{"id":2774,"date":"2025-04-08T05:15:12","date_gmt":"2025-04-08T10:15:12","guid":{"rendered":"https:\/\/www.emag.com\/blog\/en\/?p=2774"},"modified":"2025-04-08T05:15:12","modified_gmt":"2025-04-08T10:15:12","slug":"retrofit-of-aging-grinding-machines","status":"publish","type":"post","link":"https:\/\/www.emag.com\/blog\/en\/retrofit-of-aging-grinding-machines\/","title":{"rendered":"Retrofit makes aging grinding machines fit for the future"},"content":{"rendered":"

Modern <\/span>production<\/span> systems<\/span> are<\/span> a <\/span>key<\/span> factor<\/span> for<\/span> the<\/span> competitiveness<\/span> of<\/span> manufacturing<\/span> companies<\/span>. <\/span>For<\/span> high-quality <\/span>cylindrical<\/span> grinding<\/span> machines<\/span>, a <\/span>comprehensive<\/span> modernization<\/span> of<\/span> existing<\/span> systems<\/span> can<\/span> be<\/span> an <\/span>economically<\/span> interesting<\/span> alternative <\/span>to<\/span> purchasing<\/span> new<\/span> equipment<\/span>. CNC-Technik <\/span>Weiss<\/span> GmbH, <\/span>part<\/span> of<\/span> the<\/span> EMAG Group <\/span>since<\/span> 2019, <\/span>specializes<\/span> in <\/span>retrofitting<\/span> Karstens <\/span>cylindrical<\/span> grinding<\/span> machines<\/span>. The <\/span>Neckartailfingen<\/span>–<\/span>based<\/span> company<\/span> has<\/span> decades<\/span> of<\/span> experience<\/span> in <\/span>overhauling<\/span> and <\/span>modernizing<\/span> these<\/span> precision<\/span> machines<\/span>. In an interview <\/span>with<\/span> Andreas Holstein, Plant Manager at <\/span>EMAG <\/span>Weiss<\/span>, <\/span>we<\/span> were<\/span> able<\/span> to<\/span> talk<\/span> about<\/span> the<\/span> technical<\/span> possibilities<\/span> and <\/span>economic<\/span> aspects<\/span> of<\/span> retrofitting<\/span>.<\/span><\/span>\u00a0<\/span><\/strong><\/p>\n

<\/p>\n

How do you define the term retrofit in the context of machine tools?<\/h3>\n

By retrofit, we mean the modernization or retooling of older machines that are no longer in production. This includes both mechanical and control technology components. This is to be distinguished from upgrades, where existing systems are expanded in terms of functionality or safety technology.<\/span><\/p>\n

 <\/p>\n

What are the main reasons for a retrofit?<\/h3>\n

One of the main reasons is often outdated control and drive technology for which spare parts are no longer available. Added to this are worn mechanical components such as guides or inadequate machine geometry. An important economic aspect is that the investment for a retrofit is around 15 to 30 percent lower than the cost of a comparable new machine. In addition, the safety of the machine is improved and brought up to leading edge technology. All retrofitted machines are also CE-compliant.<\/span>\u00a0<\/span><\/p>\n

 <\/p>\n

How does the retrofit process actually work?<\/h3>\n

First, we carry out a detailed inventory of the machine at the customer’s premises. Based on this, we discuss the options for reworking the individual assemblies and prepare a scalable, transparent quotation. Depending on the scope, the conversion is carried out at our premises or at the customer’s facility. The modernized components of the overhauled machine reach the level of a new machine.<\/span>\u00a0<\/span><\/p>\n

 <\/p>\n

What accuracy do you achieve after a retrofit?<\/h3>\n

We are guided by DIN 8630 for cylindrical grinding machines. For example, we achieve concentricity of 0.5 micrometers or better for workpiece spindles. After the retrofit, the machine geometry and accuracy correspond to the level of a new machine.<\/span>\u00a0<\/span><\/p>\n

 <\/p>\n

How long does a typical retrofit project take?<\/h3>\n

Usually between 12 and 16 weeks, depending on the scope. As we have over 60 basic machines of all Karstens series in stock, we can often use an identical machine as a foundation. The customer can then continue production on their old machine until it is replaced. This reduces the downtime to around two days.<\/span>\u00a0<\/span><\/p>\n

 <\/p>\n

How important is energy efficiency in retrofitting?<\/h3>\n

We use energy-efficient components throughout. The grinding spindle motors comply with efficiency class IE4 and are operated with regenerative frequency converters. For machine cooling, we use room-controlled air conditioning units that only regulate by a delta to the room temperature. Hydraulic pumps work with an accumulator charging circuit and, therefore, do not run permanently. Machines with hydraulics are retooled to servomotors and are then free of hydraulics.<\/span>\u00a0<\/span><\/p>\n

 <\/p>\n

Can you introduce us to various retrofit projects from your portfolio?<\/h3>\n

One very impressive example is the previously mentioned retrofit of a Karstens K33 for an automotive supplier. The machine makes steering pinions for electric power steering systems. With the addition of an\u00a0 integrated gantry loader, we achieve a chip-to-chip time of just 19 seconds – faster than comparable new machines on the market.<\/span>\u00a0<\/span><\/p>\n

\"Retrofit

Karstens K33 cylindrical grinding machine after complete retrofit: Equipped with modern CNC control, full enclosure and integrated loading system.<\/p><\/div>\n

Another<\/span> interesting<\/span> project<\/span> was <\/span>the<\/span> complete<\/span> retrofit<\/span> of<\/span> a Karstens K11. Here <\/span>we<\/span> upgraded<\/span> the<\/span> machine<\/span> to<\/span> a W 11-Advanced, <\/span>with<\/span> ball <\/span>screw<\/span> drive<\/span> in <\/span>the<\/span> Z-<\/span>axis<\/span>, modern <\/span>motion<\/span> control<\/span> and <\/span>touch<\/span> operation<\/span>. The <\/span>micrometer-<\/span>precise<\/span> infeed<\/span> and <\/span>automatic<\/span> Z-<\/span>axis<\/span> free<\/span> movement<\/span> were<\/span> particularly<\/span> important<\/span> in <\/span>this<\/span> case<\/span>.<\/span><\/span>\u00a0<\/span><\/p>\n

\"Karstens

Retrofit universal cylindrical grinding machine K 11 with state-of-the-art control technology: Precision infeed thanks to ball screw drive in the Z-axis and user-friendly touch operation.<\/p><\/div>\n

We<\/span> carried<\/span> out an extensive upgrade on a Karstens K19. The <\/span>machine<\/span> was <\/span>equipped<\/span> with<\/span> a <\/span>stepless<\/span> B-<\/span>axis<\/span> and <\/span>active<\/span> longitudinal <\/span>positioning<\/span> on <\/span>the<\/span> grinding<\/span> head<\/span>. By <\/span>converting<\/span> the<\/span> X and Z <\/span>axes<\/span> with<\/span> servo<\/span> motors<\/span> and ball <\/span>screws<\/span>, external and internal <\/span>grinding<\/span>, <\/span>including<\/span> taper<\/span> grinding<\/span>, <\/span>is<\/span> now<\/span> possible in a <\/span>single<\/span> setup<\/span>.<\/span><\/span>\u00a0<\/span><\/p>\n

 <\/p>\n

Are there also more cost-effective retrofit variants?<\/h3>\n

Yes, a good example is the retrofit of a Karstens K56. Here we had a machine that was still mechanically very good but had control problems. In such cases, we offer a “light retrofit” in which we concentrated on replacing the control system and overhauling the most important mechanical assemblies. This is a very interesting economic option for customers whose machines are still in good mechanical condition.<\/span>\u00a0<\/span><\/p>\n

\"Karstens

Cost-efficient modernization of a Karstens K56: The machine in good mechanical condition received a new control system and a targeted overhaul of the core components.<\/p><\/div>\n

 <\/p>\n

What about the supply of spare parts for retrofit machines?<\/h3>\n

The supply of spare parts for retrofit machines is generally guaranteed in the long term, as outdated control and drive components are replaced with modern, current technology as part of the retrofit. In addition, we offer comprehensive service and still have spare parts in stock even for very old machines. In this way, we ensure that your machine can be operated reliably over its entire service life.<\/span>\u00a0<\/span><\/p>\n

Thank<\/span> you<\/span> very<\/span> much<\/span> for<\/span> the<\/span> detailed<\/span> interview<\/span>.<\/span><\/span>\u00a0<\/span><\/strong><\/h3>\n

Find more information about EMAG’s retrofit solutions here.<\/span><\/span>\u00a0<\/span><\/strong><\/span><\/a><\/h3>\n","protected":false},"excerpt":{"rendered":"

Andreas Holstein from EMAG Weiss explains the technical possibilities and economic advantages of retrofitting cylindrical grinding machines.<\/p>\n","protected":false},"author":13,"featured_media":3038,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_lmt_disableupdate":"no","_lmt_disable":"","editor_notices":[],"footnotes":""},"categories":[2656,2615],"tags":[2585,2590,2589,2591,2578,2467],"class_list":["post-2774","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-featured","category-machines","tag-cylindrical-grinding-machines","tag-grinding-technology","tag-machine-modernization","tag-maintenance-staff","tag-mechanical-engineering","tag-retrofit"],"yoast_head":"\nRetrofit of Karstens cylindrical grinding machines<\/title>\n<meta name=\"description\" content=\"Andreas Holstein from EMAG Weiss explains the technical possibilities and economic advantages of retrofitting cylindrical grinding machines.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.emag.com\/blog\/en\/retrofit-of-aging-grinding-machines\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Retrofit of Karstens cylindrical grinding machines\" \/>\n<meta property=\"og:description\" content=\"Andreas Holstein from EMAG Weiss explains the technical possibilities and economic advantages of retrofitting cylindrical grinding machines.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.emag.com\/blog\/en\/retrofit-of-aging-grinding-machines\/\" \/>\n<meta property=\"og:site_name\" content=\"EMAG Group - 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