M. SERRANO ELECTRICAL WORKSHOPS

Complete retrofit of an LC82 gear hobbing machine:
a second life for a strategic machine

Talleres Eléctricos M. Serrano needed to modernize one of its LC82 gear hobbing machines, a machine that was still mechanically robust but whose control technology had become obsolete.

Replacing it with a new machine would have involved not only a very high investment, but also long delivery times. The objective was to preserve the machine’s mechanical reliability while incorporating the technology required to meet current production demands.

The challenge

The project involved a comprehensive transformation of the machine, with several main objectives:

Renew

Completely renew the electrical and electronic architecture.

Integrate

Integrate a state-of-the-art Siemens SINUMERIK ONE CNC.

Replace

Replace the drives, servo motors, and automation systems.

Modernize

Modernize the hydraulic, pneumatic, and lubrication systems.

Develop

Develop a new tailstock with electronic pressure and position control.

Increase

Increase the tool’s operating speed to over 3,000 rpm, while maintaining process stability and precision.

The real challenge was not simply replacing components, but adapting a machine designed decades ago to operate with significantly higher performance than its original specifications without compromising its reliability.

The solution developed by Maymu

To address this challenge, Maymu developed a comprehensive retrofit combining mechanical engineering, automation, and CNC control.

The project began with a comprehensive analysis of the machine to study its kinematic behavior, identify critical components, and define the necessary modifications.

The next step was a complete technological upgrade that included:

Integration of Siemens SINUMERIK ONE

New SINAMICS drives
Replacement of servo motors
New PLC and automation architecture
Complete renewal of the electrical cabinet and wiring
Modernization of the auxiliary systems

From a mechanical perspective, various elements of the kinematic chain were also redesigned to ensure safe operation under the new working conditions.

Finally, the machine underwent a validation process in an industrial environment involving dynamic testing, parameter adjustments, and production trials until stable operation was achieved.

The results

The modernization transformed a machine with obsolete technology into equipment ready to continue operating for many years, with performance far exceeding its original capabilities.

Among the main results achieved are:

Stable operation at speeds exceeding the original design specifications.

Integration of a state-of-the-art CNC system.

Electronic control of the tailstock.

Advanced synchronization between all machine axes.

Increased reliability of the control system.

Architecture designed to accommodate future upgrades and new functionalities.

The project reached Technology Readiness Level (TRL) 9, validating the developed solution in an industrial environment.

Benefits for Talleres Eléctricos M. Serrano

Thanks to the retrofit carried out by Maymu, the customer was able to have a fully upgraded machine without having to take on the investment and lead times associated with purchasing new equipment.
The upgrade made it possible to:
  • Significantly extend the service life of a strategic asset.
  • Incorporate state-of-the-art CNC technology and automation.
  • Reduce the risk associated with component obsolescence.
  • Prepare the machine for future production needs.
  • Improve sustainability by reusing existing machinery.

A replicable retrofit model

Beyond the result achieved with this machine, the project has enabled the consolidation of a proprietary advanced retrofit methodology based on the integration of new technologies into highly complex machinery.Beyond the result achieved with this machine, the project has enabled the consolidation of a proprietary advanced retrofit methodology based on the integration of new technologies into highly complex machinery.

The experience gained in mechanical engineering, automation, CNC integration, and industrial validation enables Maymu to confidently undertake new modernization projects involving gear hobbing machines, multi-spindle lathes, and other special-purpose machines.

Conclusion

The transformation of this LC82 gear hobbing machine demonstrates that a well-planned retrofit can turn a machine with decades of service into a fully competitive asset for today’s industry.

At Maymu, we help our customers extend the service life of their equipment through retrofit, automation, and modernization solutions designed to increase availability, reduce obsolescence, and prepare their facilities for the challenges of Industry 4.0.

Because, in many cases, the best new machine is the one you already have… modernized.

Does your project resemble one of our success stories?

If there’s anything we can do to help improve your operations, don’t hesitate to let us know.

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