Currently, we are modernizing a Gildemeister NEF 320, originally equipped with a Heidenhain CNC Pilot 3110 control. The machine is mechanically impressive due to its very good condition – an ideal candidate for a cost-effective retrofit instead of an expensive new purchase.
Initial Situation and Challenges
A particular challenge with this machine is the original drive technology:
Communication to the Siemens servo drives via fiber optic cables
Proprietary system architecture
No easy integration of modern control systems
Continued operation of the existing drives was therefore not possible – a complete replacement of the power amplifier stages was necessary.
New Control and Drive Architecture
The new solution is based on an open and future-proof platform:
Control & Communication
LinuxCNC as the central CNC control
MESA FPGA Hardware for real-time signal processing
7i92M Ethernet Interface – complete communication via Ethernet
Drives
New Lichuan EtherCAT servo drives
Main spindle via DELTA frequency inverter
Encoder Integration
Particularly critical: Evaluation of the main spindle encoder
Implementation via MESA FPGA cards for precise synchronization (thread cutting, constant cutting speed, etc.)
Modern operating concept
The original monitor was replaced by an industrial touchscreen.
The user interface used is ProbeBasic:
Completely touch-optimized
Operating concept based on modern industrial controls
Direct generation of standard cycles via the interface
Integration of numerous LinuxCNC cycles (turning, threading, drilling, etc.)
The result is an intuitive and powerful HMI without proprietary restrictions.
Control cabinet and handheld operating device
The control cabinet is largely preserved:
Existing contactor control remains in its original state
Replacement of:
Power stages
I/O cards
The greatest challenge lay in the manual control device:
Special Heidenhain interface
Communication via Eltromatic bus
System analysis:
EPROM read out
Bus protocol examined
9-bit communication
Since a complete re-engineering was not feasible within the time frame, integration was implemented via MESA interface cards.
An alternative microcontroller gateway (similar to our solutions for Bosch CC) would have been possible but was not implemented for project reasons.
Mechanical Adjustments
Mechanical adjustments were also necessary:
Original Siemens servomotors:
different flange
different shaft diameter
Measures:
Redesign of adapter flanges
Replacement of the motor couplings
Thanks to the very good condition of the machine, the high mechanical precision is fully preserved.
Result
This retrofit technically brings the Gildemeister NEF 320 up to the standard of modern machine tools:
Open, future-proof control platform
Spare part availability without manufacturer dependency
Modern EtherCAT drive technology
Touch HMI with industrial operation concept
Significantly extended machine service life with comparatively low investment costs
Especially for mechanically well-maintained machines, a retrofit is the most economically sensible alternative to a new purchase.