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.

NUM CNC Retrofits

NUM offers a wide range of products for the automation of CNC machines. The modern, scalable, and high-quality hardware ensures high availability and long-lasting investment. NUM CNC systems traditionally have an open and powerful software that adapts to the respective needs of the machines to be automated. The adaptability is not limited to the PLC programs or HMI adjustments. Specific functions can, for example, also be integrated to the real-time system of the CNC control. But it is never the case that the system is only a building block. The system represents a complete and ready CNC, which can be modified at will.

The CNC control itself is a key element of the NUM solution. Powerful processors with high computing speed and an intelligent layout with potential for expansions ensure a high preservation of value. The PLC is programmed according to IEC 61131-3 and the modern development environment provides new tools for development, commissioning and servicing. With a capability of more than 200 axes, over 40 channels, 4000 IOs, more than 1 GB of PLC memory and more than 30 MB of user memory, Flexium+ can easily control the most demanding applications. Thanks to the full scalability, small configurations can of course also be optimally represented.

We Choose NUM for High-End CNC Applications
For projects in need of a High-End CNC Solution we use NUM Flexium+ 8 and Flexium+ 68 CNC Platforms. The Flexium CNC System gives us tremendous flexibility when it comes to developing comprehensive solutions for our customers. Additional options can be selected individually or as a technology package (milling, turning, woodworking, etc.). Having this kind of flexibility allows us to provide our customers with solutions in a timely and cost effective manner.

Open, User-Friendly and Ergonomic, Guaranteed Efficiency
NUM CNC systems are known for their high degree of flexibility and adaptability to various configurations. This is achieved primarily through powerful functions and operator panels with dedicated Human Machine Interfaces (Flexium+ HMI).

NUM CNC Functions
Flexium+ systems have high-level CNC functions and high performance servo drive algorithms that can be further tailored thanks to the well known dynamic operators (ISO or C) for the CNC and their new counterpart on Drive: The Drive embedded macros. This allows for the productivity of all types of machines to be maximized.

NUM Motors: Perfect for all Applications
NUM produces a comprehensive range of motors, all offering excellent volume/performance ratios and great dynamics, to suit almost any application. In combination with NUM drives, these motors provide excellent smoothness even at very low rotational speeds, and can be easily integrated into machines.

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.