When a large, three-dimensional machine suffers a critical breakdown, replacement may seem like the only option. However, specialized repair and reverse engineering can offer a technically and economically viable solution.
This is the case of a DEA Global 12.30.10, a coordinate measuring machine (CMM) that the manufacturer had declared "irreparable" after suffering a breakdown caused by an impact on the Z axis.
The failure affected a structural component connecting the bridge and the Z-axis, compromising the machine's operation. After more than two months of waiting, the manufacturer ruled out repair, leaving the customer with the prospect of making a significant investment to replace the equipment.
Téciman Metrología accepts the challenge of repairing the DEA
Given this situation, Téciman Metrology decides to address the repair of the DEA Global 12.30.10 through a comprehensive process that combined technical diagnosis, disassembly, reverse engineering, component reconstruction and geometric recovery of the machine.
The first step is to completely disassemble the MMC DEAThis is a particularly complex operation due to the machine's size and characteristics. The goal is to access the damaged part, remove it, and analyze it to determine the feasibility of rebuilding it.
From there, the technical team of Téciman Engineering develops a process of reverse engineering of the fractured piece, studying different manufacturing and repair alternatives and evaluating their technical feasibility.
This analysis allows us to define a specific solution to recover the component and return the machine to suitable operating conditions.
Reverse engineering and repair of the critical part
Repairing a DEA Global is not simply a matter of replacing a part. In a coordinate measuring machine, the Geometric accuracy of the assembly is fundamental to ensure the reliability of the measurements.
For this reason, the process includes:
- Complete disassembly of the machine.
- Extraction of the damaged structural part.
- Analysis and technical feasibility study.
- Reverse engineering of the component.
- Evaluation of different manufacturing and repair alternatives.
- Reconstruction and repair of the part.
- DEA full assembly.
- Geometric adjustment complete.
- Accredited calibration by ENAC.
Once the repair was completed, the technicians from Téciman Metrología reassembled the machine and carried out a Complete geometric adjustment, restoring the correct relationship between the different elements of the MMC.
Finally, the ENAC accredited calibration, an essential step to verify the metrological behavior of the machine and guarantee the recovery of its performance.
A fully operational AED and €120,000 in savings
The result of the project is the recovery of a DEA Global 12.30.10 fully operationalavoiding equipment replacement and allowing the customer to maintain their measurement processes.
The repair involves a approximate savings of €120,000 compared to the investment initially proposed by the manufacturer.
In addition to the cost savings, the solution has allowed for a reduction in lead times of approximately three monthsminimizing the impact that the unavailability of a CMM of this type could have on the client's industrial activity.
Repairing an AED to extend the lifespan of an MMC
This case demonstrates that a serious breakdown does not always mean that a three-dimensional measuring machine has reached the end of its useful life.
The combination of Reverse engineering, metrological knowledge, specialized manufacturing, mechanical repair, geometric adjustment and calibration It can allow the recovery of coordinate measuring machines that, under certain circumstances, have been considered irreparable.
For industrial companies that rely on their metrology equipment to ensure the quality of their processes, evaluating the possibility of repairing a DEA Global It can become a particularly interesting alternative to completely replacing the equipment.
In this project, the repair has allowed to give a second life to the MMC, maintain the customer's measurement capacity and avoid an investment of around €120,000.
Does your 3D machine need repair?
Each breakdown requires a specific technical analysis. A feasibility study can determine if the machine can be repaired, what solution is technically most suitable, and what the most efficient alternative is to replacing the equipment.
Téciman Metrología handles these types of projects comprehensively, from diagnostics and reverse engineering to repair, assembly, geometric adjustment, and machine calibration. For more information, call us at +34 947 20 91 41 or send an email to [email address missing]. teciman@teciman.com. Follow us on LinkedIn to find out all the news.