West Coast CNC now offers a combination of a world-class machine rebuild with truly a Next Generation CNC.
Why buy a new machine with old control technology and pay more when you can remanufacture your machines with better technology for less money?
The package includes:
NXGEN Control, Grinding All Ways, New Spindle Drive, New Thrust Bearings, New NSK Ball Screws, Rebuilt spindle – New Bearings, New Turcite, Rebuilt spindle motor, New AC Baldor Motors, New AMPS, Powder Coated, New lube lines, Rebuilt Tool Changer, and more!
Let’s show you the remanufacturing process
As always, it starts the the people. Most of the rebuilders at West Coast CNC are veterans from the original Fadal assembly floor in Chatsworth, California.
Before MAG Fadal closed in 2009, the Fadal machine remanufacturing section in Chatsworth was purchased separately from MAG Fadal by the West Coast CNC group, including all the original equipment and manufacturing knowledge.
Typical machines look like below when they come in for rebuilding.
After complete disassembly, all the components are cleaned and inspected to ensure factory specifications, after repaired or replacement, depending on the condition.
The Box way are reground to the original specifications of flatness and straightness.
The existing Turcite surfaces are machined to remove the old material and new Turcite is applied.
Note: Turcite B is a polytetrafluoroethylene (PTFE) based bearing material with low friction for machine tools. Turcite was implemented to avoid having a “metal on metal” surface, avoiding galling if any part of the way lube system failed.
New or rebuilt ballscrews and new thrust bearings for the ballscrew mounts are installed for each axis.
The casting are then cleaned and painted. After the Way lube lines and manifolds are completely replaced, the assembly process begins.
The 10K or 15K Spindles are rebuilt according to the original specifications.
New Timken spindle bearings are added, along with a new draw-bar and a set of Bellevue springs for maximum tool retention force.
After final assembly, he table is machined and re-scraped, to ensure the table is just as flat as it was when it originally came from the factory.
Finally, the sheet metal is cleaned, stripped and power coated, completing the final assembly.
Now that the remanufacturing process is complete, the final process is to upgrade the control with a NXGEN control.
More Pendant Information
The old pendant and wires are removed and the new pendant is installed. The old pendant used approximately twenty-five wires; since the NXGEN is mostly digital, it needs only five cables, greatly simplifying and cleaning up the control system.
To the left is a picture of the a 1997 Fadal VMC 4020 with the Legacy system before conversion.
For ease of service, notice that we have maintained the same Card Cage design with our new control. Additionally, instead of having eleven cards in the Card Cage, we’ve reduced the count in the new control to simply three boards: a CPU board, a IO board and a Motion Control board. This greatly increases the MTBF and does not give up performance. In fact we are showing a nearly ten-fold performance improvement, across the board!
With the NXGEN, just like the Legacy, it is very easy to service by simply removing only what is needed and not disturbing the other system components.
Some inferior CNCs use the older “closed box” designs, usually packed into a pendant. This design requires that the entire control system to be removed and returned for factor service or they must replace your whole system with a “used box”. The worse scenario is getting a different problem while you are in the process of servicing the original problem – not very practical for your CNC equipment or business.
The open access Card Cage design is one of the best and longest enduring designs.
This picture shows the new control installed and powered-up.
It is truly a drop-in, plug-n-play design for specifically Fadal VMC machines (1988-2010) using the Legacy control.
The upgrade uses most of the existing components such as wiring, motors, power devices and existing feedback. It is designed for a either the standard Legacy AC or DC Servo type machine (using Glentek, Baldor and AMC products).
One of the many great features is the new control power and ground design.
The NXGEN control has an isolated control power, virtually eliminating all of the power and ground loop issues that plague a CNC in reliability and component life (MTBF). Now, you have no more need for grounding rods so many machine tool builder use to solve those control “gremlins”.
Finished and ready for final testing!
Once the mechanical assembles are completed, the XYZ axes travel accuracy are checked, calibrated and compensated by using a Renishaw Laser System. The distance traveled is verified to ensure that when programming a 6″ move the slide indeed will move 6″.
During the calibration process, after running a series of of passes, the position error values are entered into the control for automatic compensation. This correction is typically know as a “pitch error” compensation.
After the Linear “pitch error” calibration with a Laser is completed, the servo mechanics are verified using the Renishaw Ballbar calibration system.
This is to ensure the circular contouring is within original factory specifications.
The Renishaw Ballbar diagnostics test measures the final contouring accuracy and quickly verifies that all the mechanical and electrical components are working in proper synchronization to move the slides accurately and at various federates. The sample readout shows the angular inconsistency, deviations and servo inaccuracies that effect the surface finish and countering roundness.
Now with a minor investment, this VMC 4020 machine is ready for another 10 to 20 years, now with all the benefits of the latest technology: Better Parts In Less Time!
Get a remanufactured machine plus the Latest CNC Technology while saving thousands!