Revitalizing a Legacy Machine: The Transformation of a CNC Machining Center
In the world of manufacturing, the longevity and performance of machine tools are crucial to the success of any organization. The BMC-10B (5) machining center, introduced in the mid-1980s, has been a staple in the industry for decades. However, with the passage of time, the original control system and tooling had become outdated, rendering the machine incapable of meeting the demands of the modern manufacturing landscape. In this blog post, we’ll explore the innovative approach taken by a leading manufacturer to revitalize this legacy machine, increasing its efficiency, precision, and competitiveness.
The Challenge
The company, which has been operating the BMC-10B (5) machine since the 1990s, faced significant technical challenges with the original CNC system. The aging device was prone to breakdowns, and its limited functionality hindered the company’s ability to subcontract abroad and produce new national defense equipment. With the introduction of new cutting-edge CNC technology, the company saw an opportunity to modernize its legacy machine and regain its competitive edge.
The Transformation
To address the challenges, the company collaborated with the National Engineering Research Center of high-end CNC to implement significant upgrades to the BMC-10B (5) machining center. The transformation aimed to integrate the latest technology, increasing the machine’s capabilities while maintaining its original functionality.
Introduction of High-End Blue Sky CNC System
The first step was to replace the outdated control system with a cutting-edge Blue Sky CNC system, featuring servo control in seven axes (X, Y, Z, A1, A2, B, and S) and five-axis liaison control (X, Y, Z, A, and B). This upgrade enabled the machine to achieve precise synchronization and smoother operation, allowing for improved accuracy and reduced waste.
Integrated Programming Technology (SIPROM)
The new CNC system was further equipped with SIPROM, a logical software that enables automatic tool changing (ATC) and pallet swapping (APC). This advanced feature allows for a random exchange of 60 tools, as well as the use of a 1000 mm x 1000 mm workbench with three stations.
Technical Updates
To take advantage of the BMC-10B (5)’s unique characteristics, the system underwent significant technical updates. The development of a symmetrical gear transmission structure allowed for accurate control of the A1 and A2 axes using servo motors. Additionally, the three linear axis servomotors (X, Y, and Z) were directly connected to the lead screw, ensuring precise movement and high cutting loads.
The system was equipped with a Kollmorgen Goldline AC servomotor from the United States, replacing the original Yaskawa DC system. This upgrade enabled the machine to achieve rapid movement and handle large cutting loads, making it suitable for high-speed cutting and high-precision applications.
Reach and Precise Positioning
To guarantee temperature compensation and maintain high-precision treatment, temperature differences between the spindle and column were compensated for, ensuring precise positioning and reduced errors.
Final Result
The comprehensive transformation of the BMC-10B (5) machining center was a resounding success, with the machine successfully revitalized and increased in efficiency, precision, and competitiveness. The upgrade allowed the company to exploit its original machine tool potential, solving technical problems, improving the technical level, and enhancing its competitive edge. The upgrade cost approximately 15% of the original purchase price, a significant investment that paid off in the long run.
Conclusion
In conclusion, the successful transformation of the BMC-10B (5) machining center is a testament to the value of innovation and upgrading legacy machines. By integrating cutting-edge technology, the company was able to breathe new life into its trusty workhorse, increasing productivity, accuracy, and competitiveness. This inspiring story highlights the importance of investing in the modernization of legacy machines, enabling manufacturers to stay ahead of the curve and maintain their position in the ever-evolving manufacturing landscape.
