The CNC retrofit skills of CSD Controls (UK) were fully tested when a large-capacity two-axis lathe needed a new Anilam control system and digital spindle drive integrated with its existing Fanuc axis drives. However, after some clever adjustments to the Fanuc motors which involved adapting new encoders and tachos to give the correct signals to the drives and the CNC system, the lathe was as good as new in terms of both accuracy and reliability. With a massive 4900mm Z axis and 620mm in X, the lathe was one of the largest CNC lathes tackled by the Malvern (Worcs) based CNC/electrical retrofit specialist since its establishment in 1994 by Colin Munn and Simon Hopkins.

CSD is an authorised Anilam and Heidenhain retrofitter and over the years it has specialised in breathing new life into both large and small machines - 'often the types that other companies don't like to tackle', according to co-director Colin Munn.

He continues: 'Our focus is control retrofitting and electrical re-engineering, but we do also carry out mechanical conversions and updates when required - it depends on what the customer wants.

But our reputation has been built on being able to solve control system problems, and the Ikegai was no exception.

'The flood damaged lathe was shipped to us by the user who had initially identified a problem with the spindle drive, but then also asked us to quote for a new control as well.

Fitting the Anilam 4200T CNC was straightforward enough, but integrating it with the existing Fanuc equipment was technically challenging since these had to be adapted to get them to 'talk' to the control.' After fitting a new 30kW variable speed digital DC spindle drive (which produces 0 to 450 revs/min across two gear ranges) CSD altered the spindle encoder to achieve outputs that the control system would recognise.

With G code input with full text editor for cut, paste, search and replace, for example, plus interactive conversational G code help graphics and CAM programming, the Anilam 4200T CNC also features constant surface speed as standard feature, to help guarantee consistent surface finish and extended tool life.

The 4200T can run in several operational modes, including teach mode achieved via single or dual handwheel operation with dual axis interpolation.

Program utilities include create, delete/undelete, list, copy, rename and print, and the system's user-friendliness is prompted by full-screen editing and conversational help menu.

'We find that all our customers comment on the user-friendliness of the Anilam systems,' says Simon Hopkins, 'especially first-time CNC users.

Another major factor in favour of these CNCs is the fact that Anilam's technical and applications support is excellent - this is very important when customers are new to CNC.' Backed up by years of experience in machine control and electrical applications, CSD has found that its focus on Anilam and Heidenhain CNC systems attracts retrofit business from all parts of the country, even including maintenance call-outs for companies that no longer have the relevant in-house skills.