Ford Motor Company’s Romeo Engine Plant wanted to upgrade their existing Sanyo and Yaskawa servo and spindle on a Toyoda crankshaft finish pin journal grinder for the facility. Because of an existing relationship with the customer, Galco was asked to offer solutions for the facility. The customer was experiencing drive failures periodically and needed a solution to eliminate expensive downtime and costly repairs.

SOLUTION

Yaskawa was chosen by the customer because of its proven track record and durability. Galco replaced the servo drive and motor for the Work Spindle, A-Axis steady/rest, X-Axis in feed, and Wheel Dresser on the GVB crankshaft grinder. The CNC unit remained intact. Galco installed new Yaskawa motors that mechanically matched the existing wheel spindle and X-Axis motors. The A-Axis, Z-Axis, and Wheel Dresser motors, on the U and W-Axes, needed adapters to mount them to the machine. After analyzing the system, Galco recommended installing the new drives on a sub-plate which enabled Galco to create the assembly at their facility. This reduced installation time which had the customer up and running faster. Galco designed adapter plates for the A and Z-Axes and Wheel Dresser motors. The manufacture of these items was coordinated and sub-contracted by Galco. A field check was performed to determine the previous mechanical information on the equipment. Prior to the retrofit, recording instruments were used to measure the speed and torque during the machines operation. This data was later used during start-up of the new servos. A field check was performed on all the motors to ensure compatibility of the new mechanical components.

Existing Yaskawa drives on the Toyoda grinder used a custom interface from the manufacturer that responded to commands from the Toyupuc PLC via an I/O interface. Galco provided custom interface cables for installation, assembly drawings and installation instructions. The original servo drives used potentiometers for set-up purposes. Upgrading to digital drives made for robust functionality; "set it once, and it’s set until you want it changed." Machine set-up was made even easier with set-up software
from Yaskawa.

OPERATION

The new system was completely programmed, tested and run-off for approval prior to installation at the customer’s site. Galco checked the machines for adapter plate accuracy as well as verifying the mechanical interface for existing Yaskawa motors on the wheel spindle. Program codes were documented while the machine was running. Traces of velocity and amperage for each axis were also recorded prior to the retrofit. The result was a more reliable product that used existing panel space.

Panel Before Upgrade

Existing Motor

Existing Motor

Panel After Upgrade