before/after retrofit example
machine control package
Siemens has announced the immediate availability of a Sinumerik 828D CNC retrofit package for 3- and 4-axis mills or 2-axis lathes - complete with CNC, three servomotors, one spindle motor and drive plus the application engineering, cabling, installation and commissioning support from an authorized Siemens solution partner. "All parts, labor and service from the Siemens solution partners are fully warranted for two years under this program," said a company spokesperson.
In detailing the program, Tom Curfiss, Retrofit Business Development Manager for Siemens Industry, Inc., Machine Tool Systems, said, "We saw a large volume of small- to mid-range 3-axis mills and 2-axis lathes in the market that average 15-20 years in age, but still have solid iron and years of viable use life left in them. So, we decided to assemble a complete package for our solution partners that would allow them to assess the needs of the shop, do the necessary engineering, retrofit the machine and get it running, often better than new, for a very affordable price, compared to buying new equipment in this demanding and competitive economy."
With this retrofit package onboard the older machines, Curfiss said, "Shops can quickly realize the benefits of new CNC technology, including faster processors, more accurate feedback devices and better performance on contours and pocket machining, while reducing downtime. The Sinumerik 828D computer numerical control also provides users graphical support for machining cycles and part production simulation, plus intuitive help functions with movie-quality animations onscreen."
According to Curfiss, various market factors and economic conditions have made the retrofit of existing machine tools a very viable option for the large metalworking department at an OEM, as well as the job shop sector of moldmakers, tool & die and contract part manufacturers alike. "Today's business climate has combined with economic factors involved in the manufacture of control packages to create an ideal atmosphere for retrofit," he said. "Our company has long been involved in the upgrade of large gantry mills for aerospace production, for example. But today, it is just as likely you will find our retrofit solution partners outfitting a 3-axis mill or even a basic lathe with a new entry-level or mid-range CNC, motor and drive package. In addition, this work can now be done at a price point comparable to just the cost of the CNC a decade ago, owing to economies of scale in the manufacture of these control packages. Under the new arrangement, the motor size on the machine will determine the final package components, but virtually any 3-axis mill in the market can be retrofit, regardless of table size or travel requirements."
Siemens' nationwide network of retrofit solution partners work in close cooperation with Siemens regarding the possibilities of retrofitting machines with Sinumerik CNC and also to provide complete services for the installation and refurbishment of the CNC machine. These partners can offer full application engineering, service and repair for Siemens CNC packages.
"Retrofit solution partners must have a demonstrated ability to work on CNC, PLC, servomotor, digital drives and all accompanying peripheral products, plus have a proficiency in the development of software packages and code-writing related to PLC and CNC applications," said the spokesperson. "Every solution partner then commits to a number of CNC training sessions and is required to keep at least two Siemens-trained engineers on staff at all times."
"Siemens solution partners are not geographic-specific, as several have proven expertise in the field working on particular types or brands of machine tools," said Curfiss. "The selection process for the appropriate partner takes many factors into consideration. We have partners who specialize in 5-axis machines, others who have expertise in a certain industry such as aerospace or medical and others who have their greatest strength in a particular area of the country. Depending upon the job specifics and the logistic costs involved, we work hard to match the right partner to the customer's needs.
"Typically, the tipping point on a retrofit job is 60% of the price of a new machine. However, many machines have outdated controls, although they still perform adequately in the shop or production environment. The challenge, when we do our on-site machine evaluation, is to determine whether a retrofit will make an appreciable difference in the performance of the machine, as other factors in the mechanics of the iron might make a retrofit impractical. Today's control technology is evolving at a very rapid rate, making some equipment that went out of production just 10 years ago less than optimum in contributing to maximum machine tool performance. Running machine tools with 20-year-old technology today will simply not keep a shop as competitive as it needs to be."
Curfiss' background in machine tools spans over 40 years. "A lot of people think their old iron is just impossible to keep running, even with a retrofit, but we are often able to make the old equipment run better than it did when it was new," he said. "This is something our customers tell me every day. This achievement is the result of faster control processors, improved motor and drive technology, even more accurate and responsive encoders as well as other machine status sensing devices. You cannot, however, fix a broken leg with a bandage, so the machine evaluation needs to be very comprehensive."
Curfiss suggests that the large production departments and job shops need to have regular assessments done on their prototype and production machine tools to determine if a retrofit might be in order. "The savings can be substantial compared to purchasing new machines, because it is not only a matter of the dollars saved at the outset, but it is also the long-term production improvements that inevitably lead to even greater profit for the job shop or OEM.
"A shop can benefit greatly from getting more life from the old iron on the floor. This package also allows our retrofit solution partners to greatly expand their customer base in a profitable manner. In the end, it really is a win-win for everyone."
For more information contact:
Tom Curfiss
Retrofit Business Development Manager
Siemens Industry, Inc.
Machine Tool Systems
4170 Columbia Road
Lebanon, OH 45036
513-234-9774
tom.curfiss@siemens.com
www.usa.siemens.com/cncretrofit