The numerical control (NC) system is the core component of a machine tool, and its selection must be based on performance, cost-effectiveness, and after-sales service. Jinjitong, a well-known platform for mechanical mold networking, recommends using branded products to ensure reliability and long-term support. The choice of an NC system should align with the machine's structure, functionality, and the required precision of the parts being machined. It’s important to match the system's capabilities without over-specifying, as unnecessary complexity can lead to higher costs and increased failure rates.
In China, which is a major country in machine tool manufacturing, increasing the NC rate of existing equipment through retrofitting is a smart strategy. Countries like Germany, the United States, and Japan have long emphasized the modernization of old machine tools, establishing comprehensive systems that integrate research, development, and production. As technology continues to evolve, machine tool retrofitting remains a crucial and ongoing process. China should promote this approach more widely, tailoring it to fit national conditions and promoting sustainable industrial growth.
There are several key benefits to CNC retrofitting:
1. **Cost Savings** – Retrofitting existing machines typically saves 60%–80% compared to purchasing new ones. For large or specialized equipment, the cost can be as low as one-third of buying new. Even full upgrades usually cost only 60% of the price of a new machine, allowing companies to make use of their existing infrastructure.
2. **Stable Performance** – Since the original machine’s base components are already aged and stable, they are less likely to experience stress deformation or accuracy loss. This makes retrofitted machines highly reliable.
3. **Increased Productivity** – With CNC retrofitting, automation becomes possible, boosting efficiency by 3 to 7 times compared to traditional methods. Complex parts benefit even more, and the need for specialized tooling is reduced, cutting both time and cost.
When planning a CNC retrofit, selecting the right control system is essential. There are three main types: open-loop systems driven by stepping motors, closed-loop systems using AC/DC servo motors with encoder feedback, and semi-closed loop systems with grating measurement. Open-loop systems are simple, cost-effective, and suitable for smaller machines. Closed-loop systems offer higher precision but are more complex and expensive. Semi-closed loop systems provide a balance between cost and performance, ideal for larger machines requiring high accuracy.
Mechanical modifications are also critical. After retrofitting, the machine must achieve high static and dynamic stiffness. This involves reducing friction, ensuring smooth motion, and improving transmission accuracy. For example, replacing sliding screws with ball screws increases efficiency and precision. Guide rails can be enhanced with Teflon belts to reduce friction and improve lifespan.
Tooling and automation are also key aspects. Installing automatic tool changers and photoelectric encoders improves efficiency and accuracy. In some cases, the spindle speed system can be retained if automation levels are low, helping to reduce overall costs.
Overall, CNC retrofitting offers a practical, economical, and efficient way to modernize machine tools, making it a valuable strategy for manufacturers looking to stay competitive in a rapidly evolving industry.
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