Spindle service capabilities

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Spindle service capabilities
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Table of Contents
1.0 About Elecon Engineering Sales 1.1 Elecon
Engineering Services Summary 2.0 About Elecon
Spindle Repair Rebuild Services 2.1 Machine
Audit 2.2 Spindle Repair Rebuild 2.2.1 Spindl
e Repair/Rebuild Stages (1-4) 2.2.2 Spindle
Repair/Rebuild Stages (5-7) 2.3 Retrofitting
Spindles/Machines 3.0 Elecon Engineering Tooling
Gauging Capabilities 4.0 Elecon Engineering
Benefits 5.0 Elecon Engineering Team 6.0 Contact
Us Information
Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing
3
About Elecon Engineering Sales
Elecon has more than 20 years experience in the
automotive and machine tool industry, and since
our incorporation in 1989 in Troy Michigan, we
have experienced growth across three continents.
Our client list speaks for itself and with our
highly skilled mechanical, electrical and fluid
engineers on call 24 hours a day, 365 days a year
across 6 countries in South East Asia we have the
capabilities and experience to solve your machine
tool issues today. Currently Elecon engineering
sales offers a wide range of engineering services
in the Asia Pacific region.   We are able to
provide services from one time emergency call
assistance, to long term comprehensive services
covering machine installation start up, machine
service, and control system design and
implementation troubleshooting.   We currently
have long term contracts in Asia with many North
American European companies.   We have a team
of mechanical engineers as well as software
engineers working round the clock, ensuring the
fastest possible response time.
Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing
4
Elecon Engineering Services Summary

• Automation services
• Equipment installation and commissioning
• Spare parts warehousing, warranty repairs
• Cutting tool sales
• Machine tool related software sales and support

• Technical documentation preparation
• Project management
• Machine tool and manufacturing system
  consulting
• Machine tool sales and post sales support

Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing
5
Elecon Spindle Repair Rebuild Services
Elecon Engineering and our partners have
extensive experience not only manufacturing
spindles, but also as being a total solution
house when it comes to repairing and rebuilding
virtually any type of spindle regardless of the
type or manufacturer. Elecons own facility, in
the suburbs of Shanghai are modern, and with easy
access to state of the art equipment corroborated
with the cumulated expertise of our people we
have the capability and knowledge to get the job
done, no matter how small or large.
Our Spindle Services Include
Machine Audit Repair
Rebuild Retrofit Spindles/Machines
Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing
6
Machine Audit
With our highly skilled technicians, we are able
to offer a comprehensive machine tool audit as
well as offering transfer line and high output
manufacturing audit. The proverb if it isn't
broken, dont fix it is certainly not applicable
in the machine tool and manufacturing industry,
where more than likely a machine tools part
quality can be improved, costs can be reduced and
improvements can be made long before anything
breaks. Elecon can help you get more out of your
current machine by providing a full audit, then
after assessing your process/application we will
propose improvements for your machine. Such
suggestions often include ways of   Minimizing
maintenance costs through decreased downtime
Maximizing revenue through increased up-time
Decreasing your cost-per-piece  
Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing
7
Spindle Repair Rebuild
Elecon offers a comprehensive spindle repair and
rebuild program for all kinds of spindle. At our
facility in Shanghai we have the technology to
repair or rebuild spindles from less than 20kg
all the way up to 2500kg. As soon as we receive
the spindle we will initiate a job number and
from this point on we will ensure that
communication with the client is maintained and
each stage is documented. We also implement a
full traceability program for all components.
Our Spindle Repair/rebuild Program Involves gt
Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing
8
Spindle Repair/Rebuild Stages (1-4)

• Failure Mode
• The next step is to identify the probable cause
  of failure. Now that we have all required data
  gathered in the tear-down report, our experienced
  technicians will analyze the information and will
  conclude on the Failure.

• Inspection
• Upon receiving of your spindle, we will assign a
  job number. Your spindle will undergo a rigorous
  inspection. We have a comprehensive method for
  evaluating failed spindles that allows us to
  identify probable root cause of failure. Our
  technicians will start by visually inspecting the
  spindle in order asses the impact of surrounding
  conditions on the spindle. A complete will
  follow. Each component will be carefully
  inspected for signs of contamination, possible
  wear or failure. Detailed conditions of core
  components (e.g. bearings, seals, motors, etc.)
  will be recorded in the tear-down report. All
  parts will be cleaned and kept together in tagged
  containers.

• Engineering Analysis
• Our engineers will evaluate your application(s)
  and will qualify the spindle for its intended
  usage. Then, based on the probable cause of
  failure from the tear-down report they may
  recommend improvements in respect with bearing
  configuration and preload, seal optimization and
  other key areas that will enhance performance and
  improve spindle life.

• Report to Client
• We are now ready to advise you on the following
  
• Probable cause of failure.
  Recommended changes (optional) that will better
  your spindle Total cost of the repair
• All our repairs carry a one year warrant

Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing
9
Spindle Repair/Rebuild Stages (5-7)
6. Assembly The assembly process is carried in
an environmentally-controlled clean room
dedicated only for precision spindle assembly
that will ensure the integrity and accuracy of
the finished assembled product. Only new
precision bearings class ABEC 7 or better are
being used with metered amounts of lubricants.
Bearing preload is paramount for spindle
performance in terms of speed and thrust
capabilities. This is the reason why close
attention is paid in attaining the proper preload
for your application.
5. Machining Balancing Based on the tear-down
inspection it may be required to sleeve and
re-bore the housing bores and/or to chrome and
re-grind the shaft journals. Spacers may be
needed to fit the new bearings as well as other
machined parts. Whatever component is required we
have the know-how and the capability to produce
it to the original specs in our machine
shop. The need for balanced rotors, spindle
shafts, is necessary in order to minimize
vibration and premature wear of bearings,
couplings, and shaft seals. In other words, a
properly balanced shaft will prolong spindle life
and will increase machining surface finish. At
Elecon, a two-plane dynamic balancing is
performed on spindle shafts which include all
rotational components (motor rotors, keys, etc.)
when available.
7. Final Inspection At this final inspection
stage, your spindle will be tested for runouts.
An axial compliance test will be
performed.Critical mounting characteristics
(e.g. face to key, base to centerline, side to
centerline, etc) will be checked as well as all
other special spindle features. The spindle
will be then tested at application speed starting
with a run-in procedure that involves an
incremental speed increase while monitoring
temperature. Temperature readings along with
vibration signatures will be recorded, printed
and added to the final inspection report which
will be presented to you.
Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing
10
Retrofitting Spindles/Machines
Retrofits can range from the addition of a simple
digital read out (DRO) system or installation of
a complete CNC automation system. We incorporate
products from companies including, but not
limited to Allen Bradley, G.E.Fanuc, Siemens,
Heidenhain, and others. After any rebuild or
retrofit we perform, we will come to your
facility to finish the job with a complete
installation and test run. Your machine will be
shipped back to your plant and usually our techs
will be there when it arrives so they can oversee
it being unloaded from the truck and set in its
location. From there they will reassemble the
machine and make all necessary hookups to
electrical and pneumatic supply lines it may
need. Next it will be aligned to compensate for
any shift that may have occurred during shipping.
Finally, several extensive test runs will be
performed to ensure the machine is in complete
working order and is up to the customers
satisfaction.
RETROFITTING Retrofitting a machine equipped
with an old or non-existent CNC or PLC control
can increase your productivity. Incorporating
automation into a manual machine can reduce the
time it takes your employees need to finish a
part, which lowers cost per part and increases
daily production. It also increases precision,
which in turn equals better products.
Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing
11
Elecon Engineering Tooling Gauging Capabilities
At our facility in Shanghai we have access to the
following equipment, machinery and gauges
required for spindle repair and rebuild
2000kg overhead gantry Frequency drives Hydraulic
fluid re-circulating systems Drawbar
actuation HSK air gauges Special indicators
Kelch tools, spanner wrenches, air purge gage,
encoder tester, misc. specialized tools 1600 line
2 channel FFT analyzer
Rotary grinders OD/ID grinders Surface
grinder CMM equipment Magnetic chuck lathe Clean
room Spindle drive Wash tanks Faraday Shielded
accelerometers 4 channel DAT (digital) tape
recorder
Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing
12
Elecon Engineering Benefits
All work and parts carry an Elecon warranty Full
utilized labor Material costs OEM
prices Specialized labor Specialized tools Local
location in Shanghai Engineered
solutions Document Management C2P/Ewie CMS
Dashboard RM root cause managed single point
of contact Predictive maintenance
Parts repair exchange 24/7 service
contracts Pricing approval system Prioritizing
FIFO or LIFC data driven Tested
documented Mature processes Commodity partners
Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing
13
Elecon Engineering Team
Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing
14
Contact Us
Elecon Inc has a dedicated team of engineers,
programmers, technicians, and support staff all
working together to provide the best possible
solutions for every one of our clients, on three
continents, 24 hours a day, 365 days a year. Why
dont you contact one of our offices to discuss
what Elecon Inc can do for you? Shanghai
Office Hong Kong Office 1 RuiJing Road
Unit B, 17th Floor 21 G Haixing Plaza
Success Commercial Building Shanghai
245-251 Hennessy Road 200023
WanChai China Hong Kong Tel [phone]
7850 Tel [phone] Fax [phone]
7851 Fax [phone] Email
sales_at_elecon-inc.com Email sales_at_elecon-inc.com
Website www.elecon-inc.com Website
www.elecon-inc.com
Elecon Engineering a competitive edge by
reducing machine downtime and predicting
preventing