When machine tools become old and unreliable, there are basically two options: Replacement or retrofitting. Particularly in hard times the decision is generally for the second option. An important precondition for the profitable future efficiency of the old machine is a competent retrofitting partner such as Kabelschlepp GmbHo with its General Overhaul Machine Service.
Leonhard Breitenbach GmbH in Siegen Trupach manufactures rollers for various sectors. They have ultra-modern processing machines used not only for producing and processing new rollers, but also for contract work, repairs and renewals. All machines are fitted with state-of-the-art CNC controls. The company invests continuously in productive and efficient plant. In addition, machines are continually modernised and brought up to the latest standards.
In order to increase productivity, to come up to the latest safety standards and to modernise and recondition the automation technology, Breitenbach was faced with the question: Retrofit or buy a new machine, i.e. partial or complete modernisation? Having carried out a calculation of profitability, it was decided to retrofit 5 roller grinding machines and a roller lathe.
Kabelschlepp GmbH in Wenden-Gerlingen, one of the world-wide leading companies in the fields of cable carrier systems, guideway protection systems and conveyor systems turned out to be a competent partner. In order to modernise plastic and steel cable carrier systems, cables, conveyor systems and guideway protection systems, the company offers tailor-made solutions for machines and plant – including in-depth consultancy and project planning specitic to the application in hand. Reconstruction measures as carried out on the machines at Breitenbach cannot be implemented during normal production as the machines need to be taken completely apart.
The retrofitting service offered by Kabelschlepp, which includes a complete machine overhaul, combines the strengths of the four production sectors: guiding components (cable carrier chains), electricity supply (cables) transport (conveyors) and protection (telescopic covers), with coordinated tailor-made solutions. Breitenbach only had to deal with a single technical consultant from Kabelschlepp for the planning, the project development and the implementation, which simplified and speeded up the whole process. It turned out that the best way to tackle the problem was to survey the old machines on site, and to list and measure those parts which needed to be replaced. The new parts were made specifically for the Breitenbach machines and were fitted and adjusted on site. The aim of the prior negotiations was to find the technically best solution involving least loss of time. The technical consultant from Kabelschlepp suggested appropriate solutions and demonstrated the potential for optimal results. He came up with a complete list of new parts required and the precise time schedule for supplying and fitting these.
Kabelschlepp has its own service centre which is responsible for implementing the agreed solutions and carrying out fitting work on site at the customer’s factory. The Managing Director of Breitenbach, Dr Uwe Fischer, stresses Kabelschlepp’s extreme flexibility when manufacturing tailor-made products: “The excellent communication between the Kabelschlepp technical consultant and our maintenance department was what made it all work. Even more important for us was the timely production and fitting of the special parts ordered so that the machines could be re-integrated in the manufacturing process as quickly as possible.
For the roller grinding machines, Kabelschlepp delivered plastic cable carrier chains from the M series, models MT 0950 and MT 0650. These are chains with plastic covers which are made exactly to the requirements of the machines concerned. A different solution had to be found for the lathe, as the cable carriers had to be installed in the area of pre-turning, where extremely hot metal cuttings are to be found. In this case the specialists chose an appropriately shaped and permanently heat-resistant cable carrier chain made of steel, model S 1250 with aluminium covers.
Concerning the electronic modernisation of the machines there were repeatedly new requirements regarding the cables to which the carriers had to be adjusted. “Kabelschlepp proved to be very flexible in both project development and realisation,” according to Fischer.
In order to protect the guiding ways in the grinding machines, Kabelschlepp individually designed telescopic covers. For those areas in which for reasons of space telescopic covers could not be used, the Retrofit Service tailor-made modified link-aprons. In addition, Breitenbach needed bellows for the guiding ways where no cooling water or hot metal cuttings are present, as well as for the hinged brackets of the machine control panel. Everything was made exactly to the requirements and conditions on site. These included metal cutting exhaust installations which run under the machine bed. Because of the limited installation space, Kabelschlepp delivered made-to-measure hinged conveyors.
The General Overhaul Machine Service is of great value, says Dr Uwe Fischer, summing up: “We had very clear ideas concerning both the investment volume and the time parameters for the modernisation of our machines. Thanks to a sophisticated retrofit concept, Kabelschlepp was able to deliver the individual components just in time, exactly as our maintenance department required them. We were extremely satisfied, as we also were with the cost/performance ratio. Furthermore, we were very satisfied with the quality of the work carried out. These modernisation measures would also be a worthwhile investment in the future.”
Dr. Rolf Langbein
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