CNC Machine Control Retrofits
Almost Daily, I get Phone Calls from People Looking for New CNC Controls for their Machine Tools. They seem to Think that This is a Fairly Easy Endeavor, In which you can Quickly & Cheaply just Unplug Their Old Control, and Plug-In the New Control, and All Their Machine Problems would Magically Disappear.
I tell All these People the Same Thing;
New Controls Retrofits are Technically Feasible,
But Are Rarely Economically Feasible!
Here's Why;
1 --- Control Retrofits are Expensive.
A P.C. (Personal Computer) Control Retrofit, in which they Replace Just the Logic & Control Section, and Recycle & Reuse the Existing Servo-Drives and Machine
Servo-Motors, Starts at about $30,000.
A more Complete Control Retrofit with New A.C. Servo-Drives and New A.C.
Servo-Motors on the Machine, will start at about $80,000 and go up from there.
Generally Speaking, Retrofits are Only Economically Feasible on "Big Iron'' Machines, like a Big Boring or Planning Mill that Cost Many Hundreds of Thousands of Dollars, and is Difficult to Move & Install. It is Worth-It to Update these Expensive Machines.
But its certainly Not Worth it, for instance, to put a New $30,000 to $80,000 Control on a Old FC1000/1 "A-Control" Strippit Machine that's worth maybe $1000. If you have a $80,000 Budget, Scrap the Old Machine, and Buy a Newer Used FC1000S or FC1250S which would have the Same Overall Cost as the Retrofit, but would be Light-Years Better in Capabilities and Reliability and Serviceability.
Some Bigger Turret Punch Machines may be worth Retrofitting, but this is a Business Decision that needs to be Based on the Worth and Replacement Cost of the Machine. Considerations include Machine's Condition, Unique Features like Table Size,
Turret-Size, Auto-Index Stations, and Punch-Tonnage. And the Fact that it's Already On-Site, Installed, Tooled-Up, and that your Operation & Maintenance Personal already Know and Understand this Particular Machine.
Most Manufactures do not do Retrofits. This is because they are in the
"Selling New Machine" Business, and Not the "Repairing Your Old Machine" Business. However, to their Credit, Amada Does Offer Control Retrofits and Refurbishing of their Old Machines. Cost is Not Cheap, I understand that New Control & Servo Packages are in the $85,000 area. Strippit does Not do Control Retrofits, Except for the FC1000R Class of Machines that have Apple-Mac and DOS-PC Controls because they are having Parts and Service Issues with these "Controls".
Strippit's Fanuc Control & Servo Retrofit for the "R" Machines is also in the $80,000 area. I would Buy a Good Used, and Far Superior, Strippit FC1000S Machine before
I would Spend 80-Large on a FC1000R Retrofit.
2 --- Manufactures, like Strippit, spent many Man-Years of Engineering Time on Tailoring a Control to a Particular Machine, and then Working the various "Bugs" out.
Control Retrofitter's Can Not Spend Anywhere Near This Much Time on a Retrofit!
A Strippit Hi-Speed CNC Turret-Punch Machine is Very Complex, with Many Activities all going on at the same Time, in Real-Time. Functions like Controlling the Acceleration, Decelerating, and Positioning of the X, Y, and T Axis at the same time. Doing the Math Calculations, in Real Time, while the Axis are Moving, during a Contour Nibbling Cycle. Handing the Clutch and Brake during a Hi-Speed Punch Cycle that may only last 110 Milliseconds. And Doing these, and Many Other Functions, while Monitoring All the Many Limit and Safety Switches and Sensors.
Now Picture a Service Tech, coming into your Shop. He wants to get the Job Done, and Go Home. In about a Week, he is Supposed to Literally Cut-Off the Old CNC Control, somehow Graft the New Generic CNC Control to the Machine's Old Wiring. Interface All the Machines Switches and Sensors. And Duplicate All the old Control's Many Functions and Canned-Cycles and Safety Features that He's Probably Not Familiar with. And get all the Various Bugs-Out. Remember, The Original Manufacturer Spent Man-Years of Engineers & Tech's Time doing this!
The Tech doing this Work in Your Shop does Not Have Man-Years to get the Job Done.
The Reality is, it will take Multiple Trips back to Work the many Bugs Out, as you slowly Discover Functions that Do Not Work. If it's a Good Retrofitter, they will spend the Time Necessary to get it as Correct as they can, with the Necessary Follow-up Bug Troubleshooting Service Trips already Built-In to the Retrofit Price.
If its Not a good Retrofitter, you are on your own! You will have to Pay to get them Back, and they are sometimes Reluctant, as they want to Move-On to the Next Project. And as you have now Bastardized the Machine, the Original Manufacturer will now Refuse to Work on it anymore. You better have a Good Relationship with the Retrofitter, and Hope that he doesn't "Go Away" or Move or Retire,
as you are now Dependent on them. I have seen this Happen more than once!
3 --- Often, The Customer is Blaming his Old CNC Control for All his Machine Problems, because it's Human Nature to Blame what We Do Not Understand.
Often times, The Problems are Not Even from The Control, but are Actually Machine Problems, like a Malfunctioning Switch, Loose Wires or Connections, or a Worn-Out Part. In my Experience, I see 4 or 5 Machine Problems for every Real Control Fault.
These are Maintenance Issues, Not "Bad" CNC Control Issues!
Most Shops Do Very Little, or even No Maintenance.
Do You Even Have A Maintenance Manual for Your Machine?
Has Anyone At Your Shop Ever Bothered To Read The Maintenance Manuel?
If Shops would Do Regular Maintenance on their Machine, And Fix Real Problems as they Appear, Instead of Allowing them to Build-Up and Accumulate,
they would be Much Happier with their CNC Machine and it's Production.
My Advise to You.
If you are having Trouble with your CNC Control,
Just Get It Repaired Properly!!!
It was Factory Designed, Built, and Interfaced
Just for Your Model Machine!!!
But Most Shop are Too-Cheap to get a Competent Serviceman in to Repair the Machine Properly, and so Problems Just Accumulate. Eventually, Machine becomes Unusable, and Production & Management People Declare "It's a Piece of Junk!".
They then Scrap Machine or Sell it Cheap, Buy a New Machine,
and Start The Cycle All over again.
I have made Tons of Money (Let's Keep This a Secret, OK?) over the Years Buying these "Pieces of Junk", Fixing All the Little Problems the Prior Owner Would Not Pay to Repair Properly, and Reselling them again. In every Case, Customers have been Happy with the Machines I sold them. The Secret of the CNC Game is Service & Parts.
The above Opinions are Based on my 30+ Years of CNC Machine Field Service.
But, as I Say Over & Over Again,
You Need To Do Your Own Research, and
Make Your Own Decisions Based On Your Unique Needs & Circumstances.
If you Still want to Investigate CNC Control Retrofits, Here are more Resources;
Automated Machinery Inc.
They do Service and CNC Control Retrofits,
with Both PC-Based and Fanuc Controls.
They Work on Strippits,
but their Real Expertise is on the
Murata / Wiedemann Punch Machines.
They seem to do a good job of Retrofits.
This page was last updated: September 14, 2007
Slicer Controls LLC
They do CNC Control Retrofits,
with Their Own PC-Based CNC Controls.
They Retrofit Strippits,
but their Real Expertise is on the
Murata / Wiedemann Punch Machines.
They have been doing Retrofits a Long Time, and I think they do a Good Job of it.
PC Controls LLC
They do CNC Control Retrofits,
with Their Own PC-Based CNC Controls.
They Retrofit Strippits, and almost any other Machine Tool, using Various Independent Contractors around the Country.
Consider Carefully, as the Quality of their Work seems to Vary with Who's doing it.
CamSoft PC Controls
They Make Various CNC Control Retrofit Software & Hardware Packages
Mainly for System Retrofit Integrators to Use,
and are Not for Shop End-Users.
However, you can Learn Much
from their Web-Site.
Altronics Service Inc.
Specializing in Retrofitting Older
Whitney 647 Series Punch Press Machines.
Also Services Westinghouse, FlexMate, and Automation Intelligence Equipment.
