SORALUCE FS 8000
Modernization, dismantling, transportation, and commissioning of a high-performance travelling-column milling machine.
Make
SORALUCE
Model / Control
FS 8000 / HEIDENHAIN iTNC 530 HSCI
Machine type
Travelling Column Milling Machine
Project scope
Mechanical, electrical, and control retrofit
Machine before retrofit
Machine after retrofit
Mechanical modernization
The modernization of this SORALUCE FS 8000 ranks among the most extensive retrofit projects ever carried out by our company. Nearly every major machine assembly was comprehensively overhauled mechanically, electrically, and in terms of the control system, making this a true 100% retrofit. The objective of the project was to bring this proven machine platform up to current technological standards while ensuring its precision, reliability, and performance for many years of future operation.
The project began with the complete dismantling of the machine, followed by the thorough cleaning of all assemblies. Each mechanical component was then carefully inspected for wear and functionality. Defective or worn parts were consistently repaired or replaced before the machine was reassembled.
A key focus of the mechanical modernization was the complete refurbishment of the axis systems. To restore the machine's original geometry and ensure consistently high positioning accuracy, numerous critical assemblies were renewed or refurbished.
Tool magazine before retrofit
The mechanical modernization included, among others, the following work:
- Installation of new guide strips and roller guide blocks for the X-axis
- Replacement of the slideway lining
- Installation of new linear guideways for the Y- and Z-axes
- Replacement of the Y- and Z-axis ball screws, including new bearing assemblies
- Re-bearing of the drive shaft and installation of a new rotary union
- Overhaul of the counterbalance system, including replacement of key wear components such as the flyer chain and headpiece
- Comprehensive overhaul of the rotary table
- Refurbishment of the tool magazine and automatic tool changer
- Inspection and refurbishment of the hydraulic system
- Installation of new protective covers for all axis guideways
- Installation of a new belt filter system for the coolant supply
- Complete repainting with a high-quality two-component textured coating system in RAL 7035 (Light Grey) and RAL 5010 (Gentian Blue)
Tool magazine after retrofit
Refurbishment of the milling head
Particular attention was also given to the machine's milling head. It was completely dismantled and disassembled into its individual components. As part of the refurbishment, the milling head was fitted with new bearings, new bevel gear sets, and all new seals. In addition, the spindle taper was precision-ground to restore accurate tool clamping and ensure the highest machining quality. The drive shaft was also fitted with new bearings, and a new rotary union was installed. Following reassembly and precise adjustment of the milling head, the machine was once again equipped with a high-performance, high-precision spindle unit.
Milling head before refurbishment
Disassembled milling head
Ball bearings from the milling head
Milling head after refurbishment
Steuerungsretrofit
In addition to the mechanical refurbishment, the control system retrofit represented the most extensive part of the project. The existing control system was replaced with a modern HEIDENHAIN iTNC 530 HSCI, including a new operator panel and electronic handwheel. At the same time, the machine's entire electrical system was completely renewed.
The electrical modernization included, among others:
- Construction of a completely new electrical cabinet
- Installation of new axis drives
- Installation of a new main spindle drive
- Replacement of the complete machine wiring
- Installation of new energy chains (cable carriers)
- Cleaning and inspection of the measuring systems
- Installation of the new HEIDENHAIN iTNC 530 HSCI with operator panel and electronic handwheel
However, replacing the hardware components was only one part of the project. The control system retrofit also required a complete PLC recommissioning of the machine. All axes, drives, and machine functions had to be reparameterized, programmed, and carefully synchronized. In addition, all mechanical travel limits were redefined, reference points were established, and all safety and machine functions were comprehensively tested before the machine was returned to service.
Recommissioning
The recommissioning alone took approximately five weeks to complete and required the highest level of precision, as well as close coordination between the mechanical, electrical, and control engineering teams.
The key activities carried out during recommissioning included:
- Precise alignment of the complete machine geometry
- Adjustment of the guide strips to ensure correct alignment and flatness
- Measurement and calibration of the machine's measuring systems
- Parameterization of all axes and drives
- Commissioning of the hydraulic, coolant, and automatic tool changer systems
- Geometric inspection and alignment of the machine bed, milling head, and rotary table
- Laser measurement and calibration of all axes
- Comprehensive functional and load testing prior to production release
Old control
New control
HEIDENHAIN iTNC 530
Erst nach Abschluss dieser Arbeiten konnte die Maschine ihre geforderte Präzision wieder erreichen. Die exakte Abstimmung sämtlicher Baugruppen und die sorgfältige geometrische Vermessung bilden die Grundlage für eine dauerhaft hohe Bearbeitungsgenauigkeit und Prozesssicherheit.
Nach Abschluss aller Arbeiten präsentierte sich die SORALUCE FS 8000 sowohl technisch als auch optisch in einem nahezu neuwertigen Zustand. Durch die umfassende mechanische Überholung, das vollständige Steuerungsretrofit und die präzise Wiederinbetriebnahme entstand aus einer über 25 Jahre alten Werkzeugmaschine wieder ein leistungsfähiges Bearbeitungszentrum auf aktuellem technischem Stand – bereit für viele weitere Jahre im produktiven Einsatz.
Disassebmly column
New electrical cabinet
Repainting of the operator station
New coolant unit