CNC Retrofit Solutions

As an Integrator with over 38 years of experience in the machine tool industry, we believe that to properly retrofit a machine tool with a new CNC system, the application and specific customer requirements must first be considered.
By carefully evaluating the specific needs of each application, we develop comprehensive turn-key retrofit solutions that leave our customers with little to do when it comes to retrofitting their machines.

Fanuc CNC Retrofits

With over 700,000 systems installed, the Series 0/0i is the world’s most popular CNC model. The latest, most powerful Series 0i-D is designed for commodity machines that demand the ultimate in reliability, performance, connectivity and safety. The Series 0i-D provides over 200 high-value features in the standard configuration.

It features 52-year MTBF and superior diagnostic tools for a low MTTR. Performance, accuracy, surface finish and reliability are optimized with high-performance hardware and innovative software.

A wide range of industry-standard protocols are supported for low-cost and flexible integration with manufacturing and business systems, including Ethernet, FTP, DeviceNet and Profibus. Dual check safety is fully supported.

Over 200 high-value features
The Series 0i-TD and Series 0i-MD are value packaged with over 200 high-value features including nano interpolation, embedded Ethernet, extended and background editing, Custom Macro with additional variables, high-speed skip, thread cutting, rigid tapping, feed-per-rev programming, tool radius compensation, tool management and multi-language display with dynamic switching. The 0i-TD also includes polar coordinate interpolation, multi-threading, thread cutting retract, continuous threading, variable lead threading, Advanced Preview Control, multiple repetitive cycles, tool geometry and wear compensation. The 0i-MD also includes helical interpolation, AI Advanced Preview Control, canned cycles for drilling, scaling, 400 tool offset pairs and 48 workpiece coordinate offset pairs.

Available on the world‘s best-in-class machine tools
Available on the world’s leading machine tools including lathes, machining centers, grinders, punch presses and routers.

Ultimate resolution and precision for quality machining
The CNC and drive system executes at a nanometer resolution all the way down to the 16-million count encoders for the maximum precision and the smoothest contoured surface finish quality.

High-speed machining for quality and reduced cycle times
Advanced software algorithms analyze part geometries and machine capabilities and adjust trajectories and feedrates to provide the smoothest tool paths for the highest processing speed at the specified precision.

Simple operation for maximum productivity
Operators with previous FANUC experience can use their existing skills as they learn new techniques, and existing part programs will run smoothly with little or no modification.

Connectivity for today’s high-tech manufacturing
The 100-MBit Ethernet interface integrates the CNC into a network for high-speed part program transfers and the collection of process related data. It also supports remote troubleshooting from the maintenance department or a machine tool builder anywhere around the world. Because the Ethernet port does not use a public operating system, it is practically “hacker-free” and virus immune.

High reliability and easy maintenance
Reliable hardware with clear diagnostics provides a stable platform for maximum machine availability. With a mean-time-between-failure of 52-years, and production lifetime product support, FANUC controls provide machine availability that far exceeds any competitor.

Powerful simulation tools
Simulation of CNC operation, part programming and maintenance screens for effective training of operators, part programmers, maintenance engineers and technicians in a safe environment.

Customer specific solutions
Unique solutions may be realized using powerful programming languages, user interface development tools, real-time macros and PC functionality. Series 0i-D CNCs may connect with the Automotive HMI, Windows compatible PCs, or rugged, diskless Windows CE.NET operator interfaces.

Project Evaluation Process

Machine Tool Specification

During the evaluation process we look at key characteristics of the machine tool. Such things as machine type, number of servo axes, number of spindles, motor nameplate information, type of feedback, motor cable lengths, and machine auxiliary functions are key in determining the correct solution. We also look at the specific control features the customer must have to do their machining functions. These features may be canned cycles, macro programs, rigid tapping, threading, spindle orientation, and C-axis functionality, to name a few. We also look to see if the customer has any mechanical and/or electrical information for the machine. Having electrical schematics can help minimize initial cost to the customer. Digital pictures of the overall machine, the electrical cabinet (inside and out), and the operator station help us determine the machine layout and the design required for the solution.

Condition of Machine

It is extremely important to review the condition of a machine both mechanically and electrically when evaluating it for retrofit. Wear of various mechanical components can lead to poor performance of the control system. Such things as wear in the ways, ballscrew components, and spindle bearings need to be addressed during the control retrofit process. Additionally, components on the machine that are not working properly such as lube systems, field indicators (switches, etc.) and hydraulic leaks can all cause the machine capability to deteriorate. In some cases a good control system can work around worn components for a while, but in most cases this is not desirable. Also evaluated is the condition of electrical components such as field devices, enclosures, and cooling systems. This evaluation determines if existing components can be reused or if they need to be replaced.

Application Requirements

The customer’s specific use of their machine determines the application requirements. In some cases a customer may want to add material handling, remote access, supervisory information, or additional control features. It is important to discuss the customer’s application requirements in detail during the evaluation stage so that all control options needed are reflected in the quotation.

Current Control Shortcomings

The customer knows all too well the shortcomings of their outdated control system. These shortcomings can increase operating and support costs and increase machine down-time; which ultimately cuts into profits. Such things as control speed, program memory, internet access, and on board programming can all effect the cost of manufacturing. Newer control platforms allow the customer to address areas such as these and many more.

Project Timeline

The project timeline is important for a number of reasons. The customer may need to know how long the machine will be out of service during installation or how long the overall project will take to complete. The timeline will also help determine how part shipments, system build, and installation effect the customer directly. Medium size retrofit projects on average take 8-12 weeks from order placement to completion of the project. This can vary based on the size and complexity of the machine. In some cases emergency retrofits can be performed within a couple weeks if parts are in stock and the integrator’s schedule is open.

Retrofit Budget

A customer’s available budget or what they are willing to spend will in many cases determine the type of retrofit they have done. Cost can increase substantially if a customer wants more than just the control replaced. Such things as upgrades to magnetic, drives, and enclosures can as much as double project costs. Additional things such as special control features and mechanical work can also effect the overall project cost.