Retrofit For Machine Tools

Retrofit for machine toolsMachine modernization directly from theCNC manufacturer – increasing efficiency andeconomic feasibilitysiemens.com/motioncontrolservices

Since its retrofit, this Ravensburg turning machinePKZ is again state-of-the-art – at half the cost ofbuying a new machine and with a much fasterdelivery time. What’s even better is that Siemensdelivered a complete solution consisting of bothmechanical and electrical modernization.2

Greater productivity –at half the costMachine retrofits: increasing productivityand efficiencyAfter ten or more years of operation, themechanical components of machine toolsare usually still in good condition. Butcontrol and drive technology has continuedto advance steadily during this time – introducing new functions that make productionmore precise, more energy-efficient, andmore economical. Retrofits are one way togive older machines access to these innovations by replacing old functions with newones. The challenge lies not only in replacinga technical component but in exploiting thevaried capabilities of modern control anddrive systems, which offers the user newbusiness opportunities. The main goal is tosmoothly integrate the advantages of driveand/or controller upgrades into the existingmachine concept so that the user workswith a proven machine – one that is nowstate-of-the-art – without having to purchasea brand-new one.Spare parts supply: ensuring machineavailabilityThe main concern of machine tool users,however, is not the use of new capabilitiesof modern controllers but rather the certaintythat by modernizing or upgrading their investment, they will ensure their productivity overthe long term. This especially applies to spareparts availability, which is longer for moderncomponents than for older ones. Electroniccomponents are a good example of this,because their integrated circuitry is replacedby the next generation every few years.3

Customized retrofits –for better performanceModernization made to measureEach retrofit begins with a thorough assessment of the requirements to be met, alongwith an in-depth customer consultation. Onthis basis, Siemens develops the best possiblesolution concept with scalable systemcomponents, depending on the CNC machine’stechnology, functionality, and performancerequirements. The Siemens specialistsexamine all the machine’s components:the CNC controller, drives, motors, measuringsystems, switchgear cabinet, and, if necessary, the machine integration into theproduction network. If needed, Siemens canalso perform mechanical reconditioning orpartial modernization by replacing CNCtechnology and reusing the machine’sexisting analog drive system. The goal isalways to optimize machine productivity inline with the range of applications and thecustomer’s goals.Declared goal: maximum performanceand flexibilityThe retrofit service can be supplementedwith numerous services beyond the use ofcutting-edge SINUMERIK controllers, SINAMICSdrive systems, and SIMOTICS motors. Thegoal is always to ensure the full benefits ofthe modernization work. The precise planning and careful preparation of the retrofitby our service technicians guarantee minimaldowntimes in the case of individual production solutions. This includes a significantamount of added quality and flexibilitythanks to the performance of cutting-edgecomponents supported, for example, bygeometric measurement and compensationof dimensional deviations in large machines.Through the use of Siemens’ PLM software,customers gain greater transparency inproduction planning and the digitalizationof their production process. Tools and NCprograms are managed by NX-CAD / CAM,Teamcenter, and SINUMERIK Integrate withManage MyTools and Manage MyPrograms,which optimally integrate them into theproduction process. Siemens Motion ControlServices also offers training courses as wellas repair and service NUMERIKEthernet,CF-Card, USB4SINUMERIKIntegrateSINUMERIK &NX CAMTeamcenter

Siemens offers a comprehensive portfolio ofcontrol and drive solutions for a wide range ofrequirements – from standard turning and milling machines to systems in the upper performance range.SINUMERIK 840D slThe open CNC for individual retrofit solutionsThe SINUMERIK 840D sl features maximum openness andflexibility, making it the optimal CNC for individual retrofitsolutions.SINUMERIK 828The compact CNC for standard machinesThe SINUMERIK 828 controller is suitable for modernizingstandard turning and milling machines for small andmedium-sized applications.SINAMICS S120Drive with an extremely high degree of flexibilityThe SINAMICS S120 is a high-performance, highly flexibledrive for modernizing machine tools. Thanks to the widerange of motor modules, it can meet all drive requirements.SIMOTICS motorsThe powerful drive systemHigh static torque, high maximum rotation speed, andperfect concentricity combined with Weiss spindletechnology make SIMOTICS the optimal drive system forretrofits.5

Efficient operation –safety at workSINUMERIK controllers are extremely user-friendly thanks to numerous functions inSINUMERIK Operate. These include modern touch and gesture control as well as workwith animated elements.Touch and gesture controlThe SINUMERIK touch panel generationwith projective-capacitive touch technologyoffers top-level performance for complexPC-based visualization tasks as well as anattractive front-end design. Thanks to thescratchproof, coated user interface with itsbrilliant display, it supports operation evenin harsh environments.Animated elementsWith animated elements, SINUMERIK Operate makes entering parameters extraordinarily easy. A unique display with animatedsequences renders operation even moreconvenient through the use of animatedelements.6Side screenThe preconfigured sides creen providesadditional operating area with more functionsin the HMI. For each operating situation, theuser has all the information at a glance andcan scroll both vertically and horizontallythrough the collapsible side screen.

All-around safety:SINUMERIK Safety IntegratedSINUMERIK Safety Integrated is the safetypackage for controllers and drives. It combines protection of people and machineswith high efficiency and profitability, because all functions can be integrated intothe control and drive technology. Thisguarantees safe and practice-orientedoperation under all operating conditions.The safety functions meet DIN EN 61508requirements for applications up to andincluding safety integrity level SIL2 andcategory 3 as well as performance levelPL d according to DIN EN ISO 13849-1.This means that functional safety requirements can be implemented easily andeconomically, including, for example: Functions for safe monitoring of speedsand downtimes Functions for safely separatingworking and protection space (SIDOORautomatic door controllers) and fordetecting areas Direct connection of all safety-relatedsignals and their internal logic operations.The safety functions are available in alloperating modes, can communicate withthe process via safety-oriented input / outputsignals, and can be implemented for eachindividual axis and spindle.7

Complete retrofit servicepackage – from a single sourceOperation with Ctrl-EnergyEnergy consumptionof the complete machineSENTRON PACpower meterEnergy consumptionof the drive systemSINAMICS S120drive8Ctrl-Energy gives you full controlSINUMERIK Ctrl-Energy builds on an extensiveportfolio of SINUMERIK CNC controllers,SINAMICS drive systems, and motors; thisallows you to optimize energy in yourmachining processes. You also save energy,for example, through power recovery, flowreduction during partial load operation, orreactive power compensation. Targeteddocumentation and evaluation of your energyconsumption enable you to make improvements in operations as well as retrofits.

Efficient NC program conversionSiemens offers a special service for upgradingolder NC programs to the latest versions –an invaluable benefit for any user, becausesubprogram archives not only involve a greatdeal of work but recreating these programswould be extremely expensive. The NCprogram conversion service ensures thatexisting CNC subprograms can be used evenafter a controller retrofit.Customized trainingSiemens does not abandon users once theirmodernized machines are in place. Instead,experienced trainers provide users with theknowledge they need to operate and maintain their modernized equipment in customerspecific training courses. Siemens alsoprovides technology training as well ascourses in SINUMERIK and SINAMICS systemsat its own training center. SinuTrain CNCtraining software also provides the option oftraining through self-study.Failure tolerance and maximumavailabilityRegular maintenance is indispensable formaximizing system availability. That’s whySiemens Motion Control Services offerscustomer-specific service contracts in additionto the retrofit. This modular approachallows users to put together a package of allthe services they need to ensure smoothequipment operation. The scope of servicesunder these optional service contractsranges from after-sales service availability tomaintenance and fault clearance, includingfast spare parts service.Financing advancesSiemens Financial Services also includeattractive financing models that are tailoredto the machine users individual operatingneeds – with customized installments andcontract duration harmonized with thecustomer’s intended machine utilizationperiod. With this option, the customer isassured not only state-of-the-art technologybut a lasting competitive edge as well.Motion Control ServicesWhether as expert consultant,service specialist, or spareparts supplier: Siemens is theright partner in every phaseof a machine’s lifecycle.Siemens offers services thatgo beyond the retrofit toincrease your equipmentavailability: Online supportEverything from productsupport to service andsupport activities – anytime, over the Internet. Technical supportExpert telephone consultingto resolve technical issues. Repair and spare partservicesFaster spare parts availability and repairs reducedowntimes in the production process. Service contractsHigh productivity thanks toshort reaction times andthe fastest possible faultclearance by qualifiedservice specialists.9