Train wheel form and surface were checked; It was observed that the deviation and dimension difference value between the two wheels was as high as 0.01 mm. The machine we built was checked and approved by the ECM Manager. It was found suitable for processing wagon wheels of freight trains.
Mechanical and electronic synchronization should be done exactly in order to convert universal machining machines to CNC and to work as a real CNC. This can only happen with Mechatronics Engineering. It should not be forgotten that a mechanical workbench designed and manufactured to operate as a universal machine must be redesigned and manufactured according to Cnc ergonomics. Practices made by teams that do not have sufficient knowledge and experience in such applications cannot achieve results.
In order to perform such an application competently, it is necessary to have a good knowledge of manufacturing, a high level of mechanical experience, electronic systems, automation and software. When these three elements come together, it is possible to make a real Cnc conversion. We realize our projects with our experience in manufacturing, machine mechanics and Cnc control systems and software that we have gained in our work in Germany for many years. In order to increase the torque and features of the machine in retrofit applications, our company creates the working scenario of the machine required. Machine working scenario is written by the team of Macro software Cnc Center.
The application to be done for CNC conversion should generally be as follows:
Whether the machine is suitable for Cnc conversion is determined. The project does not give the desired results on the wrong machine.
It is decided whether the machine axes need to be ground or not.
The machine is disassembled and the application starts in line with the planning. (At this stage, all axes of the machine are disassembled and many operations and additions are made).
The working principles of the machine are redesigned according to new and digital technology and the working scenario of the machine is created.
Trapezoidal axis shafts and red nuts are thrown away. Instead of these, ball screw and ball screw nuts are installed.
Screw shaft bearing bearings are designed, manufactured and installed.
Bearings are selected in accordance with Cnc ergonomics.
Axis servo motor connection bearings are designed and manufactured.
Spindell motor connection design is made, manufactured and connected.
Hydraulic design is done and hydraulic unit is mounted. The hydraulic piston, hydromotor and hydraulic equipment used are connected.
Electric cables, communication cables, hydraulic hoses, automatic skid lubrication lines are newly used.
Electric cables, communication cables, hydraulic and pneumatic hoses, automatic slide lubrication lines that have to go to the moving parts of the machine are carried by a moving cable channel.
Application should be made in accordance with the work safety criteria.
Machine skids should be planned to be protected against external factors.
Performing the necessary tests on the mechanical parts while collecting the machine. If these tests are skipped, the ball screw, ball screw nut, ball screw shaft bearing bearings and similar malfunctions are frequently encountered.
Installing and wiring the automatic slide lubrication system.
All of the special software required for the processing of train wheel profiles were written by the Cnc Center team. If these train wheel profiles do not meet ECM standards, train wheel processing permission cannot be obtained.
The automation panel specially prepared for the machine is mounted in the most suitable and safe area.
The cnc control unit is installed in the safest area.
Entering system parameters.
Writing the macro software.
Synchronizing servo motors.
Gathering the entire controller in the Cnc Control unit.
All connections of the automation panel and the Cnc Control unit are established. According to the working scenario of the machine, the mechanical and electronic systems are introduced to each other.
Mechatronics engineering, mechanical and electronic systems, modified with manufacturing knowledge and experience, transforming it into an integrated system that integrates with each other and commissioning the machine.
Quick response to possible malfunctions with Turkish definition is provided.
Providing a connection to the machine over the internet with a computer connection, entering the macro software of the machine and preparing the necessary infrastructure for intervention. Unnecessary time and service loss is prevented.
The machine is completely removed from the operator's initiative. The human error factor is minimized.
Back-ups of macro software, electrical-electronics project, hydraulic scheme and necessary technical specifications.
Painting the machine.
All this must be done by contract.
Such projects are made for the efficient, stable and long-lasting operation of the machinery and equipment in the inventory. We can contribute to our national economy by increasing market values with our machinery, national wealth and high technology.
Cnc conversion made by incompetent people creates irreversible or costly problems in the machine with the loss of money and time. Our company gives 2 (two) years of warranty to its CNC conversion. Machine torque controls are controlled with maximum loading. Cnc conversions are made together with mechanics and electronics, and we take full responsibility.