Used PFAUTER PSA500 | Gear Shapers
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ConditionUsed
1 available
The Gleason Pfauter PSA-500 remains one of the most robust and intelligently designed gear shaping platforms in its class. When we source one for a customer, the goal is not simply to “freshen it up,” but to methodically convert it into a modern, production-ready CNC shaping system with long-term serviceability in mind. Machine Tool Builders performs a full electrical re-control and recertification, beginning with a detailed engineering review of the machine prints and mechanical condition. Based on prior experience with this exact model, we incorporate additional software development and Fanuc Flex Sync functionality to precisely synchronize the stroke motor and cam motor. Motor sizing is reviewed and upgraded as required to ensure torque capacity, duty cycle reliability, and accurate timing under load. The result is a shaping platform that retains the rigidity of the original Pfauter build while operating with modern digital precision.
The re-control package centers around a Fanuc 0i-MD CNC system with Fanuc Alpha HVi digital servo drives and motors, selected specifically for the axis configuration and dynamic requirements of the PSA-500. The existing electrical cabinet is completely replaced with a newly engineered MTB cabinet containing all new components—power distribution, relays, transformers, I/O systems, starters, and associated hardware. Legacy feedback devices are removed and replaced with modern absolute encoders and scales, eliminating homing procedures and improving repeatability. Our conversational programming interface is integrated directly into the CNC, providing operators with a menu-driven, shop-friendly environment for entering workpiece data, fixtures, and process parameters without the need for extensive G-code knowledge.
From purchase order to completion, the full sourcing, re-control, and recertification program is typically executed within approximately six months. The process begins with an on-site engineering evaluation to confirm measurements for scales, brackets, wiring routes, and mechanical interfaces. A complete re-control kit is then engineered and assembled at our facility before installation. Once returned to the customer’s site, our service team completes installation, testing, synchronization, and part prove-out to ensure the machine is cutting to specification prior to sign-off. The finished PSA-500 leaves our program electrically new, digitally modernized, and recertified for reliable production service—bridging classic German mechanical design with contemporary CNC performance.
Pfauter Gleason PSA500 Gear Shaping Machine - Re-control & Recertification Program:
1 All work will be done within MTB's Facility in Machesney Park, IL.
2 The machine will be fully recontrolled with a new CNC, new drives and motors, and a new electrical cabinet.
3 X axis (Radial) will receive a new servo motor
4 Z axis (Axial) will receive a new servo motor
5 C axis (Worktable Rotation) will receive a new servo motor
6 B axis (Cutter rotation) will receive a new servo motor
7 E axis (Stroke) will receive a new servo motor
8 A axis (Cam) will receive a new servo motor
9 V axis (Stroke Setting) will receive a new servo motor
General Mechanical:
10 Engineer as required then manufacture and supply all motor adaptation flanges, couplings and pulleys.
11 Remove old servo motors and install new servo motors.
12 No other mechanical repairs will be undertaken unless required to complete the recontrol. Should MTB identify any mechanical issues during the recontrol we will bring them to your attention and a course of action can be determined at that time.
Shaping Head:
13 No other repairs will be undertaken. Should MTB identify any mechanical issues other than we have stated we will bring them to your attention and a course of action can be determined at that time.
Work Table:
14 No other repairs will be undertaken. Should MTB identify any mechanical issues other than we have stated we will bring them to your attention and a course of action can be determined at that time.
Hydraulic:
15 MTB will interface the new CNC/PLC with the existing hydraulic system. However no hydraulic system modifications will be undertaken unless required to complete the recontrol.
16 No other hydraulic repairs will be undertaken unless required to complete the recontrol. Should MTB identify any hydraulic issues during the recontrol we will bring them to your attention and a course of action can be determined at that time.
Lubrication:
17 MTB will interface the new CNC/PLC with the existing lubrication system. However no lubrication system modifications will be undertaken unless required to complete the recontrol.
18 No other lubrication repairs will be undertaken unless required to complete the recontrol. Should MTB identify any lubrication issues during the recontrol we will bring them to your attention and a course of action can be determined at that time.
Coolant:
19 MTB will interface the new CNC/PLC with the existing coolant system. However no coolant system modifications will be undertaken unless required to complete the recontrol.
20 No other coolant system repairs will be undertaken unless required to complete the recontrol. Should MTB identify any coolant issues during the recontrol we will bring them to your attention and a course of action can be determined at that time.
Chip Extraction:
21 MTB will interface the new CNC/PLC with the existing chip extraction system. However no chip extraction system modifications will be undertaken unless required to complete the recontrol.
22 No chip extraction/filtration repairs will be undertaken unless required to complete the recontrol. Should MTB identify any issues during the recontrol we will bring them to your attention and a course of action can be determined at that time.
Electrical:
23 A new electrical cabinet will be manufactured with new IEC devices and circuit breakers. This cabinet will house the axes and spindle drives, plus any magnetics and controls required to support the recontrol project.
24 A new operator's station (CNC Control Panel) will be installed on the side of the electrical cabinet, similar to its existing set-up. It will include the CRT, Keyboard and Machine operation panel mounted inside. Note: Engineering to discuss with plant manager the correct height of CRT, as a small platform will be used for operator and CRT may need to be raised.
25 Machine wiring which is not directly a part of the recontrol or retrofit will be reused, and connected via terminal strips within the new panel.
26 MTB will provide all wire, tags, conduit, flex and other miscellaneous equipment required to complete the installation per NFPA codes.
27 All electrical prints and parts lists will be drawn with AutoCAD Electrical.
28 All new servo motor power and feedback cables will be run for only the replaced servos on the machine.
29 All new secondary encoder cabling will be run for only the replaced servos on the machine.
30 New cabling to the operator’s station or pendant will be run.
31 Unless otherwise stated all axes will be measured from absolute encoders within the servo motors.
32 X axis (radial) will use a new absolute scale (No referencing required upon power up).
33 Reuse any electrical cabinets, duct way and junction boxes that are practical to reuse, unusable ones will be replaced with new
34 Power requirements will be 460VAC, 60Hz. Power figures will be available after the electrical engineering is completed.
Controls:
35 Fanuc 0i-MD CNC Controls System with a Fanuc 10.4" horizontally arranged color display and machine operator's panel.
36 Fanuc Alpha HVi digital servo drives and motors.
37 Fanuc Alpha HVi digital spindle drive(s) and motor(s).
38 Fanuc’s Flex Sync option to time the stroke motor and the cam motor.
39 ATTENTION - If your plant power system is not a wye scheme with grounded center point, you will require an isolation transformer for these new drives.
Shaping Software:
40 CNC based conversational platform with significant software development for additional shaping requirements.
41 Up to four sequential surfaces (Only practical if elevation setting is under CNC control)
42 Up to five cuts per cycle
43 Spiral or Plunge infeed cycle
44 Programmable rotary dwell
45 Digressive infeed feedrate
46 Inch / Metric switchable
47 Spiral out of cut
48 M and G code programming is allowed with conversational programming present.
49 Multiple program storage and retrieval
50 Quick recut cycle
51 Auxiliary function selection (tailstock/clamping seq.)
52 Automatic cutter indexing (Requires independent cutter 'B' and worktable 'C' axes)
53 Orientation of cutter and workpiece (Requires independent cutter 'B' and worktable 'C' axes)
54 Clamp avoidance (Requires independent cutter 'B' and worktable 'C' axes)
55 Slotting capability (Requires independent cutter 'B' and worktable 'C' axes)
56 Programmable elevation (Requires servo elevation axis)
Painting:
57 The electrical cabinet will be painted in the color of your choice, or to match the machine. Please specify with order.
Documentation:
58 Two (2) copies of the wiring diagrams on 11x17 paper
59 Two (2) copies of the MTB operators Instruction manuals
60 Two (2) copies of spare parts and service manuals for equipment supplied by MTB
61 Two (2) copies of the PLC logic interface program and backup CDROM
62 Two (2) copies of any mechanical prints for changes which MTB makes during the recontrol / retrofit / rebuild
Installation and Run Off:
63 Installation, runoff and training at your facility
Training:
64 MTB will supply 2 days of operator training at the completion of the installation
65 MTB will supply 1 day of maintenance training at the completion of the installation
Build Specifications:
66 Electrical, mechanical, hydraulic, pneumatic and safety systems will be installed in accordance with all applicable customer specifications, and ISO, IEEE, ANSI, DIN and NFPA standards
Gleason Pfauter PSA500 Shaping Machine Specifications (subject to change based upon re-control program parameters):
Gleason Pfauter PSA-500
CNC Gear Shaping Machine – Mechanical Specifications:
Workpiece Capacity:
Description Metric Imperial
Maximum Workpiece Diameter (External) 500 mm 19.7 in
Maximum Internal Gear Diameter ~500 mm ~19.7 in
Maximum Module 8 mm ~3.18 DP equivalent
Maximum Face Width 200 mm 7.87 in
Maximum Stroke Length 470 mm 18.5 in
Minimum Stroke Length ~25 mm ~1.0 in
Table & Workholding:
Description Metric Imperial
Table Diameter 450 mm 17.7 in
Table Bore 125 mm 4.92 in
Maximum Table Load ~1,000 kg ~2,200 lbs
Shaping Drive & Motion:
Description Metric Imperial
Ram Speed Range 90 – 900 strokes/min 90 – 900 strokes/min
Cutter Spindle Diameter (Typical) 50 mm 1.97 in
Helix Capability Yes (with electronic/guide control) Yes
Machine Data:
Description Metric Imperial
Approximate Machine Weight 13,000 kg 28,660 lbs
Floor Space (L × W) 4,300 × 2,500 mm 169 × 98 in
Machine Height 3,300 mm 130 in
Connected Load (Typical) ~40 – 50 kVA ~40 – 50 kVA
General Description
The PSA-500 is a mid-size, heavy-duty gear shaping platform designed for internal and external spur and helical gears up to 500 mm in diameter. The machine architecture combines a rigid column and table assembly with a high-speed stroking ram capable of both roughing and finishing applications. Its generous stroke length and face width capacity allow it to address a broad range of automotive, aerospace, industrial gearbox, and off-highway gear components.
When sourced and re-controlled, this platform offers a particularly attractive blend of mechanical mass, table capacity, and moderate footprint. It occupies the sweet spot between smaller 300–400 mm shapers and large 700+ mm production machines—large enough to matter, compact enough to fit into real-world plant layouts without moving walls.
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