CNC 116 Gear Generator is specially designed using a Gleason 116 Generator casting that has been remanufactured and retrofitted with a new GE Fanuc Series 16 controller. As this machine is made from the reliable Gleason 116, all tooling that would fit a manual Gleason 116 will still work on this machine. The CNC 116 has run five successful test parts and is in like new condition.
The machine was remanufactured to convert the machine from manual operation to CNC control. The work piece infeed and rotation, and the cradle (cutter) rotation are computer controlled along with cutter RPM. The other machine axes are manually set with the help of digital readouts that were added to each manual axis.
The following axes are used on the machine:
1. The sliding base is CNC controlled and controls the tooth depth.
2. The work head rotation is CNC controlled.
3. The cradle rotation is CNC controlled.
4. The swinging base is manually rotated to the root angle stated on the summary while looking at the digital readout. This setting is used to control the root angle.
5. The work head cross slide position is manually set while looking at the digital readout.
6. The work head vertical position is manually set while looking at the digital readout.
7. The cutter spindle rotation angle is manually set while looking at the digital readout.
8. The cutter swivel angle is manually set while looking at the digital readout.
9. The eccentric angle is manually set while looking at the digital readout. This adjustment determines the distance between the cutter center and cradle axis.
REBUILD
Cradle rotation
A majority of the existing drive gearing that was used to rotate the cradle is removed. A GE Fanuc motor is installed and used to rotate the cradle through one set of worm gears. The feedback is taken from the motor. The part program controls the start and stopping along with the feedrate of the cradle.
Work head rotation
A majority of the exiting drive gearing that was used to rotate the work head has been removed. A GE Fanuc motor was installed and used to rotate the work head through one set of worm gears. The feedback was taken from the motor. The part program controls the start and stopping along with the feedrate of the work head.
Sliding Base Infeed
Sliding base ways were scraped and refitted as necessary to correct alignment to OEM
specifications. A ball screw and GE Fanuc motor were installed and used to move the base. The feedback was taken from the motor.
Hydraulic components
All hydraulic components were repaired or replaced as necessary to insure correct operation without leakage.
Lube system
A new external lube system was installed to lubricate the work spindle assembly of the machine. The existing hydraulic system was used to lubricate the cradle and sliding base ways. Its junctions and meter valves inspected and replaced as needed.
Cutter Drive
A GE Fanuc AC motor was used to drive the cutter wheel. A variable speed drive was used to control motor RPM. The motor is mounted to the backside of the cradle. Speed changes are done through the control.
Electrical Components
New wiring, switches, and control relays will be provided. The motor starters, disconnect switch, and contactors will be replaced. The electrical devices are 50/60 cycle. The machine is currently wired for 440Vac, 3 phase.
Enclosure
A new magnetics enclosure was mounted on the machine. The operator's station is incorporated into the magnetics enclosure.
Guards
A new system of guards have be added to provided coolant containment of the work area.
Paint
The machine is painted in a blue and white color scheme.
Coolant System
The existing coolant system has be used. This includes the coolant pump mounted to the side of the base with the base used as the coolant tank.
CONTROL SYSTEM
Control Systems
A GE Fanuc 16MB 3 axes Controlled Motion system has been provided. The control includes a 9" Color CRT and operators station. In addition, 160m part program storage, Custom Macro, and a Manual Pulse Generator have been provided.
Servo System
New AC Digital servo drives and motors have been added to the three axes. The cradle uses a Fanuc A30 1200 RPM motor with 265 in lbs of torque. The work spindle and sliding base uses Fanuc A12 3000 RPM motors with 106 in lbs of torque.
Closed Loop Feedback
The GE Fanuc controlled motion system has closed loop feedback with encoders mounted on the motors.
Interface Software
Interface software was supplied and installed by CNC Machinery Sales.
Gear Generation Software
The software required to generate different gear types and sizes was installed by CNC Machinery Sales. Gear Generation Software incorporates a series of menu driven screens to enter standard Gleason summary values that are used to control the machine. The programming screens are generated by a series of macro executor programs that control the display, storage, and retrieval of data. The system can store data for up to 99 different parts that can be called up at a latter time. The programming data can also be transferred to/from a host computer for storage. Data for the selected part is then transferred to the CNC control as macro variables that are used by G code programs located on the CNC. This system provides a very open environment were changes can easily be incorporated to configure the machine to the customers needs.
Cutter Spindle System Drive
A new alpha 8, 10 hp, GE Fanuc AC spindle motor and drive have been provided for the cutter. The motor is a variable speed unit with a range of 45 to 6000 RPM with a 10 HP continuous rating. This could provide a max cutter speed of 500 RPM, but to keep the same range as original, the speed is limited to 110 RPM.
