Innocenti HBM Retrofit and Re-Location

The machine was built in the 1970's and had been partially retrofitted with an old SINUMERIK 820M some years ago.  Our customer's requirement was to dismantle in USA, pack and ship to Indonesia and then to re-assemble and commission. During the process, the machine is to be fully mechanically reconditioned, re-engineered with new capabilities and fitted with a new CNC system and electrical system.

Inspection by our people in the USA showed that the main guideways and saddles were worn and the semi-hydrostic lubrication systems were not working. The positioning of the column was jerky and we found this to be due to wear in the column drive gearbox and skewing of the column. In addition the previous retrofit a linear scale had been mounted at the back of the machine. We decided to relocate this near the main drive rack to prevent positioning errors and increase the axis stiffness.

Our basic reconditioning work scope is:

• Remachine the main horizontal column (X) and vertical axis (Y) saddles (we have done this at the Ingersoll works before shipping)
• Scrape the  bed and column guideways.
• Recondition and rebuild the column saddle semi hydrosatic lube system
• Fit new servo motors and gearboxes for the X and Y axes
• Fit new linear measuring scales for the X and Y axes.
• Completely rewire the machine and fit new conduits and cable carriers
• Supply a new electrical cabinet and operator console
• Design, supply and install a new high pressure coolant system for modern tooling
• Supply new swarf conveyor extension and riser
• Retrofit with Siemens Sinumerik 840D CNC system and 611 Digital AC servo drives.
• Supply and fit new guideway covers for vertical axis.
• Design new foundation plan for machine, floorplates and services.

Re-Engineering of Spindle Headstock

Our Customer has requested a number of modifications for the headstock. These are:

• Increase the maximum milling spindle speed from 800 to 1200 RPM
• Modfy the spindle gearbox gear ratios and convert to a 2 range automatic gear change.
• Increase the spindle motor power from 20 KW to 50 KW.
• Convert the tool clamping system from a simple screw attachment to a proper BT63 tool nose with collet clamping system.
• Replace the lubrication systems for the spindle gearbox and Z and W axes.
• Fully recondition the ways and the ram and replace the spindle bearings
• Fit new Z and W ballscrews
• Fit a new spindle motor, axis servo motors, Z & W linear scales and spindle encoder.

Moving and Logistics:

As this is a very large machine it was important that the logistics of dismantling, packing, shipping and re-assembly were managed carefully. Our Project Management Team has managed all of the sub-contractors and our engineering and installation personnel for this process. As the total machine weight is in excess of 300 tonnes the packing and shipping were a major excercise.

The machine is now in Indonesia for re-assembly and is due for completion early 2010.