Aerospace

OSAI-UK has an on-going programme of retrofits at a well known aerospace company in the midlands.

Over the past 5 years a number of K&T Moduline have been retrofitted with the 10/Series control system - replacing the original Allen Bradley 7320 controllers.

A part program emulator was developed to allow the 7320 programs to be emulated on the 10/Series. Although the 7320 programs are often similar to the 10/Series, these early machines featured Leading zero suppression i.e. 23.4 mm would be represented as 23400.

Several Morando VTLs have been retrofitted. The 4 axis VTLs were originally fitted with Allen Bradley 7340 controllers which featured dual interpolation from a spindle part program, allowing each pair of axes to work independently until required to synchronise with spindle speed changes. These machine featured tool measurement systems that had been especially developed for the 7340 system in the UK.

The powerful features of the 10/series with its integrated Windows interface and Para macros allowed OSAI-UK to develop the original emulator developed for the Heylingenstaedt dual lathes by our parent company in Italy, to suit the Morando machines and provide not only part program compatibility but also a similar operator interface. This meant that minimal operator training was required.

The reliability of the machine was increased by the addition of Intrebus S fieldbus devices to manage the I/O on each head. This reduced the wiring from the control system to the machine to a single 5 core cable instead of the many individual connections used before.

The success of the four axis retrofits was followed by a two axis version. The same Windows interface was modified for 2 axes again to allow program compatibility and to allow commonality for the operators.

The results - improved accuracy, lower scrap rates and reduced maintenance have quickly repaid the investment in the retrofits.

The latest project was to utilise the Windows feature to develop an easy to use interface for a Hauni Blohm creep feed grinder, replacing a Siemens Sinumeric 3 controller. The flexibility of the 10/series allows this feature to be used for any grinding machine - only the editor screens and the supporting Paramacro cycles need to be modified for other machines.

Current projects in progress are 10/Series retrofits to Heylingenstaedt 4 axis lathes, in one case replacing a 7340 and including a complete mechanical overhaul by the OEM and in the other an 8600 controller, where only the CNC will be replaced and essential machine rewiring will be carried out.

NB: All these projects have been completed with the assistance of System Automation (LEICS) Ltd who have undertaken the machine rewiring where required and the CNC control panel mounting.
In some cases they have acted as sub-contractors to OSAI-UK while in others they have been the main contractor. Contact Andy Austin on +44 (0116) 2460151 for more information.