Wanderer 400 LinuxCNC Retrofit

Project Overview

A complete retrofit was carried out for a Wanderer 400. The goal was to modernize a high-performance 4-axis machining center (BAZ) with:

• Swivel head

• 100-fold tool changer with shelf system

• Pallet changer

• extensive peripherals

The machine’s mechanical structure remained intact while the control, drive technology, and operation were brought up to the latest state of the art.

Reverse Engineering of Bosch Peripherals

A central component of the project was the reengineering of the Bosch EA assembly.

• Analysis and documentation of existing interfaces

• Development of a custom gateway board based on an STM32 microcontroller

• Communication via USB and RS485

• Control of all inputs and outputs via LinuxCNC

This allowed the complete machine peripherals to be reused without complicated rewiring.

Drive Technology with MESA FPGA Hardware

Axis control is handled via MESA motion control cards:

• FPGA-based signal processing

• 10 MHz update rate

• Precise generation of analog setpoints

• High-resolution encoder evaluation

• PCI interface for standard industrial PCs

The PC mainboard was mounted together with the MESA card on a plug-in sheet and can be used directly instead of the original PLC CPU.
The result: minimal modification effort with maximum performance.

Interface Board for Fast Installation

To further reduce retrofit time, an additional adapter board was developed:

• Reuse of existing DSUB and Phoenix connectors

• No rewiring necessary

• Plug-and-play integration of the new control system

• Ideal for series retrofits of this machine type

New Operating Concept

The original control panel was completely replaced by:

• Mobile control panel

• Wireless handheld operating device with:

  • Handwheel (MPG)

  • LCD display

• Comfortable setup and manual operation directly at the machine

The LinuxCNC interface was specially adapted to the requirements of the Wanderer 400.

3D Machine Visualization & Virtual Processes

For maximum operational transparency, a custom machine visualization was developed:

• Display of 3D models for tools and workpieces

• Virtual representation of:

  • Tool changes

  • Magazine movements

  • Machine states

• Complete overview of all processes – even with limited visibility, e.g. due to cooling mist

Enhanced Safety: Collision Monitoring

As an additional feature, a software-based collision monitoring was integrated:

• Real-time monitoring of axis movements

• Protection against collisions with:

  • Workpieces

  • Clamping devices

  • Machine components

• Increased process reliability and reduced downtime

Result

• Significantly extended machine lifespan

• Modern, open control platform (LinuxCNC)

• Minimal modification time through use of existing interfaces

• High performance thanks to FPGA-based motion control

• Improved operability and process safety

Your Advantage

The Retrofit GmbH offers tailored modernization solutions for machine tools – from interface analysis through hardware development to complete commissioning.

Would you like to modernize an existing machine?
Contact us – we will make your system fit for the next 15–20 years.