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Original Condition
This machine came to MTB with very unreliable controls, old
and dry rotten cabling, and a poor hydraulic and lubrication system. The CNC
was a Heckler & Koch 783 with very limited programming storage and M/G code
programming format. The original drives with Siemens DC with Heidenhain
encoders and scales for position control.
The Recontroled and Recertified Machine
As part of the recontrol project Machine Tool Builders
designed and manufactured a completely new electrical cabinet and we rebuilt
much of the hydraulic
and lubrication systems. We replaced many machine mounted components and
cables due to the dry rot. We installed all new motor power and feedback
cables. Connection from te machine to the cabinet was made through Harting
connectors for fast disassembly and easy re-assembly in the field. We
engineered and manufactured the mechanical adaptations required to convert
the machine from the old DC servo's into a
fully digital system.
The new control system was centered around a Siemens 840D CNC
and a PCU 50 front end with Windows Embedded XP Pro and the drives were all
changed to new Siemens 611D servos. All new Heidenhain absolute encoders and
scales were installed so that no homing was required. This combination of controls was extremely cost
efficient, offered short lead times and was very easy to implement, which
translated into savings for the customer.
The machine was fully recertified after the recontrol was
completed. The recertification process MTB uses encompasses the following
key checks.
During the process of the recertification all obviously worn
equipment is replaced. Items like chaffed hoses, broken cables,
non-functional gauges, pressure switches, proximity switches etc. are
replaced as required. For safety reasons, the guarding is returned to OEM
design if all the pieces are present.
This machine was also cleaned and painted at the customers
request. However this is an optional service which does not have to be done
on every machine.
The Conversational Software
We installed our newest version of MTB GearCAM
software which allows for very easy Windows based programming for the gear,
cutter and process information. The software is structured around a database
concept, where you can store multiple gears, cutters and processes. Then at
the click of a mouse, you can select any combination of gears, cutters and
processes to be executed. Storage and retrieval of the completed programs is
made easy due to the Windows environment and the PCU 50's onboard hard
drive.
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