NUM’s CNC technology has been used to bring the programming software and motion control system on an old floor-type horizontal boring mill originally manufactured by Gray up to state-of-the-art standards.

The electrical upgrade was performed by the automation system integrator, MasterControls LLC Inc. (MCI), and was part of a complete mechanical rebuild of the mill by a major US machine rebuilder. The machine is now in production with an end-user working in the mining industry.

The mill - which has a massive 42-foot travel on the main horizontal axis and weighs over 100,000 pounds (>45,000 kg) - had originally been converted from manual to CNC operation back in the 1970s. However, the control system was primitive by today’s standards, with numerous drawbacks including limited CNC functionality, a very small memory size, and no networking capability.

MCI and its rebuilder customer performed an extremely comprehensive electrical and mechanical rebuild on the mill - even adding a secondary x-axis. By choosing a NUM CNC kernel, MCI has been able to bring the mill’s CNC functionality up to modern standards. New capabilities include compatibility with RS274 G-code programming, probing functionality, and an industrial PC front end providing unlimited program storage - as well as networking.

MCI’s introduction of a tandem drive arrangement on the x-axis has made a major contribution to the machine’s performance and accuracy, increasing torque dramatically for the main axis of the machine. The two axes are now synchronized in a master-slave arrangement, with the new secondary axis set to lag the primary axis very slightly in order to maintain tension in the geartrain and eliminate backlash.

The flexibility of the drives and control software that allowed this configuration was an important reason behind MCI’s decision to base the upgrade on NUM technology, as its drives support master-slave architectures. As this was a critical element of the project, MCI visited NUM’s facility in Illinois during the development of the control system to physically test the tandem control, as well as to get the CNC vendor’s feedback on MCI’s proposed control and programming scheme.

Improving the underlying precision and accuracy of the heavily-built mill was a major feature of the control system upgrade, and MCI additionally implemented a table with laser measurements of axis positions to compensate for other variations in the mechanics.

Other key factors in choosing NUM’s CNC system was the ability to upgrade the servomotor drives to advanced digital operation with absolute feedback - enhancing precision a step further. This also eliminates the need for homing moves - freeing the end user from having to reference the machine on power loss or after shutdown.

All of the control system engineering and panel building was done off site. When the retrofit control system was complete, MCI took the package to the customer rebuild site and started installation. This phase was achieved in just three days. After testing and training, the whole machine was then disassembled and shipped to the end user.

According to Jeff Petry, MCI’s Managing Partner, “The refurbished mill now has both a machining accuracy and a rich programmability that is comparable with a brand new mill - but at a fraction of the cost. The technical support available from NUM, who partner with us on applications like this, makes us comfortable taking on these types of major projects.”

MCI has become well known for automation upgrades on machine tools. The system integrator has over 25 years of experience in the business, replacing legacy CNC systems on lathes, mills, grinders, gear hobbers and other capital equipment. One reason behind MCI’s significant share of the US machinery rebuilding market is its willingness to retain existing analog-interfaced servomotor drives on CNC systems - for economy - although this was not a factor in this latest project where the demand was for optimum precision.

In turn, MCI relies on close relationships with a number of reliable control system equipment partners, including NUM for CNC applications. If the choice of CNC technology is left to MCI, the system integrator typically chooses NUM because of the programming flexibility the system provides, and the company’s willingness to provide in-depth technical support.

“Strong engineering support, and a partnership approach has always been a major element of NUM’s business philosophy,” adds Steve Schilling, General Manager of NUM Corporation in Naperville, Illinois. “It’s one of the reasons behind the company’s success with small to mid-sized machine tool OEMs, and system integrators and upgrade specialists such as MCI.”

http://www.wordsun.com/release.php?id=1058

Chicago, IL - Siemens Industry, Inc. announced today a new, economical CNC machine tool retrofit package based upon its Sinumerik 802D sl system platform that will bring end-users new levels of efficiency and productivity for less cost. This retrofit service is ideal for three-axis milling or true two-axis turning machines.

The Sinumerik 802D sl is an operator panel-based control system that combines the numerical control (NC), the programmable logic controller (PLC) and the human machine interface (HMI) in a single, maintenance-free unit. It has been engineered with a 10.4-inch color TFT display, graphical support for machining cycles and simulation, a USB-interface built into the enclosure for simple program handling and transfer, intuitive help screens and remote diagnostic capabilities.

Pre-configured to meet the majority of current applications in the market, this space-saving and cost-effective retrofit package consists of a control-only retrofit, which maintains and integrates a machine’s current motors and drives. A complete Sinumerik 802D sl CNC package with new Siemens motors and drives is also available to meet specific customer needs.

Professional installation by a certified Siemens machine tool retrofit solution partner makes the Sinumerik 802D sl retrofit package virtually “plug-and-play” with reduced machine downtime.

http://www.machinetoolsonline.com/article.mvc/New-Sinumerik-CNC-Retrofit-Package-Brings-New-0001?VNETCOOKIE=NO

Dec 07, 2009 – Plasma Technologies, a leader in CNC plasma systems integration is excited to announce an easier, faster way for integrators to retrofit plasma and oxy-fuel cutting machines. The QuickFit line of retrofit packages transforms an otherwise difficult process into a simple one by providing all components and cables making retrofits as plug and play as possible. Just mount the components and plug them in. This innovative new design drastically reduces costly mistakes and customer downtime.

Plasma Technologies’

Rather than replace an older, but very useful CNC horizontal machining centre, a vintage car restorer opted to retrofit an up-to-date CNC and so saved on machine tool replacement costs.

The opportunity to turn a hobby into a business doesn’t arise every day, but this is exactly what happened to Will Fiennes, a lifelong fan of Riley motor cars, 30 years ago he hung up his physicist boots to follow his passion of restoring vintage motor cars.

Leaving behind his role with Smiths Industries - where he applied his degree in tribology, electrical engineering and physics - and upon establishing Fiennes Restoration because he ‘preferred to get his hands dirty’, he focused on the supply of new spare parts for, and the restoration of, pre-war Derby Bentley and Rolls-Royce cars.

Such is the success of the operation that today he works for customers the world over.

“It was clear then that not many people knew too much about these cars,” said Fiennes, “And that the supply of appropriate spares was dwindling.

So, having identified that demand, I set about satisfying it.” To give some idea of the scale of the operation, at any one time around 20 cars are at various stages of restoration, and the spares inventory now extends to an amazing 7,000 different line items, all computerised and ‘accessible’ online (www.fiennes.co.uk) via the company’s website.

“The business hasn’t changed that much during the past decades,” he reflected, “Though CNC machines have helped us considerably to achieve consistently accurate and more cost-effective batches of machined parts.” He said: “In this respect, CNC brings a new dimension to the word ‘efficiency’ even for a company like this (where a large batch may be just five-off components) though our manual machines do remain very effective for the production of suitable, relatively simple jobs.” He explained that the company havd a very old Britan capstan lathe, which it had bought secondhand with a new CNC lathe, and this wonderfully designed machine continues to reliably and accurately produce bushes and other small parts.

Fiennes said: “I discovered during the early days of Fiennes Restoration that nothing is impossible; everything can be made if you have the right tools and attitude.

But over the years it has become clear that the nation’s craft skills have dwindled rapidly, though we’ve been lucky in being able to maintain a high skills base, even though we’re based in the wilds of Oxfordshire.” This is certainly evident among the company’s 23 employees, and particularly in the mechanical restoration, coachwork and spare parts machining activities, where a very high standard of manual dexterity combines perfectly with high-technology equipment, tools and materials to enable the workforce to achieve finished results that the original car manufacturers would envy.

CNC was introduced 18 years ago, following a contract to machine cylinder head castings.

But lead times were extended to 40 hours per head when machining these parts on a DRO-driven vertical milling machine, and then sub-contracting the thread milling content as well as combustion chamber machining.

One option was to invest in CNC machinery.

However, to some extent this required a leap of faith, machining components designed 60 or 70 years ago using modern technology.

“I was sure that the way to shorten such an extensive lead time was to machine as much as possible in-house by CNC; ideally by using a horizontal machining centre where all faces of the castings could be machined in a single set-up,” said Fiennes.

“But a horizontal would have cost us at least six times more than the route we adopted - a CNC Avon turret mill, fitted with Anilam GXM control.

The versatility of the Avon allowed us to machine all faces of the 28in long casting with appropriate fixtures, albeit with a sacrifice of rigidity.” He said: “This served us well for 15 years, when we found that increasing demand could not be met by the now elderly Avon.

We then invested in a new VMC with full fourth axis, but did not dispose of the Avon.

In fact, the VMC could not do everything that the Avon did, and in particular the end faces of the cylinder head castings continued to be machined on the Avon.

It has to be said that the horizontal option, with a substantially greater investment, would have allowed all the machining to be achieved on the one machine.” However, while the Avon has remained mechanically sound (ballscrews and motors, for example, were fine), the G and M code programming routines via the original GXM control were, he says, obviously suffering from age and were proving tiresome.

But rather than invest in another new vertical mill or machining centre, Will Fiennes decided that an Anilam 3000 Series CNC upgrade from ACI (UK) would be an ideal solution - and at least 70% cheaper than investing in an equivalent new machine.

ACI (UK) simply replaced the control and wiring, and the machine - which suffered a downtime of no more than 48h - “Has been given a new lease of life”, Fiennes said.

With the switch to the three-axis Anilam 3000M CNC, and after suitable onsite training, the ease of use of Anilam’s renowned Machinist’s Language quickly came to the fore.

Of particular merit, said Fiennes, was the control’s wide range of standard cycles such as ‘peck’ drilling, pocket milling and face milling, as well as its advanced cycles that include ellipse, spiral, helical, tapping, irregular pocket milling and profile milling.

The special cycles such as counterboring are also highlighted as being especially useful.

Illustrating the system’s ease of use, he says, is the standard cycle for bolt hole patterns that enables patterns of any configuration to be quickly produced by answering five simple questions.

Likewise, after answering a few questions, the drill cycle takes users through simple drill, peck drill and boring routines.

“In addition to the continuation of the cylinder head work, the revitalised Avon is used for producing a myriad of parts including the machining of small castings and various moulds and tool steel components that utilise the machine/control combination’s three-axis capabilities.” Fiennes said: “I set up Fiennes Restoration with no formal business training, which is just as well, because we continue to this day to break every rule in the business book, particularly in terms of best practice work-in-progress and stock levels.” He concluded: “But I’d like to think that I’ve learned a thing or two over the years, and the financial sense of adopting the ACI (UK) rebuild is one example.

It’s a business I wouldn’t change for the world - and when I do find time to retire, I’ve still got a Riley waiting at home for me to restore.”.

http://www.manufacturingtalk.com/news/aie/aie201.html

MISSISSAUGA, ONTARIO, July 14, 2009 // - DiPaolo CNC Retrofit Limited (DiPaolo), the pre-eminent resource for North American manufacturers seeking precision machinery rebuilding and retrofitting services, announced today that ABLE Machine Tools Incorporated (ABLE) will be their representative in Massachusetts, Vermont, Connecticut, New Hampshire, Rhode Island and Maine. The premier machinery dealer in New England, ABLE’s expert field service technicians will provide after sales service and support while a team of outside sales engineers will traverse and tend to this territory.

“Manufacturers have a laser-like focus on the bottom line so when scouring the market for machining solutions that’ll meet the business need without bruising the budget, they’re often frustrated. But we know how to solve their problems. With ABLE representing us in New England, we’ll continue to revitalize and build machines for countless businesses across North America,” points out Nelson Martins, DiPaolo’s GM.

DiPaolo provides a one-stop shop for the entire machine user cycle - whether sourcing, buying or selling new or used, repairing and maintaining machinery. Many rebuilt or retrofitted machines are running accurately and productively after many years of constant use. Their finished machines equate new ones in performance, appearance and reliability with the only difference being a significantly reduced price.

Experience with almost every machine part, piece and problem out there has meant a loyal, diverse customer base for both of these economically stable companies - companies who share a long term view to business relationships. Significant, ongoing investment in research and development keeps these companies abreast of emerging technologies. An important addition to the marketplace, ABLE will bring DiPaolo to those manufacturers in New England requiring improved equipment performance, technically superior products and an increased market position.

“We’re pleased that ABLE has been selected as DiPaolo’s New England representative. We’ll help companies choose machines and incorporate processes that’ll satisfy their manufacturing requirements now and for years to come. Our technical staff will get things into production quickly by providing the employees with the support and training they’ll need in order to easily, and successfully, install and operate their equipment,” explains Alan Lockery, ABLE’s President.

http://news.thomasnet.com/companystory/563278

A Marwin 40m long Alumax CNC twin-gantry milling machine, used for ‘prepping’ wing stringers, has been retrofitted with a user-friendly contouring CNC capable of controlling up to 13 axes

The 40m long by 3m wide bed of the Marwin Alumax CNC twin-gantry milling machine located in Hangar 14 on the 800 acre Cambridge site of Marshall Aerospace enables ‘prepping’ operations to be carried out on aircraft stringers up to 22m in length. Purchased initially as two separate machines, which were then dismantled, moved and re-installed as one machine by Electron Engineering Services, a Heidenhain-approved TNC retrofitter, this refurbished machine is playing a key role in the supply of 11,700 stringers destined for the Airbus range of aircraft.

This is under the terms of an initial two-year contract with CAV Aerospace that requires the Manufacturing 3rd Party Department of Marshall Aerospace to hold buffer stocks of ‘prepped’ stringers ready for supply to the Tier One supplier.

According to Colin Flack, business development manager (Manufacturing), it became a ‘race against’ time to complete both the extensive hangar refurbishment and the commissioning of the re-manufactured gantry mill.

In fact, the entire project was completed within the 24 week deadline, with the official opening taking place as planned in October 2006.

Since then, Hanger 14 has become home to several thousand ‘prepped’ stringers as well as to a sizeable quantity of free issue material and, says Colin Flack, the expectation is that the sizeable order from CAV Aerospace will be the precursor to further support work in the future.

Refurbishment of the gantry mill by Halifax-based EES involved the replacement of an obsolete Allen Bradley control with a Heidenhain iTNC 530 contouring control capable of controlling up to 13 axes.
This has been fitted into a new cabinet on the first travelling gantry, which is equipped with two spindle heads.

A new, heavy-duty, 40kW spindle complete with chiller unit carries a large indexable-insert face mill that machines the upper and lower faces of stringers, with a 3.4mm depth of cut on the first X-axis pass over the work piece and a 0.8mm depth of cut on the return pass completing the milling of each face.

A second Gamfior high speed spindle, which can also swivel (A axis) through +/-20 deg, traverses the Y-axis to machine profiles on the stringer, as and when required.

EES is one of Europe’s leading machine tool CNC retrofit and refurbishment specialists, and its recommendation of the Heidenhain iTNC 530 CNC was accepted after in-depth discussions with Marshall Aerospace.

This was on the basis that future ‘prepping’ work involving more complex shapes and profiles will require a significant five-axis capability.

The intention is to equip the second travelling gantry, which has still to be refurbished, with two five-axis spindle heads that will be under the control of a second iTNC 530 CNC.

Operators report that the new control is extremely user-friendly, although Colin Flack says current machining operations are not especially complex.

Longer term, however, the decision to install the Heidenhain CNCs is regarded by Marshall Aerospace as essential to the cost-effective production of highly accurate, complex workpiece contours machined in the shortest possible time.

The iTNC’s short block processing time of 0.5ms for a 3D line segment without tool compensation permits fast traversing speeds, even on complex contours, and with its optimised tool path control, pre-calculation of the contour, and algorithms for ‘jerk limitation’, it ensures that the end result is a perfect mirror surface finish.

According to Heidenhain, this reflects the fact that for more than 20 years TNC contouring controls have been proving themselves in daily use on milling, drilling and boring machines and machining centres.

The iTNC 530 is the latest version and features a more powerful processor architecture.

However, like its predecessors, the iTNC 530 is both easy to use and flexible as it can be programmed remotely on a CAD/CAM system or on the shopfloor, with complex programs verified quickly and simply by way of the control’s optimised graphics build-up.
http://www.manufacturingtalk.com/news/hei/hei156.html