A mechanical and CNC electrical re-fit of a Farrel 12 meter CNC Vertical boring mill.
Customer:
Alstom. A world leader in transport and energy infrastructure
Overview:
Alstom is an international company that provides equipment and services for power generation and rail transport. With plants and offices all over the world, they often buy and move large pieces of equipment, such as the Farrel Vertical boring mill, between countries and sometimes between continents.
This project started with a Vertical boring mill in Alabama that Alstom was interested in purchasing for their plant in India. Team Machine Tools Inc. was hired to assess the boring mill as to what level of work was needed to refurbish it. After providing their positive evaluation to Alstom, Team was then given the job of moving, refurbishing and installing it in India; a logistically challenging project that involved 3 countries and tight timelines.
Project Milestones
The Farrel boring mill is dismantled by Team Machine in Alabama and shipped to Toronto. Over the next six months, Team Machine completes an entire mechanical and CNC electrical re-fit of the machine at their warehouse.
The boring mill is then shipped to Vadodara, India, via Saint John and Mumbai.
Over the next 2 ½ months, Team Machine engineers assemble, install and test the newly retrofitted boring mill at Alstom’s Vadodara plant.
The Benefit of Retrofits
A new machine of this size would take 2-3 years to build and would cost between 7 and 8 million dollars. In 11 months, Team Machine completely re-fitted it with modern-day capabilities and automation, bringing it up to the standards of new machines – at a fraction of the cost.
Older machines have a level of stability in the major component castings that is often difficult to duplicate. Therefore, in most cases, the larger the machine, the more justification in automation upgrading and refurbishment - not to mention the significant saving of time!
A Project Handled from A-Z
Team Machine managed all logistics for the project, including transportation, packaging etc.; a huge undertaking that involved 3 countries, international trade laws, and tight timelines.
Team Machine also managed all the small contracts that came with the project – brokerage, insurance, trucking, logistics and training.
Team Machine successfully met all the project target dates and requirements, even when faced with delays that were beyond their control.
Apollo Machine and Welding Ltd.: Edmonton, Alberta
Apollo Machine services the oil field and gas industry with production inventory consisting primarily of directional drilling tools, shocks, jars, wellhead equipment and flow measurement and flow control equipment.
Overview:
Team Machine has a long history with Apollo Machine, performing all their major service work including laser and calibration and machine moves. Team had also previously retrofitted two European lathes and was now asked to retrofit Apollo’s Toshiba VMC 85.
While Apollo Machine regularly purchases new technology and hi-tech machine tools, they have a stable of core machines that they maintain for critical processes. The Toshiba VMC 85 was one such machine. This vital and reliable machine tool was well worth restoring, and once CNC and hi-tech components were added, the overall quality and production ability of the machine was elevated to an unparalleled level.
Project Milestones
The VMC 85 was dismantled and shipped to Team Machine’s facilities in Mississauga where the machine was completely retrofitted.
Team undertook a complete refurbishment of all electrical, mechanical and hydraulic components, integrating Fanuc 32.I CNC applications.
Once run-offs were approved, Team dismantled the VMC 85, shipped it to Apollo and installed the newly refurbished machine.
Project Outcome
Team Machine completed the retrofit of the VMC 85 within Apollo’s time frame and budget.
In addition to the integration of CNC and hi-tech components, The VMC 85’s core components were all restored as well, resulting in a machine that not only ran far better, but also ensured the continued reliability of Apollo Machine’s valuable asset for years to come.
Relocating a specialized machining cell from Ohio to Wisconsin
Customer:
Spincraft: New Berlin, Wisconsin
Spincraft is a key fabrication supplier to the aerospace, aviation, defense and energy industries, delivering integrated, single-source manufacturing solutions for complex fabrications and assemblies. The company offers capabilities for metal spin forming, heat-treating, machining and welding for virtually all workable metal alloys.
Overview:
Team Machine Tools provides integrated full service to Spincraft. Having previously retrofitted and relocated several machines for them, Team was now asked to move a specialized machining cell from Ohio to their plant in New Berlin, Wisconsin. The CNC machining cell consisted of two Berthiez VTL’s and a Forrest Line machining center utilizing 9 pallets and a motorized set-up station. Between the two VTL’s was a CNC-programmed rail-guided vehicle that shuttled the pallets within the cell.
Project Milestones
Team Machine dismantled and removed the machining cell from its original location and handled all logistics (rigging, packaging, etc.) to move it to the plant in Wisconsin.
Since the new plant had a different layout, the machining cell had to be re-configured from the way it was designed by the OEM. This also involved developing a new foundation for the cell, which Team helped Spincraft to modify.
The VTL’s, machining center, storage locations and the set-up station were all re-arranged to fit the new layout.
Once the machining cell was installed, Team re-calibrated, re-wired and re-programmed the cell; including programming the new coordinates into the rail-guided vehicles. Team Machine then provided training to Spincraft employees on basic operation of the cell.
Project Outcome
Team Machine successfully moved and reconfigured the machining cell to fit the different layout at the factory in Wisconsin.
The installation was a very specialized project due to the cell’s modifications. This had Team Machine employees working closely with Spincraft to ensure the project was done to their specifications.
A complete electrical rebuild and retrofit of a 13.2m Dorries VTL
Customer:
Voith Hydro: York, Pennsylvania.
Voith Hydro is a supplier of advanced hydroelectric equipment, technology and services in the renewal energy market. Their North American headquarters in York are home to one of the world’s largest dedicated hydro turbine equipment manufacturing facilities.
Overview:
In spring 2008, Team Machine Tools was asked to undertake a complete electrical rebuild and retrofit of Voith Hydro’s 13.2m Dorries VTL. While Team had worked with Voith previously on smaller machines such as their 3M VTL, this project was of a much bigger magnitude, as the 13.2m VTL is one of the five largest machines in North America.
And to make the project even more challenging, there was a time frame of 10 weeks to install the new components, as this VTL was central to Voith Hydro’s manufacturing and its downtime had to be minimal.
Project Milestones
To meet the timeline of 10 weeks, Team did all the designs and preparatory work at their own facility far in advance of the actual installation.
Once on site, Team Machine replaced all the VTL’s original electrical components, including a new Siemens 840D CNC system, new servo and spindle motors and drives, two operator panels, complete new wiring, and also integrated the original 100 KW DC table motor with a new drive and system.
To increase the machine’s reliability (and as an added-value), Team also calibrated the scales and motors separately, so the machine could operate accurately if the linear scale should fail.
At the machine’s retrofit completion, it achieved C-axis positioning with a +/- 2 arc seconds with table capacity up to 300 tons.
Project Outcome
The customized electrical refit of the 13.2 VTL resulted in a completely updated machine that was now running at optimal performance.
As the minimum downtime of this VTL was vital, Team was given 10 weeks to install the new components. Team Machine completed the job in 7 weeks and met all Voith Hydro’s in-house health and safety requirements as well as all commercial issues.
Voith Hydro was extremely satisfied with the retrofit project and as a result, referred Team Machine to other customers.
