Programmable Logic Controller Retrofits for
CINCINNATI HyPowermatic Milling Machines
For cost effective stock removal in medium to
long-run jobs, few machines can beat a horizontal
spindle production mill. But cost effectiveness
can be lost fast if the machine is plagued with
constant down-time. In today’s just-in-time
manufacturing environment machine tool
reliability is essential. Due to their rugged
construction most mills built in the 1970’s
or 1960’s are still in good mechanical
condition but are suffering from more and more
electrical control problems, especially those
with the complicated wiring required in rise
& fall versions.
With few, if any, new bed mills being built,
Industrial Surplus saw a need to extend the life
of machines currently in service and designed an
electrical control retrofit package centered
around a programmable logic controller. The
entire electrical panel with its complex relay or
pegboard based wiring is replaced as are the
operator’s console and limit switches. In
keeping with the goal of utmost reliability, each
machine is stripped down to the bare casting and
rewired. Utilizing customer feedback, the
programming and layout has been continuously
refined to the point where we are confident we
offer the finest PLC system available.
The HyPowermatic family of milling machines
built by Cincinnati-Milacron was chosen as the
retrofit vehicle because of the broad range of
styles and sizes available and for its reputation
for strength and durability. These easily rank as
the best mills of their type ever built. Good
availability of repair parts, both new and used,
also were strong elements favoring this line of
machines.
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Standard 200 Series Machine |
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All machines are stripped down to
bare castings |
We maintain an inventory of the most
popular machine sizes, ready for conversion. If a
customer requires a different configuration, such
as a duplex machine, we can usually find one
available from one of our contacts. Spindle
horsepowers can also be increased or decreased,
within a range, to accomodate specific
requirements.
Our retrofit package is applicable to the full
range of HyPowermatic mills from the most popular
200 Series to huge 500 Series machines with 50 HP
spindles. Although most machines that receive
retrofits are rise & fall models, plain
machines can also benefit from the increased
reliability of the new electrics. Plain machine
retrofits can utilize a simpler PLC unit and need
no trip assembly for vertical motion so the cost
of components and labor is less. Purchase of one
of our retrofitted plain machines costs only
marginally more than non-retrofitted ones
available elsewhere but ours come with the
benefits of solid state electrics.
Prior to rewiring, each machine is thoroughly
tested for any mechanical problems such as
spindle runout, bad bearings, hydraulic leaks or
lack of adequate pressure. Most tables are
resurfaced and most oil seals replaced. Almost
all machines receive some repairs but due to
their rugged constructon major rebuilding
operations such as way regrinding are seldom
necessary, allowing us to keep the cost
affordable.
Several styles of retrofits have been
developed to fit the needs of most applications
and budgets:
- Basic retrofit of the existing electrical
control system with the new PLC. This
package retains the original axis drives
and all travels, stops, rapids, etc. are
set with trip dogs and limit switches.
The new Baluff brand switches and solid
state electrics acheive the high level of
machine reliability which is usually the
main goal. This meets the needs of the
vast majority of customers.
- PLC installation as above but with the
use of linear encoders in place of limit
switches in one or both axes of travel.
This option is usually chosen to control
the cutting height of the spindle carrier
when changes of cutters or cutting
heights are frequent. New positions are
programmed into the system on the keypad
located on the operator’s console.
- PLC installation but with one or more
axis drives replaced with servo motors.
This is also usually done for the
vertical positioning of the spindle
carrier. This option provides the
greatest accuracy of positioning.
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Operator’s console, 300,
400, 500 Series |
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Condensed electrical box replaces
large free standing cabinet |
The installation of a solid state
programmable controller and other up-to-date
components greatly simplifies the wiring and
reduces the space required to house the
electrics. This allows for the elimination of the
separate free standing electrical cabinet that
some 200 Series and all 300 and larger size
machines come with. A smaller cabinet is mounted
directly to the machine, saving valuable floor
space and simplifying any movement or transport
of the machine that may ever be required.
Profile milling by use of a hydraulic tracing
attachment is available. Machines so equipped are
programmed for both standard operation and tracer
control. A key lock switch on the operator’s
console activates the profiling cycle. This
option is not available on machines equipped with
servo drives.
The use of a PLC unit also allows auto
indexing or other workholding fixtures to be
easily incorporated into the auto cycles. We can
also arrange for the design and construction of
automatic parts loading systems.
Full documentation is provided with each
machine or retrofit. This includes a manual for
operating the new PLC system, wiring and ladder
logic diagrams, original operators, parts &
service manuals and all literature on the new
components.
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Hydraulic Profiling Attachment |
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Machines with Servo Rise &
Fall |
Field Installations & Contract
Retrofits
We also offer our retrofit package to
customers who already have HyPowermatic series
machines and want them updated. Machines that are
shipped to our facility can also have their
mechanical systems evaluated, ways reground, etc.
Any major repairs would be discussed with the
customer.
For customers with mechanically sound 200
Series machines who want their machine
retrofitted without the downtime and expense of
shipping the unit to our facility, on-site
installations of our PLC packages are available.
Completed electrical panel, operator’s
console and wiring harnesses will be shipped to
the customer’s plant. Two of our service
people will remove the old electrical system and
install the new in one week's time.
Larger 300, 400 and 500 Series machines can
also be retrofitted on-site but these require
more custom fitting and a longer downtime.
Warranty
ELECTRICAL: Overall
electrical system is guaranteed for one year.
Warranties on individual components are extended
to purchaser and limited to the
manufacturers’ guarantee.
MECHANICAL: Mechanical
components such as pumps, gearing, hydraulic
motors, etc.are guaranteed for 90 days on an
exchange basis.
Service technicians are available free of
charge for repair work during the warranty
period. Customers beyond a 100 mile radius of
Berlin, CT assume the cost of transportation,
lodging and meals.
All warranty periods are from the date of
arrival of the machine at the purchasers
facility.
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