According to CNC Design , retrofits and modernisation can extend the life cycle of machines and systems. Individual components are replaced with modern and innovative technology, can provide machines with new control and drive technology, expanded functions and mechanical refurbishment. Complete solutions for mechanical and electrical overhauls secure the long-term machines and plant investments.
Modernising machines by retrofits is an economical way to upgrade the plant. Retrofits are important for medium to large machines of high value. The mechanics of older machines may still be in good condition or may require re-conditioning. Often the control and electrical components become obsolete or unreliable and need replacement. It is vital that machines conform to the new safety regulations. CNC Design can provide electrical and mechanical turnkey solutions.
The degree of modernisation and the technology used to update to the new Siemens motion control products, determines the scope of the retrofit package. Each machine needs to be evaluated and CNC Design can offer a variety of additional options and services such as training courses, service contracts and software functions.
Retrofits of the existing machines have the following advantages:
- Improved availability
- Increased levels of efficiency and productivity
- Secure and long-term supply of spare parts
- Improved operating and programming comfort
- Faster machining cycles for complex parts
- Reduced downtimes and mean time to repair (MTTR)
- Reliable data management and increased storage capacity
- Low-cost alternative to purchasing new equipment
- Short down times
- Quick availability of a new working machine
CNC Design have completed retrofit projects for small, medium and large sized machines in Australia, New Zealand and the South East Asia region. CNC Design can also finance machine or plant modernisation with leasing contracts offered by Siemens Finance.
Upgrading an NC machine to the new CNC systems is a common form of CNC retrofit. In this case, CNC Design can supply a new Siemens SINUMERIK CNC system, servo drives, spindle drive and encoders. CNC Design can also provide a new electrical cabinet and machine wiring. Mechanical design for most modern CNC machine tools differs from conventional machines. CNC conversion may involve re-surfacing slide ways, fitting balls crews and lubrication systems. CNC conversion can add modern features including tool changer, part probing and pallet shuttle.
Large component manufacturing in heavy engineering industries such as shipbuilding, power generation, gear and gear box manufacture, mining, paper, steel making, truck, rail and defence requires gigantic machine tools and special purpose machines. Retrofitting these kinds of machines requires special expertise. CNC Design offer retrofits for roll grinders, wheel turning and re-profiling lathes or gear grinding machines.
CNC Design retrofits have the following advantages:
- Higher productivity with new CNC programming and interpolation functions
- Increased accuracy and surface finish due to new digital servo drives and high speed cutting technology
- User-friendly conversational programming and simulation with graphical support
- Easy operation and maintenance with modern fault monitoring and diagnostics
- Network-capability over Ethernet including remote diagnostic feature through Internet
- Customised solution for applications
- Tool management software
- Part probing and gauging
- Long term local support for spare part, field service and service contract
- Savings on foundations and tooling
In general, the lifetime of web based production machines (printing, paper converting, flexible packaging line, laminating-coating) exceed the 20-year mark. All requirements have been met assuring that they can run the intended production in multi-shift operation. To a certain degree, the best technology can also not satisfy increasing demands from the users. It is not only the markets for end products which change but also operational requirements such as high speed, flexible configuration, less waste or energy usage.
Most of older web-based production machines are still equipped with DC drives or old type of AC drives which have functioned reliably for years. However, they are based on analogue control technology with limitations on synchronisation, diagnostic function and integration within other control system within factory.
In addition, they may be obsolete and spare parts are hard to find. These can be the main reasons for considering drive retrofit with new technology AC or DC drives. CNC Design have completed drive upgrade projects in various types of web based production machines including printing, paper converting and packaging machines.
CNC Design and their subsidiary Advance Engineering System offer service for complete electrical and mechanical turnkey solutions for individual projects.
The extended services cover a wide range of expertise, such as rotogravure and flexographic printing, UV and air impingement drying, extrusion and adhesive lamination, printing registration systems, web turner bars and a range of in-line finishing systems, such as rotary die cutting, embossing, creasing, punching, sheeting and slitting. Having designed and built high speed web fed machines, capable of non-stop production of flexible packaging and folding carton substrates, CNC Design and AES have technology relating to flying splice unwinding and rewinding systems and associated web tension control. CNC Design provide custom designing enhancements and modifications to existing printing and converting machines.