Paul:
Bit slow here so thought i would share some thoughts about retrofitting a Deckel FP-NC, on the off chance that some of this had not already crossed your thinking on this project.
First off, the work for the machine needs to be specific. If you are looking to start a "job shop" using a Deckel you have already lost.
Limits of the FP-NC design make them unsuitable to be competitive in a job shop environment. Low spindle speed (even at 6300 flip) lac of a tool changer...Relatively slow rapids and long gear shift times
all limit the machines ability to compete even assuming the modern control retro was successful.
You need to have a "niche" work/machine requirement that plays well with the strengths of the FP-NC structure....Horizontal / vertical spindles with sensitive quills.
Full working spindle horse power when working at low RPM's (full gear drive) Flexible setups, and the ability to utilize the factory accessories to advantage. Overall accuracy with relatively large work envelope in a reasonable
sized package.
All this, to me, suggests either hobby, inventor, model maker, specialized component maker or repair as some of the areas that the Deckel NC's would excel at.
I am more or less an old school guy. Not a big fan of the Centroid system. Some have had good results, others seem to end up with a "working" machine, that is less than ideal, of course your results may vary.
Personally i Love the Dialog4 setup. For me it is almost ideal. Don't need a control with more features. If i need to do complex shapes (3-D) i do so programming off line on a good CAM system (SurfCam)
I could stand to have higher look ahead and higher processing speed....My Dialog has the factory DNC so i am not limited to program size. Have easily run programs that have 80,000 lines of code with no issues.
If i was considering a retro i would be looking seriously at Heidenhain. I like their interface (nothing is as nice or functional as the original Dialog user interface) Like the fact that they use discrete buttons (hard)
for functions, not PC style "F" keys.....
Currently there are several Heidenhain TNC controls with keyboards and monitors on E-bay for reasonable money....
If the incentive to go with the Centroid is based on having support , i would want to know if the reseller has any experience at doing a Deckel.....Lots of detail differences here as compared to a Bridgeport or Tree retro.
As example...the spindles , horizontal and vertical rotate in opposite directions...Has to do with the gearing. The Deckel operator never sees this. Changing the tool release from vertical to horizontal also changes the logic
for the spindle rotation....so the horizontal will operate same as the vertical...its seamless, a small detail, but necessary.
Gear changes employ a system of low speed (voltage dropping resistors) spindle jogging while releasing the brake...goes three / four cycles,then reverses for another three/four cycles then back forward for another set.....if the gear is not found in all that,the machine faults.....This is all something that can be handled with a PLC , but it takes doing and it has to work every time.
A few words about the servo's.
The Siemens servos are reputed to be "bullet proof"....My experience supports that view!
Some would argue that DC servos are a maintenance issue....Maybe, but i have been running my FP4NC since 1993 and have yet to need to do any service to the servos including motor brushes.
Nice thing about the factory motors is that they are nicely integrated and fitted with internal brakes to hols slides when is turned off...or if you need to lock them.
The factory setup also incorporates over load clutches to protect the machine from damage in event of a crash....
The Factory Bosch servo drives cone in two versions. The later style interchanges with the earlier and can be mixed within the overall chassis, with the restriction that the newer amplifier card can only be
used with the newer regulator card (there are two cards for each axis, and slots to run 4 axis standard)
The newer series of servo drive cards (has a piggy back board that carries the resistors to tune the motor for its specific axis) are more desirable, deemed more repairable.
Newer boards should have the beginning part number of : 047--------
Early version : 038-------------
Seems that some retrofitters believe that the Bosch unit is fine. FPS(Germany) does Heidenhain control retrofits but retains the original Bosch setup for the servos.
I have been succesfull running an FP2NC using a modern servo drive. My selection was to use AMC (advanced Motion Controls) Digiflex digital servo drive: DPRANIE -030A400
See here for specs:
DPRANIE-030A400 Modbus RTU RS485 servo drive
I did this several years back to see if i could come up with a useable substitute for the Bosch drive.....
Only did one axis, but the results were fine, performance as good or better than the Bosch setup.
Choose the digital drive for several reasons. First off they can be programmed..comes with software to set and monitor the operating performance. Interface with a PC through a RS232 port,
software includes an "O-scope that graphs accel and decell curves.
Further the digital drive has logic that allows it to be switched on and off for doing stuff like enabling the hand wheels....
Also this drive was self contained. Has its own internal power supply so all it needs is to be fed three phase power in the correct voltage range.
At the time i was looking to have a replacement servo drive that would work with the existing Dialog control.
There were some hurdles to using this drive. First and most importnt was the original tach output.
The digital drive is designed to accept analog tach input. That is good but the voltage range on the drive is too low (-10 +10v) The output of the factory tach on rapid i believe can
reach 50vdc , too much for the drive.....
I solved this (with help) by scaling the tach output.
In the end i did not finish a full three axis setup, but i was satisfied that the digital replacement would be a good choice.
If i was doing a complete servo drive change i would consider removing the tachometers from the factory servos and replacing them with digital encoders.
Think encoders have fewer maintenance issues and might provide better overall servo performance.
There is space in the servo enclosure , would require mounting and additional cable to the electrical cabinet....
The Digital servos are a bit pricey. Costing around $1000.00 per axis when i bought these several years back....Analog units would be more cost effective, but would not have the tuning software and might need hardware component (resistors) changes to tune the servo action .
For me the digital setup was worth the extra.
Hope some of this is of value
Cheers Ross