[Recommended]Machine overhaul and CNC transformation
Gas Wellhead,Gas Lift Wellhead,Natural Gas Well Head,Natural Gas Wellhead Jiangsu Solid Machinery Manufacturing Co., Ltd. , https://www.oilsolid.com
The machinery manufacturing industry plays a vital role in the global economy as a foundational sector. In response to this, economists and business leaders around the world continuously explore advanced manufacturing technologies and strategies to meet new challenges. The machine tool industry, as the core of manufacturing, serves as the backbone of industrial development and is essential for all sectors.
**I. Social and Economic Foundations of Production and Development**
(1) China’s existing fleet of outdated and obsolete machine tools provides a practical foundation for their overhaul and modernization. As a developing nation, China has long struggled with economic limitations due to structural inefficiencies. Outdated technology and equipment have significantly hindered national economic growth. To address this, over the past two decades, China has actively introduced advanced foreign technologies and equipment while simultaneously working to develop its own domestic machine tool industry. This dual approach includes partnerships with leading global manufacturers to produce high-standard machine tools and direct imports of various types of equipment. These efforts have greatly contributed to the rapid growth of the national economy.
However, prolonged use, overloading, and insufficient maintenance have led to severe wear and loss of precision in many machines. Some are left idle due to changes in company structure or lack of technical expertise. Machines that should be used often become rusted, with control systems failing to start. Additionally, the need for new products has rendered some older machines inadequate, creating an urgent demand for upgrades. The rapid advancement of computer and network technologies has also accelerated the obsolescence of CNC systems, making spare parts harder to find. With most Chinese machine tools aging, these factors make overhaul and numerical control conversion essential.
(2) A large number of new and used machine tools have acted as catalysts for the overhaul and modernization process. Since the reform and opening-up, many companies have imported old but still functional equipment from abroad. However, due to limited experience, technological gaps, and a lack of spare parts, some of these machines became non-operational after purchase. Many of these were later transformed and reintroduced into production, offering significant value when properly upgraded.
(3) Significant economic benefits drive the development of machine tool overhaul and numerical control transformation. For machine tool owners, achieving similar performance at only 30% of the cost of a new machine is highly attractive. Even when completely restructured, the cost is typically around 60% of buying a new one. For large manufacturers, this not only brings substantial social and economic returns but also ensures their long-term survival and growth.
(4) Overhaul and modernization offer key advantages that support industry sustainability. Compared to purchasing new machines, the following benefits stand out: shorter delivery times, especially for large or special-purpose machines; more stable performance due to reduced stress and deformation; lower design risk; greater flexibility to incorporate user preferences; easier maintenance and operation; faster access to updated spare parts; cost savings; and reduced investment risks.
(5) Socialization and specialization are essential trends for machine tool overhaul and modernization. This process is not only necessary during the current economic transition but also a strategic move for long-term enterprise development. In today’s knowledge-based economy, enterprises face restructuring, market integration, and increased competition. Companies must focus on innovation, agile manufacturing, and green technologies. As a result, maintaining in-house repair teams is no longer feasible. Instead, professional and specialized service providers will become the norm. While this industry is still emerging in China, it is expected to grow rapidly with the right conditions and expertise.
**II. Selection of the Major Modification Plan**
If the project receives strong technical support from experienced companies, it can be completed more efficiently and effectively.
1. **Preliminary Preparation Work**
(1) A technical feasibility analysis is conducted to evaluate the condition of the machine, including its structure, performance, and accuracy. This involves checking whether the original design is sound, if components are intact, and if the mechanical transmission system is suitable for CNC conversion. It also includes reviewing past failures and preparing a detailed transformation task book to ensure the machine meets modern standards.
(2) An economic feasibility analysis assesses whether the investment required for transformation is justified. Factors include the machine’s value, its importance in production, the return on investment, and potential benefits such as improved product quality or new product development. Reliable funding sources are also critical.
(3) Choosing the right machine builder is crucial. A competent partner ensures successful transformation, while a poor choice may lead to wasted resources and operational delays. Users should carefully select based on the builder’s experience and capabilities.
2. **Preparation of Technical Solutions**
(1) The mechanical and hydraulic systems must be evaluated first. For example, when converting a conventional machine to a CNC one, the guide rail type and ball screw installation are key considerations. Mechanical transmission gaps and stiffness must also meet CNC requirements.
(2) The electrical system involves selecting a suitable CNC system. Leading manufacturers like Siemens, Fanuc, and Mitsubishi are recommended for their reliability and ease of maintenance. Users should also consider the compatibility of the existing drive system with the new CNC setup. The measuring system, such as encoders and grating scales, must also be upgraded to match CNC requirements.
(3) Installation methods for the control, drive, motor, and measuring systems must be carefully planned. The location of the control cabinet, cooling, cable routing, and motor mounting all affect performance and maintenance.
**III. Project Implementation**
1. **Selection of Construction Team**
A skilled and experienced team is essential for successful modification. The team should include mechanical, electrical, and hydraulic engineers with proven expertise. Effective management and a flexible organizational structure are also important to adapt to market demands.
2. **Hardware Orders**
After finalizing the plan, the order list is prepared. Both the user and the engineering company collaborate to ensure cost-effectiveness and reliability, then sign a formal contract. Meanwhile, the engineering team begins mechanical repairs, electrical preparation, and software testing.
3. **On-Site Commissioning**
This stage involves installing and adjusting the CNC system, optimizing drive parameters, and preparing for acceptance.
4. **Test Processing and Acceptance**
Standard test cuts are performed according to international guidelines, and machine accuracy is verified using tools like laser interferometers. Adjustments are made to ensure compliance with specifications.
5. **Information, Training, and Warranty**
After acceptance, technical documentation is compiled, and users receive training and warranty support to ensure smooth operation and long-term reliability.
The transformation of old CNC machine tools is gaining momentum. With a large number of faulty and imported machines in need of upgrading, this process offers a cost-effective way to enhance productivity and create value for many companies.