ELECTRONIC RETROFIT

An electronic retrofit involves the replacement or upgrade of electronic components such as:

  • Rotary encoders
  • Servo motors
  • Servo drives
  • Controllers
  • Linear encoders

In our retrofitting projects, we primarily and preferentially use HEIDENHAIN products due to their superior performance and reliability.

ROTARY ENCODERS

Rotary encoders are sensors mounted on motor shafts that detect angular position, speed, and direction of rotation. They are used for feedback in closed-loop systems (servo motors).

LINEAR ENCODERS

Linear encoders measure the actual displacement of a machine axis independently of the mechanical transmission. They are mounted directly on the machine’s guideways and detect the actual movement of the tool, compensating for mechanical errors (e.g., backlash, friction, thermal expansion).

Advantages:

  • Higher resolution → smoother interpolation and increased accuracy
  • Lower susceptibility to interference
  • Non-contact sensing → less wear, longer service life
  • Support for modern protocols (EnDat, BiSS) for faster data transmission

Advantages:

  • Highest level of accuracy
  • Independence from mechanical drive errors
  • Complete reliability in high-precision applications
  • Suitable for long travel distances and high speeds

SERVO MOTORS

Servo motors are the main axis drives that perform movement with high precision based on commands from the CNC controller.

SERVO DRIVES

Servo drives convert digital commands from the CNC controller into analog power for the motors. They control current, voltage, and signal strength. They are the core of communication between the controller and the motors—their performance affects the operation of the entire machine.

Advantages:

  • Faster response time and greater dynamics
  • Higher power in smaller dimensions
  • Lower energy consumption
  • Quieter operation and longer service life

Advantages:

  • High efficiency and lower energy consumption
  • Built-in protections and diagnostics
  • Ability to regenerate energy during braking (up to 50% savings)
  • Communication via modern protocols (EtherCAT, Profinet, CANopen)

REGULATORS

Regulators are devices that manage the operation of servo motors by precisely regulating speed, position, and torque based on encoder feedback. They are essential components of all CNC systems with servo drives.

They act as an interface between the CNC regulator and the motor: the CNC sends a command, and the controller converts it into the optimal electrical signal to drive the motor according to the desired movement.

Advantages:

  • More precise motor control – better positioning accuracy
  • Advanced regulation of torque, speed, and position
  • Support for digital communication (e.g., EtherCAT, PROFINET, CANopen)
  • Ability to regenerate energy during braking (reducing consumption by up to 50%)
  • Built-in diagnostics – immediate detection of faults and alarms
  • Faster integration with other systems (fewer cables, standardized interfaces)