Machine tools

RETROFIT AND MODERNIZATION

Machine tools

RETROFITS AND MODERNIZATION Our family owned company develops and manufactures customized machines and designs machine tools based on work piece requirements successfully since 1970. The worldwide customer base comes from different industry branches, such as: ■ aviation and aerospace ■ ship building ■ automotive industry ■ power plant components ■ paper machine industry ■ roll maker ■ railway machining ■ machining of forged components ■ aluminum and graphite machining ■ portable machining units for construction and assembly areas

Machines maintained at an optimum, also need to be retrofitted after years of productive operation in order to increase their economic efficiency. If we look at the continuously increasing demands on quality and the rationalization involved, it is not enough to re-condition the existing machine tool „as good as new“. Changing given parameters or add new components and sub-assemblies require constructive assessment and design. In a lot of cases these measures lead to higher efficiency then it would be achieved with a new standard machine. Therefore a retrofit is an economical alternative to buying a brand new machine. Advantages of a modernization: ■ restored or often increased productivity ■ increase of machine performance ■ use of state of the art technology and components ■ wider machining range ■ availability of control components and spare parts is guaranteed again ■ infra structure stays in place, e.g. foundation, chip conveyor

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SERVICE

NEW MACHINES

OVERHAULING

USED MACHINE TOOLS

Machine tools

By combining our experience from designing and building new machines with the experience from revamping and modernization of different machine types from various machine tool builders, together with the extensive experience from repair and maintenance contracts, we can provide a wide range of services: ■ check and measure the machine to be overhauled ■ work out possible solutions and a cost analysis of the machine which should be revamped ■ design changes, re-designing and new design of machine subassembly groups ■ geometrical overhauling respectively replacement with state of the art guiding systems ■ modernization of mechanical sub-assemblies, accessory units and machine components ■ modernization of hydraulic and pneumatic components ■ applying new high-performance main drives and auxiliary drives ■ applying of state of the art powerful control systems ■ mounting and integrating additional accessory equipment ■ manufacture machine housings ■ training and introduction on the overhauled and modernized equipment

Retrofit and modernization of machines from the following machine tool builders: ■ ASCHERSLEBEN ■ BOHLE

■ KOPP ■ MEUSELWITZ

■ BUTLER ■ COLLET + ENGELHARD ■ DROOP + REIN

■ MICRON ■ PEGARD ■ RAVENSBURG ■ SCHARMANN

■ GEORG ■ HEYLIGENSTAEDT

■ SCHIESS ■ TOS

■ HOESCH MFD ■ HURON ■ INGERSOLL-BOHLE ■ IRLE ■ JUNG-JUNGENTHAL

■ WALDRICH COBURG ■ WALDRICH SIEGEN ■ WOTAN ■ WOHLENBERG

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SERVICE

NEW MACHINES

OVERHAULING

USED MACHINE TOOLS

Machine tools

Modernization of machines make Collet & Engelhard Service and spare parts for machines make Collet & Engelhard We received the complete technical documents of the former Collet & Engelhard AG, Offenbach, Germany. This enables us to provide the complete qualified service o all their machine tools. Besides a qualified spare parts service, based on original machine drawings, we are also able to provide complete service including revamping and overhauling of these machines.

Collet & Engelhard horizontal boring machine with traveling column type Bf 100 ■ new headstock with Z-axis travel Z = 800 mm, 15 kW power and spindle diameter 110 mm, speed range 1 – 1,500 RPM ■ increased column height by 600 mm ■ new feed drives in X- and Y-axis with ball screws, linear distance measuring systems and AC servo drives ■ complete new electrical equipment including CNC control make Siemens

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Machine tools

Examples for overhauled machines Ravensburg facing lathe type 2400-CNC Besides a complete basic geometrical modernization this facing lathe make Ravensburg has been equipped with various peripheral units. A new tool changer with modular tooling system and measuring unit has increased the level of automation significantly. It enables to use larger basic tool holders and longer holders for the new, form-closed clamping system which can be changed automatically very precise and rigid. The tools are mounted by a CAPTO-system on the tool holder. A special, CNC controlled measuring unit is used for measuring the exact tool tip position. This measurement is transferred as correction value to the Siemens 840 D control unit. The tool magazine is provided for 12 tools. With these peripheral units the level of automation has been increased significantly. Non-productive time has been reduced drastically and clamping time has been reduced due to using new tools. Work area housing, dust collection system and chip removal system has been changed based on the new machine configuration. By this modernization and using the solid basic machine concept the complete machine has been changed technically so that it equals the state of the art technology available on the market at the moment.

prior

new tool magazine for 12 tools

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machine with closed housing

machine with open housing

Machine tools

Examples for overhauled machines Portal type milling machine type FP 2000 SA, make Droop & Rein This Droop & Rein portal type milling machine type FP 2000 SA has been geometrically reconditioned. In addition is was provided with a new Siemens 840 D control system, provided with special functions for operating the machine in tool and die shops. The enlargement of the tool holder from 40 to 60 tools enables an easier tool management. Furthermore the revamping of the CNC fork milling head has improved quality and availability of the machine. Hydraulic unit, complete coolant supply and the central lubrication system have also been modernized with state of the art components.

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fork head prior

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fork head afterwards

Machine tools

Examples for overhauled machines Portal type milling machine type GF-H20, make Waldrich Siegen We did the complete modernization of the portal type milling machine type GF-H20 (make Waldrich Siegen) based on customers request for higher performance and easier maintenance. After the modernization the machine was equal to a new machine. The target made is necessary to design all main components new. ■ Completely new manufacturing of 8 milling units, each with 32 at a maximum speed of 6,000 RPM. The increase of power and torque on the spindle has been achieved by changing the performance characteristic. A planetary-type change-over gear with more powerful main spindle motor has been used. ■ provided in modular design, which enables to machine 8 work pieces simultaneously prior main spindle motor incl. gear box feed drive of tool length compensation working spindle with automatic tool clamping complete V-axis for spindle distance adjustment ■ elimination of all power-drive transmission and use of single drives with gantry function respectively synchronization function ■ gantry function on X-axis drive with hydraulically adjustable bracing; pre-stressing programmable through CNC control ■ powerful chip conveyors and mist collection system ■ Siemens Sinumerik 840 D control system with 29 NC-axes ■ tool changer with space for 240 tools and automatic tool length measuring system integrated

machine control make Siemens

8 spindles

tool changer

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machine front view

machine back view

Machine tools

Examples for overhauled machines Rebuilding, overhauling and modernization of a lathe make Heyligenstaedt ■ center of this retrofit was the geometrical overhaul based on DIN 8607 standard and modernization of all main components ■ slots have been milled into the bed guides and hardened steel bars (thickness 12 mm) have been put in and were complete ground afterwards ■ counter guides coated with special plastic material Biplast ■ installation of a direct measuring system on the Z-axis ■ exchange of all bearings, lubrication piping, ball screw drives, electrical cables on components such as head stock, tail stock, support and steady rests

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Modification and modernization of roll lathe make MFD to a CNC-controlled roll lathe with rigid railhead ram ■ geometrical overhaul of the bed including new hardened ribbed guides ■ new manufacturing of a rigid railhead ram with plate holder ■ providing X- and Z-axis with ball screw drive and linear measuring system ■ AC feed motors with analog control ■ complete new electrical equipment including new R+D CNC-control system

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rigid railhead ram

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Machine tools

Examples for overhauled machines Rebuilding, overhauling and modernization of a lathe make Meuselwitz ■ center of this retrofit was the geometrical overhaul based on DIN 8607 standard and modernization of all main components ■ re-grinding of machine beds ■ counter guides coated with special plastic material Biplast ■ exchange of all bearings, lubrication piping, ball screw drives, electrical cables on components such as head stock, tail stock, support and steady rests ■ new hydraulic and lubrication ■ exchange of control unit from Siemens 840 C to Siemens 840 D

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Vertical lathe make JUNG-JUNGENTHAL The following sub-assemblies and components have been retrofitted and installed new: ■ control system Siemens SINUMERIC 840 D ■ measuring system: Heidenhain incremental length measuring system type LS-LB, distance coded ■ main spindle drive type 1PH7-AC make Siemens (55 kW) and Siemens 611 with modular drive system ■ axis drive as servo motors type 1 FT 6 make Siemens and feed drives ■ electric cabinet with all components – axis drives, spindle drive and auxiliary drives ■ new cables on the complete machine ■ control station including monitor, TNC control panel and machine operation panel ■ complete geometrical overhaul

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Machine tools

Examples for overhauled machines WALDRICH SIEGEN portal type milling machine type PFH 75 with enhanced cross rail The new slide including angular milling head can be used vertical or horizontal. It was the basis fort he power enhancement from 60 to 135 kW. Guiding distance of the cross rail was enlarged and a complete new electrical system including Siemens 840 D control system has been provided. Also a new tool changer (12 tools) and pick-up station for additional angular heads have been installed on the machine.

afterwards

angular head with 135 kW

Droop & Rein portal type milling machine type FP 160-2 This Droop & Rein portal type milling machine type FP 160-2 is used for machining rails and switches. ■ installation of new Heidenhain CNC control system ■ complete new cables and electrical cabinet ■ all guide ways are re-ground, coated with special plastic material and scraped ■ complete geometric test according to DIN 8626 standard ■ new central lubrication and hydraulic unit

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prior

prior

Machine tools

Examples for overhauled machines Double spindle portal type milling machine make Reichle & Knödler This portal type milling machine make Reichle & Knödler is used for machining of forged steel blocks. To ensure a long term performance of the machine a complete geometrical revamping of guide ways and spindles has been provided. In addition all parts of the hydraulic, lubrication and electric (Siemens 840 D control) have been changed.

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afterwards

Modification of a two column planning machine to a high performance portal type milling machine with CNC control and 3 machining spindles (360 kW total spindle power) ■ new 2-spindle vertical milling head stock, each with 120 kW ■ reinforcement of the cross beam and providing wider guide ways distance ■ new horizontal milling head stock with one machining spindle, also with 120 kW ■ all NC-axis are provided with new ball screw drives, linear measuring systems and digital feed drives ■ hydraulic weight relieve system ■ altering table drive to NC-axis ■ new supply of complete electrical equipment including Siemens 840 control system ■ semi-automatic tool changer for all three machining spindles afterwards

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prior

Machine tools

Examples for overhauled machines

prior

Pegard milling and boring machine type Precivit 3.S.BC Modernization: hydrostatic instead of slide ways The table type milling and boring machine make Pegard with 60 kW power has been modernized with hydrostatic guide ways and back-lash free drives. A main disadvantage of slide ways is the relative high wear and varying friction. Especially when milling contours – simultaneously with several CNC axes – the stick-slip effect can be noticed at very low feeds or when changing the direction. This results in contour inaccuracies. With hydrostatic guide ways, the contact surface of components which slide on each other is separated by an oil film. This minimizes the friction coefficient significantly and the stick-slip effect no more exists. Using these almost wear-free guides combined with drive elements free of back-lash guarantee an increased accuracy over the whole machine life cycle. We use a controlled hydrostatic to ensure an optimal adjustment to the existing machine elements. Each hydrostatic pocket can be controlled separately. One of the many advantages is a higher rigidity versus the conventional hydrostatic system and the required amount of oil is reduced. Thanks to this techniques and the use of a modern CNC control type iTNC 530 make Heidenhain provide the machine with a new level on quality.

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Machine tools

Examples for overhauled machines Scharmann milling and boring machine Ecocut 2.2 ■ complete geometric accuracy according to DIN 8620 standard ■ re-grinding of guide ways, new coating of counter supports including

scraping ■ new hydraulic, lubrication and cooling ■ changing of all bearings and sealings ■ complete new electric including Heidenhain iTNC 530 control

system

TOS boring and milling machine type WD 130 ■ new headstock with travel in W = 900 mm and Z = 1,000 mm, power 60 kW, speed range 2.5 – 2,000 RPM, spindle diameter 150 mm ■ new feed drives for X-axis and y-axis with ball screws and AC servo drives ■ increased column height by 350 mm and hydraulic weight relieve system ■ all NC-axes are provided with incremental, distance coded length measuring system ■ complete new electric including HEIDENHAIN control system type TNC 426

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Machine tools

Examples for overhauled machines

prior

Roll neck milling machine type DFF 33, make Irle The portal type roll neck milling machine has been provided with two new milling heads. Each head has a power of 71 kW at a maximum of 2,400 RPM. Both new headstocks are provided with two spindles each. The spindles are under 90° to each other and can be operated independently. Steep tapers SK 60 for tool clamping are integrated in the well dimensioned spindles. An optimized speed-torque characteristic allows for milling operation with high torque as well as drilling operation with higher speeds. During the design phase the criteria’s for high torques and high speeds have been integrated. An easy to maintain structure with a low number of gear components was given a high priority. Torsional stiffness, low noise level, dampening and temperature stability lead to a high work piece quality on an economic cost level. Part of the scope fort he modernization of the roll neck milling machine was besides the new headstocks a complete overhaul of the guide ways, drives and clamping system. Also the weights relieve system and dividing unit have been retrofitted and a new Siemens 840 D control was integrated. With newly designed components all feed axes are designed backlash-free. A special measuring system allows for precise positioning of the roll on the steady rests via NC axis. In addition to the increased performance, another advantage of this modernized machine is that set-up times and non-productive times have been considerably been reduced.

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Machine tools

Examples for overhauled machines Turbine blade groove milling machine make KOPP ■ complete geometrical overhauling ■ new guide elements ■ digital axis drives ■ two-step main drive ■ oil cooling unit ■ hydraulic weight relieve system ■ tool clamper ■ chip conveyor ■ electrical equipment including two Siemens control units type 840 D

Modul high performance gear milling machine type ZFWZ 100 ■ providing complete new electric and Siemens 840 D control system ■ rebuilding to single drives with electronic positive drive ■ bed extension on X-axis by 3,000 mm ■ change to ball screw drives ■ new hydraulic weight relieve system with gas pressure accumulator ■ complete geometric test according to DIN standard

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The customer is the focus of everything we do. Together with him we want to fulfill his aims and requirements!

Certified to EN ISO 9001 Certification Registration No.: 20 11 66

Rottler Werkzeugmaschinen GmbH Ingenieurbüro und Maschinenbau Hauptstrasse 39 D-57555 Mudersbach Germany

Anlagen Maschinenbau Automation GmbH

Phone: (+49) 271 35 91 90 Fax: (+49) 271 35 47 52

Phone: (+49) 271 35 92 20 Fax: (+49) 271 3 57 63

Hauptstrasse 39 D-57555 Mudersbach Germany

E-Mail: [email protected] Internet: www.rottler-maschinenbau.de