Fellows 10-4 Recontroled & Recertified CNC

Fellows 10-4 Shaping Machine Re-Control & Recertification Program - 3 Axes of CNC Control. Specifications below are typical for type, but may differ slightly as a result of the condition & type of your model.

The following program is for a Re-Control of your existing Fanuc controlled machine, with the work to be done in Machesney Park, IL. MTB will address the mechanical issues with the machine via our recertification program as detailed below. Some mechanical issues may be encountered during this program that may preclude the completion of the recontrol work - and these issues will be addressed on a case by case basis when they are over & above what we have listed here as the scope of work.

As your machine is understood to be already CNC controlled, the program we are offering herein is a hybrid, between our full rebuild program whereby we start from an electromechanical machine originally produced by the Fellows Shaper Company and a standard recontrol. So this recertification program serves to address the mechanical shortcomings of your machine which will involve some decisions after the core machine is received and inspected by our team.

I. MACHINE SPECIFICATIONS - Typical of type:

• Maximum workpiece diameter: 10” / 254 mm
• Maximum stroke length: 4” / 102mm (See Below for Add'l Options)
• Maximum Diametral pitch (spur): 4DP / 6.35 Module
• Maximum Diametral pitch (helical): 5DP / 5.08 Module
• Maximum strokes per minute: 750 SPM / 1,200 SPM (Optional)
• Maximum center distance workpiece/tool: 14” / 355.6 mm
• Distance between worktable and cutter: 13.0” / 320.2 mm
• Bore through work spindle: 5.875” / 149.225 mm
• Cutter spindle diameter: 3.543” / 89.998 mm
• Fanuc α15/7000 HVi spindle motor: 20 HP / 15 kW
• Rapid traverse rates:
- X axis: 118 in/min / 3000 mm/min
- B axis: 40 RPM / 14,400 deg/min
- C axis: 40 RPM / 14,400 deg/min
• Linear axis resolution: .0001” / .001mm
• Rotary axis resolution: .001° / .001°
• Plant power requirement: 460V 60Hz 3-Phase
• RS-232 port or up/down loading programs.
• PCMCIA port for up/down loading programs.

II. MACHINE RECONTROL & RECERTIFICATION FEATURES:

Item GENERAL
1). All work will be done at Machine Tool Builders facility located in Machesney Park, IL.
2). The machine(s) will be inspected and mechanically recertified; components will be repaired or replaced only where inspection finds wear beyond acceptable tolerances.
3). The spindle speed will be controlled through a new spindle drive and spindle motor.
4). The radial axis (X) will receive a NEW CNC controlled axis.
5). The cutter rotation axis (B) will receive a NEW CNC controlled axis.
6). The worktable axis (C) will receive a NEW CNC controlled axis.
7). The elevation will remain a manual adjustment.
8). The stroke length will remain a manual adjustment.

CLEANING:
9). Machine will be cleaned before the start of the program.
10). Disassembly and cleaning of the machine.

GENERAL MECHANICAL:
11). Disassembly of the machine and inspection of all parts for wear.
12). Inspection of all major components for wear. Replacement or repair of the worn components as required. (Index and hob head final drive gear sets are excluded).
13). Each pair of machine guide ways will be refinished if required. All guideways will be verified and adjusted if required to be as close as possible to the original equipment specifications.
14). Turcite material on the column underside will be inspected and replaced only if wear is found affecting alignment with the drive shaft and screw.
15). Mechanical systems which are no longer in use, if applicable, to CNC will be removed from the machine.
16). Radial ballscrew will be inspected and reworked only if wear is found beyond acceptable tolerances.
17). Radial guideways will be inspected and reground only if wear is found beyond acceptable tolerances.
18). Radial slide gibs will be reset.
19). Engineer as required then manufacture and supply all motor adaptation flanges, couplings and pulleys.
20). Remove old servo motors and install new servo motors.
21). Remove old spindle motor and install new spindle motor.
22). Bearings and bushings will be inspected and replaced where worn.
23). Seals opened up during disassembly will be replaced; sealing surfaces will be repaired where damaged.

SHAPING HEAD:
24). Shaping head to be fully disassembled and parts inspected for wear.
25). Inspection of guides.
26). Bearings will be replaced with OEM or equivalent where wear is found.
27). Bushings will be replaced where wear is found.
28). Seals will be replaced with OEM or equivalent where wear or damage is found.
29). Shaping head will be fully re-assembled with the proper lash set on the worm drive.

WORKTABLE:
30). Worktable will be fully disassembled, cleaned and inspected.
31). The worm and worm wheel will be replaced or repaired if required.
32). Bearings will be replaced with OEM or equivalent where wear is found.
33). Sealing surfaces will be repaired if damage or excessive wear is found.
34). Seals will be replaced with OEM or equivalent if damage or wear is found.
35). Table top surface will be inspected and reground only if wear is found beyond acceptable tolerances. Minus material sections will be left as-is.
36). The table will be fully re-assembled with the proper lash set*.
(*Provided the worm wheel is not worn out, and the worm is adjustable)

STROKE DRIVE/ELEVATION/LENGTH ASSEMBLIES:
37). All assemblies will be fully disassembled, and all parts inspected for wear.
38). Bearings will be replaced with OEM or equivalent where wear is found.
39). Bushings will be replaced where wear is found.
40). Seals will be replaced with OEM or equivalent where wear or damage is found.
41). All worn parts will be either repaired or replaced as required.

HYDRAULIC:
42). Hydraulic pumps, hoses, valves, pressure switches, pressure reducing valves, flow controls and pressure regulators will be inspected and replaced where worn, damaged, or not functioning to specification. Piping will be re-used if not bent.
43). Manifolds will be reused if they are in good condition and applicable.
44). The hydraulic motor(s) will be inspected and rebuilt or replaced only if found worn or not functioning to specification.
45). Pipes will be reused if they are in good condition and applicable.
46). Power clamping base will be inspected, and repaired or replaced only if found worn or not functioning to specification.

LUBRICATION:
47). Lubrication valves, pumps, meter blocks, hoses and feedback sensors will be inspected and replaced where worn, damaged, or not functioning to specification.
48). Manifolds will be reused if they are in good condition and applicable.
49). MTB will either rebuild or replace the lubrication system motor(s) only if found to be worn or not functioning to specification.
50). New lubrication lines will be run to the ballscrew nuts and bearings.
51). Pipes will be reused if they are in good condition and applicable.

COOLANT:
52). The coolant system motor(s) will be inspected and rebuilt or replaced only if found worn or not functioning to specification.
53). Coolant components such as pumps, hoses and nozzle(s) will be inspected and replaced or repaired where worn, damaged, or not functioning to specification.

CHIP EXTRACTION:
54). Standard Chip collection is done with a catch basket.

GUARDING:
55). All guarding will be inspected and repaired or replaced where damaged, and returned to its original configuration and function at the time the recertification program started, unless otherwise noted.

ELECTRICAL:
56). A new electrical cabinet will be installed with all new equipment inside. IEC devices along with circuit breakers will be used wherever possible.
57). A new operator’s station will be installed where the current one is. It will include the CRT, Keyboard and Machine operation panel mounted inside.
58). Installation of all new machine wiring.
59). MTB will provide all wire, tags, conduit, flex and other miscellaneous equipment required to complete the installation per NFPA codes.
60). All electrical prints and parts lists will be drawn with AutoCAD Electrical.
61). All new servo motor power and feedback cables will be run for only the replaced servos on the machine.
62). All new secondary encoder cabling will be run for only the replaced servos on the machine.
63). New cabling to the operator’s station or pendant will be run.
64). Unless otherwise stated all axes will be measured from absolute encoders within the servo motors.
65). Reuse any electrical cabinets, duct way and junction boxes that are practical to reuse, unusable ones will be replaced with new.
66). Power requirements will be 460VAC; 60Hz. Power figures will be available after the electrical engineering is completed.

III. ELECTRICAL & SOFTWARE:

CONTROLS:
67). Fanuc 0i-F+ CNC with 10.4" horizontally arranged color display and machine operator's panel.
68). Fanuc Alpha iS HV digital axes drive(s) and motor(s).
69). 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:
70). Conversational based platform within the CNC.
71). Up to four sequential surfaces (Only practical if elevation setting is under CNC control).
72). Up to five cuts per cycle.
73). Spiral or Plunge infeed cycle.
74). Programmable rotary dwell.
75). Digressive infeed feedrate.
76). Inch / Metric switchable.
77). Spiral out of cut.
78). M and G code programming is allowed with conversational programming present.
79). Multiple program storage and retrieval.
80). Quick recut cycle - allows the operator to bring the workpiece into size without changing the programming parameters.
81). Auxiliary function selection (tailstock/clamping seq.).
82). Automatic cutter indexing (Requires independent cutter 'B' and worktable 'C' axes).
83). Orientation of cutter and workpiece (Requires independent cutter 'B' and worktable 'C' axes).
84). Clamp avoidance (Requires independent cutter 'B' and worktable 'C' axes).
85). Slotting capability (Requires independent cutter 'B' and worktable 'C' axes).

PAINTING:
86). A complete repaint is not included in the standard recertification scope; touch-up painting of repaired or replaced components is included. A full repaint can be quoted as an optional add-on.

DOCUMENTATION:
87). Two (2) copies of the wiring diagrams on 11x17 paper.
88). Two (2) copies of the MTB operators Instruction manuals.
89). Two (2) copies of spare parts and service manuals for equipment supplied by MTB.
90). Two (2) copies of the PLC logic interface program and backup CDROM.
91). Two (2) copies of any mechanical prints for changes which MTB makes during the recontrol / recertification process.

INSTALLATION & RUN-OFF:
92). Installation, runoff and training at our facility in Machesney Park, IL. We can quote Installation, runoff and training at your facility for additional charge.

TRAINING:
93). MTB will supply 2 days of operator training at the completion of the installation.
94). MTB will supply 1 day of maintenance training at the completion of the installation.

BUILD SPECIFICATIONS:
95). 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.