot before integrating it into a palletizing cell: what we do, what we measure, what tests it must pass, and what documentation we provide to the customer.
Overview of the " REFIT " Process in Numbers
- Source: KUKA robots dismantled by Atlas technicians at an automotive plant; they remained in production until the day they were dismantled.
- Total hours worked: About 30,000 hours at an automotive plant with scheduled maintenance.
- Final arm test: 4 hours of continuous operation with all axes in motion.
- Workshop installation test: 2 hours of full operation under the customer's actual conditions.
- Factory Acceptance: one week of actual production.
- Mean Time Between Failures (MTBF): approximately 100,000 hours of operation for industrial robots of this size.
- Deliverables: operation and maintenance manuals, electrical schematics, diagnostic reports, software backups, recommended replacement parts, and the cell's CE marking.
Why an automotive robot is the best place to start
Working with teams that have been operating for several years gives us two guarantees that are hard to come by otherwise.
The first is that they do not have any hidden manufacturing defects. In industrial reliability, this is known as the bathtub curve: manufacturing defects typically manifest within the first few thousand hours of operation. A robot with 30,000 hours of operation has long since passed that initial phase and is now in its steady-state failure phase—the most stable and predictable phase of its entire lifespan. If a manufacturing defect were to occur, it would have already done so.
The second is the maintenance history. These robots have undergone professional preventive maintenance throughout their entire service life—the kind typically seen only in automotive plants: scheduled lubrication, battery replacement, gearbox inspections, and incident logging. This standard of care is far superior to the industry average.
From that point on, the reconditioning process is methodical and always the same.
The " REFIT " Process, Step by Step
1. Disassembly and Transport
Our technicians always perform the disassembly. This is no minor detail: handling the equipment from the very beginning allows us to ensure its integrity both during disassembly and during transport to our facilities. It also allows us to document the initial configuration at the source.
2. Initial Cleaning
Once at Atlas, the first step is a thorough degreasing to remove any dirt that has accumulated during the unit’s operation at the plant. Without this cleaning, it is not possible to properly inspect the housings, gaskets, or connections.
3. Grease Replacement and Gearbox Diagnostics
Here we degrease the robot again, but with an additional goal: to analyze the used grease. The color and the presence of metal particles provide us with valuable clues about the internal condition of each gearbox. Any anomaly can be an early warning sign of a defect, so this analysis serves as an early diagnostic tool, before investing even a single minute in the rest of the process.
If everything is correct, we lubricate the system again and run a test program that moves each axis in a controlled manner. We want the movements to be smooth and ensure there are no creaks or unusual noises that might indicate a problem with the gearboxes. As part of this same process, we inspect the electrical connections, paying special attention to those for axis 1, which bears the greatest mechanical and electrical load.
4. Atlas Painting and Image
Once the inspections are complete, we use masking tape to protect all the parts we want to keep in their original color. We then apply one coat of primer and two coats of Atlas white paint.
It is important to emphasize the order: Painting comes after the diagnosis, never before. A robot that fails the mechanical inspections does not make it to the paint booth. It is either repaired or scrapped. This is exactly the opposite of standard practice in the used equipment market, where the equipment is cleaned and painted first so it can be sold.
5. Electrical Panel
In the electrical panel, we remove all non-essential components, thoroughly clean the interior of the components, panels, and filters, and seal off the input ports that are no longer needed. A cleared-out and sealed panel reduces points of failure and facilitates future maintenance.
6. Formatting and Installing Official Software KUKA
Next, we formatted all the computers and installed the official software from KUKA, without any automotive-specific customizations. The robot is delivered to the customer in a clean state from the manufacturer, free of legacy programming from its previous use or proprietary third-party configurations.
7. Verification of the KCP Controller
The controller (KCP) undergoes a full battery of tests: display lighting, mode selector, emergency stop button, dead man's switch, and other safety and control features. It is only approved once everything is working perfectly. A KCP verified in this way can be installed on any of our robots.
8. Wiring Inspection
We inspect the power and data cables one by one. Those in perfect condition are sent to the warehouse, ready to be used in any of our robots. Those with any issues are not reused.
The validation protocol: what tests it must pass
A robot doesn't leave Atlas just because it's clean and painted. It leaves only after it has passed three consecutive validation levels.
Final arm test: 4 hours of continuous operation
The final test for a refurbished robot is to run a program that moves all the axes for four hours straight. The acceptance criterion is clear: if no problems, noises, or abnormal vibrations are detected in any of the gearboxes, the robot is considered acceptable. If any such indication is detected, the process goes back a step.
Workshop installation test: 2 hours under real-world conditions
The latest evidence of a palletizing system It operates continuously for two hours under the same conditions it will encounter at the factory.: same product, same mosaic, same rhythm. This isn't a demonstration cycle—it's the customer's actual application, replicated in our workshop before shipment.
Factory acceptance: one week of production
The final acceptance test is conducted at the customer's facility and consists of a full week of actual production. Only then is the installation considered complete.
The diagnostic report: traceability of each critical element
With every installation, we provide a diagnostic report on all critical components: gearboxes for each axle, motors, electrical connections, control panel, and controls.
The report details the measured condition of each component at the time of delivery, not a general assessment. It also serves as a baseline for future maintenance: when, three years from now, a decision must be made about whether a gearbox requires repair, there is a documented starting point against which to compare it.
CE Marking and Safety Regulations
This is the most frequently asked question and the source of the most confusion in the market. It’s important to distinguish between two things.
The robotic arm, on its own, is a quasi-machine. Industrial robotics manufacturers, including KUKA , supply the arm with a Declaration of Incorporation in accordance with Annex II-1-B of Directive 2006/42/EC, not with a CE marking as a finished machine. An arm without a tool, without a defined application, and without guards cannot be assessed as a complete machine, because its risk depends on its intended application.
Formatting the controller and reinstalling the official software from KUKA does not change this situation. We are not modifying any security features or altering the device's behavior: we are restoring the manufacturer's software and removing any third-party customizations. In that regard, the device is in the same condition as it was before.
We issue the CE marking ourselves, and it applies to the entire product. When we integrate the arm into a palletizing cell—with its gripper, guardrails, photoelectric barriers, control panel, and safety logic—we are bringing a new machine to market. Atlas Robots acts as the manufacturer of this assembly: we conduct the risk assessment, define the safety architecture, prepare the technical documentation, and issue the EC Declaration of Conformity and the CE marking for the entire cell.
The technical specifications for an Atlas cell are based on these directives and their transposition into Spanish law:
- Directive 2006/42/EC, on machine safety — transposed by the Royal Decree 1644/2008.
- Directive 2014/35/EU, low-voltage — implemented by the Royal Decree 187/2016.
- Directive 2009/104/EC, on minimum health and safety requirements for the use of work equipment — transposed by the Royal Decree 1215/1997.
The third one deserves an explanation, because it's the one that's most often overlooked: It does not impose an obligation on the manufacturer, but rather on the employer who will be using the machine. Designing the cell with this in mind is what prevents the customer from receiving equipment that is fully compliant but that nevertheless makes it difficult for them to meet their own obligations on the production floor.
It is also important to distinguish between two levels that are often confused. The directives specify what requirements must be met. How compliance is demonstrated is covered by the harmonized standards, which provide the presumption of conformity and, in the case of a palletizing cell, address risk assessment, the architecture of the control system and its performance level, electrical equipment, emergency stop, safety distances, and interlocked guards.
An important date to note for any buyer: Directive 2006/42/EC will remain the applicable framework until January 19, 2027. Starting on January 20, 2027 The following will be mandatory: Regulation (EU) 2023/1230, which repeals it and incorporates new requirements regarding software, cybersecurity, and digital technical documentation.
How long does a REFIT robot last, and what determines its lifespan?
The typical sales objection is straightforward: How long will it last compared to a new one? The answer has two parts, and the second one is the one that really matters.
The first is the technical detail. An industrial arm of this size has a mean time between failures (MTBF) of approximately 100,000 hours in operation. That figure measures how often a failure occurs, not when the machine is retired. These are two different things, and it's important not to confuse them.
The second one has nothing to do with wear and tear: An industrial robot is "dead" when there are no more replacement parts available or when it is no longer cost-effective to repair it.. That is, in fact, what happens to the arms we recover. An automotive robot is retired after about 30,000 hours, and it isn't worn out—it's just that the car model it was manufacturing is no longer in production.
At Atlas Robots , we work to combat planned obsolescence. We repair and replace whatever is necessary to keep the robot running: If the grease analysis or the diagnosis of a gearbox raises any concerns, it is either repaired or scrapped; if a cable raises any concerns, it is not reused. And the robot leaves the workshop with a diagnostic report, a preventive maintenance plan, and a list of recommended replacement parts—which is what keeps a machine running for decades.
What sets a used REFIT robot apart from a new one, therefore, is not how long it lasts: it is the amortization period, which is substantially reduced while maintaining the same production capacity.
What documentation does the customer receive?
Traceability doesn't end in the workshop. With every installation, we provide:
| Deliverable | What is it used for? |
|---|---|
| Operations Manual | Daily use of the cell by the operator. |
| Maintenance Manual | Preventive maintenance plan, lubrication points, and intervals. |
| Diagnostic Report | Documented condition of gearboxes, motors, and shafts upon delivery. |
| CE Marking and Declaration of Conformity | Legal compliance of the entire unit. |
| Wiring Diagrams | Diagnosis and intervention by on-site staff. |
| Program Backups | Restore the equipment to its original condition in the event of any incident. |
| List of Recommended Replacement Parts | Recommended minimum inventory to minimize downtime. |
In addition to this, we offer two optional services with every installation: a annual maintenance contract and a KUKA KR Basic Programming Course for the client's staff, so that the plant can become self-sufficient in managing its own equipment.
Frequently Asked Questions About the Refurbishment of Industrial Robots
What is the difference between a used robot and a refurbished robot?
A used robot is sold as-is, sometimes cleaned and painted. A robot that has been refurbished using Atlas’s “ REFIT ” process has been degreased, internally inspected through its grease, checked shaft by shaft, formatted with the manufacturer’s official software, and subjected to a four-hour continuous cycle before being integrated into a cell. The difference isn’t just cosmetic: there is a documented acceptance protocol.
How many hours of testing does a robot undergo before it leaves Atlas?
Four hours of continuous operation with all shafts in motion, with acceptance criteria based on the absence of abnormal noise and vibration in the gearboxes. The complete cell is then tested for an additional two hours under the customer’s actual operating conditions, and final acceptance is based on one week of production at the destination plant.
Does a refurbished robot comply with safety regulations?
Yes. The arm is supplied from the factory as a partly completed machine with a declaration of incorporation, and the complete cell that Atlas builds around it bears the CE marking and an EC declaration of conformity issued by Atlas Robots as the manufacturer of the assembly, along with the corresponding risk assessment and technical file.
Does reinstalling the software affect the CE marking?
No. Formatting the controller and installing the official software from KUKA restores the factory settings and removes any third-party customizations; it does not modify security features. The cell's compliance is established based on the installed system, including its security logic and safeguards.
What is the MTBF of a refurbished robot?
The MTBF (mean time between failures) for an industrial robot arm of this size is on the order of 100,000 operating hours. It’s important to understand this figure correctly: it measures the frequency of incidents, not the equipment’s lifespan, and depends on both the application and the maintenance plan. When making a purchasing decision, another factor carries more weight: the existence of a preventive maintenance plan, available replacement parts, and someone willing to repair the machine rather than replace it.
How long does a refurbished palletizing robot last?
What determines the lifespan of a palletizing robot isn’t the number of hours it has accumulated, but rather the availability of replacement parts and maintenance. The mean time between failures for an industrial arm of this size is around 100,000 working hours, and at Atlas Robots we repair and replace whatever is necessary to keep it running. The oldest palletizing robot we’ve installed has been in production since 2015.
Why does Atlas disassemble the robots at the source?
Because it is the only way to ensure the equipment’s integrity during disassembly and transport, and to gain firsthand knowledge of its operating and maintenance history. Buying lots that have already been disassembled by third parties means accepting equipment without knowing how it has been handled.
A process, not just a facelift
The market for used industrial robots is full of clean, well-painted machines that no one can tell what’s inside them. The “ REFIT ” process at Atlas Robots exists for the exact opposite reason: to ensure that every cell that leaves our workshop comes with a detailed diagnostic report, a proven testing protocol, and a complete set of documentation.
If you're considering automating your end-of-line process, we can show you the diagnostic report and validation protocol for an actual cell before you make your decision.