Liebherr LC-1002 Hobber CNC Re-Control / Re-Certification Program

Description

A Used Liebherr LC-1002 Vertical Hobber has arrived @ Machine Tool Builders' assembly floor in Machesney Park, IL. The original Liebherr controls were non-operational, so this machine will be subject to a standard Machine Tool Builders Re-Control program along with a Re-Certification Program to bring this productive machine back to life. As a result of these two services, we can provide additional coverage in terms of a more comprehensive warranty on the machine that will be explained further within this proposal.

The Machine Tool Builders approach will be a tear-down and inspection of the machine and CNC retrofit from existing Liebherr controls to a Fanuc type 0iF+ CNC Control with 10.4" LCD Mount Touch Screen and Fanuc Servos throughout. The Re-Certification process involves addressing mechanical issues encountered (as a matter of course), but ALSO to a level to allow for Re-Certifying that the machine meets original factory specifications and is capable of producing factory fresh workpieces. In addition to providing more warranty coverage, additional work is done to the machine over and above a re-control level as described further in this section below.

The expected time of completion of this machine on our floor is expected to be 6 to 8 months from time of order.

CNC Controls - MTB Re-Control Program Features:
• Fanuc 0iF+ CNC w/10.4" LCD Mount Touch Screen.
• Fanuc Alpha iS Series servo drives and motors (specifications subject to change or alter pending receipt of machine).

SERVOS:
X Axis Fanuc Alpha iS 12/4000.
Y Axis Fanuc Alpha iS 4/5000.
Z Axis Fanuc Alpha iS 12/4000.
A Axis Fanuc Alpha iS 4/5000.
C Axis Fanuc Alpha iS 30/4000.

• RS-232 port or up/down loading programs.
• PCMCIA slot for program backups.
• Ethernet port for network up/down load of programs.
• An entirely new electrical panel will be installed with all new electrical equipment inside.
• A new Operator Cabinet will be constructed & installed to house the control.
• New Heidenhain absolute scales and encoders will be installed for X & Z axes.
• All new feedback and motor cabling will be installed.
• MTB will install a new magnetic interlock door switch for the operator door, and a two hand safety system for dangerous motions as part of our initial offer. MTB will interface the new CNC controls with all other existing safety devices on the machine i.e. door safety switches, remote E-Stop buttons, light curtains etc. MTB will not be adding any additional safety devices above what is stated in our proposal and this email.

MTB Re-Certification Program Features:
• Hob head will be checked for any problems.
• Work table drive system checked for problems.
• Hydraulic system drained and cleaned.
• All filters changed.
• Polycarbonate guarding windows will be replaced.
• Machine will be thoroughly cleaned & repainted.
• All cycles will be tested and verified as fully functional.
• All worn hoses replaced.
• All broken electrical wires and cables will be repaired.
• All defective controls will be replaced or repaired.
• All features will be tested and verified as fully functional.
• Coolant system checked for problems.
• Coolant tank and chip collection system cleaned.
• All axes checked for accuracy and repeatability.
• All axes will be recalibrated for correct home positions.
• Machine geometry checked and recorded.
• Tuning of all axes servos will be verified & adjusted.

Following are special features & benefits regarding this specific machine:
- The machine was originally designed as a universal machine for individual and small-batch type production.
- Automatic Hob Swivel for helical workpieces. The hob swivel angle will be set by the CNC based on the information that the operator enters in the part program. No need for operator intervention.
- Quick Change Hob Arbor. Features a motorized outboard support and a hydraulic quill for clamping the hob arbor. This allows the operator to remove the hob arbor by a press of a button.
- Servo-Driven Tailstock allows you to set the clamping position of the tailstock via the HMI. No need to adjust any dogs during setup; simply change the values inside the HMI.
- The tailstock swings UP and out of the way during overhead crane operations providing easier (and safer) workpiece loading and unloading operations.
- Workpiece clamping cylinder. This allows the operator to use a drawbar to either actuate a collet-type system or clamp a workpiece onto the table.
- Hob head speed maximum = 360 RPM.
- Work table speed maximum = 12 RPM.

Machine Programming includes:
• Metric or Inch data.
• Up to three (3) cut axial or radial/axial hobbing cycles.
• Same or alternating direction on the axial cycles.
• Shifting with table compensation.
• Cluster gear cycles (4 maximum) with or without tooth alignment.
• Double helical gear (herringbone) cycle with apex alignment.
• Centered and offset crowning.
• Taper compensation.
• Automatic or manual approach and over travel calculations.
• Automatic or manual hob swivel angle calculation.
• Automatic hob shifting, with programmable limits.
• Automatic or manual auxiliary function control.
• Automatic loader control.
• Radial only cycle.
• Simple single index tooth milling.
• Custom cycles via Fanuc native M and G codes, and ISO RS-274.
• Programmable dwell.
• Operator entered, on the fly size compensation.
• Re-settable workpiece counter.
• Multiple program storage and retrieval.

Software Options includes:
• Taper root cycle.
• End relief cycles.
• Size measurement over pins or via span measurement.
• Double helical cycle.
• Automatic stock division software and hardware.
• DIP cycles (dip at either end or both ends)
• Enhanced single index tooth milling.

- Some specifications subject to change based on unexpected additional equipment or configurations made over time by existing customer or 3rd parties.
- MTB Warrants this machine for 1 year from time of installation. This warranty includes mechanical parts associated with the Re-Certification process as outlined elsewhere in this proposal. Standard warranty on Fanuc Controls is 2 years. Please refer to Terms & Conditions elsewhere in this quotation for additional details.