Overhaul / Retrofit
Overhaul is the work that renovates machine tools which accuracy has deteriorated over time to the same specifications as new ones. Retrofit is the work that rebirthes machine tools by installing new functions or replacing them. Both works are the technology that makes it easier for customers to use their familiar machine tools and allow them to be used for a longer period of time.
We have got the manufacturing sector 'Shiga Manufacturing' that overhauls and retrofits machine tools in-house. There are more than 1,270 machines which have been overhauled and retrofitted such as gear processing machines, several grinding machine as of end of September 2020. We could also respond your requests such as remodeling machines made by overseas manufacturers with difficulty to handle, overhauling machines which needs discontinued parts and machine tools used in overseas factories. In addition, we propose environmental improvement such as electrical equipment renewal work accompanying machine tools' overhaul and retrofit.
What is the overhaul work?
The overhaul work is disassembly, cleaning, inspection, repair, test cutting and accuracy check for machine tools which accuracy has been degraded because of aging degradation, and restores them as new ones.
It means you could continue to use the existing machines, it is directly related to environmental preservation which has been attracted more attention in recent years as people have been more aware of the SDGs.
What is the retrofit work?
The retrofit work is the technology which mounts new functions such as automation or NC and reborns existing machines to cutting edge machines.
We improve productivities by adding new functions while the production flow is as it is.
You could reduce cost and time for installing machine tools.
Rough Flow until Delivery of Overhaul / Retrofit
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Current Situation Analysis, Meeting, Estimate
-
Delivery to Shiga Manufacturing
-
Disassembly, Cleaning, Selection (Attendance at Disassembly)
-
Part Design, Setting, Assembly
-
Operation Adjustment, Test Cutting (Trial)
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Complesion Attendance
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Delivery from Shiga Manufacturing
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Installation On-site
Achievement Examples
- Hobbing Machines
- Gear Shapers
- Gear Grinders
- Shaving Machines
- Thread Grinders
- Cylindrical Grinders
- Slotters
Hobbing Machines
Achievements
Machine Name
MODUL ZFW1250 Hobbing Machine (Modified in 2008)
Overhaul Details
- ❶
- We newly design and manufacture column, hob saddle and hob head with high rigidity in order to enable to process workpieces with module 15.
- ❷
- We have achieved the full automation skiving processing (tooth matching/processing) by developing the aoutomatic gear matching device.
- ❸
- We have changed the number of NC control axis to 5.
- - Radial, axial, table, hob shaft rotation, tangential (hob shift)
- ❹
- We have adopted Sanwa Seiki original dialogue program.
- - Operability improvement
We have other results.
List of Actual Machines
| CIMA | CE350 |
|---|---|
| MITSUBISHI (NIDEC MACHINE TOOL) |
FP250 FP250A FP600AC GA25 GA40 GB10 GB15 GB20 GB25 GB40 GBH18 GC25 GC40 GD15 GD20 GH200 GH201 GH250P GH300 GH630 GHP15H GN10A GN20A GN25A GT06 SP120 SP180 SP181 SC15 |
| KASHIFUJI | KS600 KA220 KA80 KB200 KB400 KP150 KR600 KS14 KS150 KS20 KS250 KS300 |
KOHCHIYAMATECH |
SH15 |
| SEIWA TEKKO | MH600 MH600D MS30 |
| NIHON KIKAI | ND4 NDP2 NDP3 |
| PFAUTER | P251 P630 P750 PE750 P900 P1250 PE1000G PE1000 PE800/1200 RS3V RS00 |
| MODULE | ZFWZ1250 ZFWZ2000 ZFWZ3150 ZFWZ800 ZFWZ10 |
| LIEBHERR | LS652 |
| TOSHIBA | HHC150/200A HHC150C HHC250A |
| NACHI-FUJIKOSHI | HB400 HB400H |
KARATS |
GHM10A |
Gear Shapers
Achievements
Machine Name
LORENZ LS1000 Gear Shaper (Modified in 2008)
Overhaul Details
- ❶
- Overhaul
- ❷
- 5-axis NC Retrofit Work
- ・We have adopted FANUC16iMB.
- ・We have improved performance and operability by modifying all functions of cutter rotation, table rotation, cutting, spindle stroke and vertical position of cutter by CNC (5-axis).
- ❸
- We have adopted Sanwa Seiki original dialogue program.
- ・We have shortened non-cutting time and improved the productivity.
- ・We have adopted the built-in software for quick return of cutter spindles (processing speed : twice).
- ・You could flexibly set the processing conditions by using a servo motor for circomferential feed and cutting. You could improve the productivity by setting the processing conditions such as work materials and elements.
- ・We have standardized the multi-step cutting feed. We have minimized the wasted time by speed-up feed of radial feed at air cut parts with quick cuts and small depth of cut.
We have other results.
List of Actual Machines
| OHE TEKKO | SS180 |
|---|---|
| KARATS | GS101 GS200 GS201 GSM-12N |
| FELLOWS | 4GS THE36 |
| MITSUBISHI (NIDEC MACHINE TOOL) |
SA25 SA40 SC15 SC25 SD15 SD25 SE25 SH1000 SH180 SH250 SH251 SH400 SH630 |
| YUTAKA SEIMITSU | GPB35 GPN203N |
| LORENZ | GS101A LS1000 LS150 LS200 LS400 LS424 LS630 LS632 |
Gear Grinders
After Retrofitting
Before Retrofitting
Achievements
Machine Name
Overhaul of SGR300 manufactured by REISHAUER (Modified in 2006)
Overhaul Details
- ❶
- Simplified the spindle structure
- ❷
- Domestic production of high-rigidity spindles
- ❸
- We have adopted the built-in motor for work spindles.
- ・We have removed the gear train and improved the pitch accuracy.
- ・You could improve depressions around tooth profile PCD.
- ・There is no influence of the meshing accuracy of master gears, and the accuracy of the tooth stripe of the helical gear has been improved.
- ❹
- We have exchanged to NC control for index (C), depth of cut (X), axial (Z), dress forming (V), dress cutting (U), whetstone shift (Y), whetstone spindle (CS) and differential (EGB).
- ・You could process fully automatic except mounting/removing works.
- ・You could modify tooth stripe easily.
- ・You could control the operation by NC for crowning and taper processing.
- ・You could operate it easily with the direct interactive method for data input.
- ❺
- Equipped with an automatic whetstone balancer (special accessory).
- ・Easy maintenance of processing accuracy
We have other results.
List of Actual Machines
| TSUGAMI | SGT300 |
|---|---|
| OKAMOTO | SHG360 SHG300 SGO360 SGO400 |
| GLEASON | TAG400 |
| REISHAUER | NZA ZB ZE811 SGR300 SGR700 RZP200 RZ300E RZ362A RZ361S RZ801 RZ301S |
| MITSUBISHI (NIDEC MACHINE TOOL) |
SD300 |
| NILES | ZSTZ ZSTZ630 |
Shaving Machines
List of Actual Machines
| KANZAKI | GSA350B GSC250 GSC400B GSD250 GSD400 GSD400B GSE400 GSF400B GSF400P GSK400 GSK400B |
|---|---|
| CARL HURTH | ZSA220 ZST7 |
| MITSUBISHI (NIDEC MACHINE TOOL) |
FA30 FB30 FD FE30A SV300 SV310 |
Thread Grinders
List of Actual Machines
| KLINGELNBERG | HSS350 HNC35 |
|---|---|
| NIHON KIKAI | GA100 GA350 |
| MATRIX | 1600 |
| REISHAUER | UL900 US RG1000 |
Cylindrical Grinders
List of Actual Machines
| SEIKO | SCG30C |
|---|---|
| MITSUBISHI (NIDEC MACHINE TOOL) |
RB35 RB32 |
| TOYODA (JTEKT) | GOA15 GUP32 GXN25x63 GOP20 GOP30 |
| OKAMOTO | OGM350 OGM250 |
Slotters
List of Actual Machines
| YAMAGE | MY230 MY280 MY450 MY600 MY800 |
|---|
We could overhaul or retrofit other machines listed above.
If you have any questions, please feel free to contact us.