DSG 2413 Refurbishment and
Fagor 8040TC Retrofit

Project overview

Our customer sourced this twenty year old machine with the expressed intention of having the machine retrofitted with a new easy to program CNC Control.  The Customer has a profitable business producing quality gear, shaft and related components using highly skilled operators with conventional machines.  They identified the requirement for a CNC turning capability to ensure future long term competitiveness, to reduce the time overhead for multiple operation products, allow complex profiles to be generated more easily and ensure the best utilisation of the Highly skill work force.  The customer had carried out detailed research into the capabilities of current CNC systems and found that a CNC system that was capable of producing complicated profiles by means of a conversational-graphical programming environment would allows for the smooth transition of the operators from conventional operation to CNC operation.  A conversational-graphic programming environment would also allow for rapid production of part programs.

Seymour Engineering discussed the CNC options available for the project.  The CNC system chosen was the Fagor 8040TC based on feedback from existing users of the system, the capabilities of the system, the low training requirements and the excellent value for money of the Fagor.  An initial scope of work was agreed on, which included inspection and test of areas of the machine which experience has proven to be the cause of possible problems.  After these inspections the problems found were addressed by means of repair or replacement.  This was done with the aim of keeping the overall cost of the project to a minimum whilst ensuring quality of the final product

Project summary

• Inspection of all Sliding surfaces and returning to machining accuracies.
• Overhauling of the Sauter turret.
• Replacing the Existing GEC axis drives with New.
• Complete machine re-wire.
• Interlocking of the sliding guard in compliance with current legislation.
• Feed, Speed and operational restrictions whilst the guards are open.
• Complete re-painting of the machine by means of powder dip, spray and hand.
• New compliant Emergency Stop (E-Stop) circuits.
• Removal of the original Philips 3000 control.
• Redesign of the electrics to reduce the number of components, increase reliability and integrate comprehensive operator messaging.
• Complete overhaul of the retained Spindle and Axis Servo motors.
• Removal of console fascia, push buttons, switches and Handwheel.
• Integration of all new console fascia, push buttons, switches and Handwheel.
• Integration of the new Fagor 8040TC.
• PLC programming of the Fagor control using previously proved and new code.
• Commissioning and optimisation of the Axes and Spindle.
• Overhaul and test of the Lubrication systems.
• Operator Training and documentation.

The refurbished machine

The new panel	The new control console

Home