该分阶段现代化改造项目由斯达 拉格实施，服务对象是一家生 产核心零部件的领先航空航天 制造商。两台机床交替施工：一台保持生 产，另一台拆机重建。首台机床验证通过 后，随即切换施工另一台；最终两台杜普 莱恩 FOGS 机床均按时、按预算交付。对 该客户而言，改造方案的经济性显著更优： 机床机械结构状态完好，且已完全融入高 度优化的生产单元。项目不仅成本可控， 还避免了新增大规模机床所需的漫长交付 与调试周期。“采购新机床大约需要两年， 而改造的停机时间仅 7 个月。成本节约 十分可观。”斯达拉格美国服务经理斯蒂 芬·巴克利 (Stephen Barclay) 表示。客户 获得的远不止是“原样延续”。改造后的 两台机床配备了全新电气架构、最新一代 西门子数控系统、全新驱动与电机，并在 整个加工范围内实现了体积误差补偿，同 时具备基于传感器级数据采集的预测性维 护能力。改造在保留客户依赖的原有工艺 基础上，全面提升了可靠性、加工性能、 功能性与运行可视化水平。两台杜普莱恩 FOGS 高架龙门五轴机床分别于 2004 年 和 2011 年投入使用。“直观来说，它们 长 16 米、宽 6 米、高 2.5 米，专为超大 型飞机机身零部件的超高精度加工而设 计。”斯蒂芬·巴克利介绍道。他全程负 责该项目，并与斯达拉格德国工程团队协 同推进。这种规格的机床，精度以体积精 度而非线性精度衡量。“我们的目标是： 在五轴加工环境中，无论刀具位于整个工 作空间的任何位置，都能够将刀尖定位在 一个直径为 55 微米的球体范围内。”斯 蒂芬·巴克利解释道。在持续超过 15 年、 全天候（24/7）连续生产运行的情况下， 这两台机床始终保持着这一精度水平，甚 至表现得更为出色。

The most demanding requirement was continuity, not speed or accuracy. ”The customer wanted to minimize disruption and internal requalification effort,“ says Stephen Barclay. ”Any significant change to the production platform would have required extensive process validation, programming, and qualification work. A key requirement was that the machine had to run all existing code, use all existing tooling, and integrate seamlessly into the established production environment. By maintaining the proven machine architecture while upgrading the technology platform, we were able to preserve validated manufacturing processes and minimize operational disruption.“

In aerospace, that is not merely a convenience. It is a compliance requirement. ”Aircraft parts are like medical parts. You can’t just randomly decide to build them differently. Every component is serialized. The manufacturing process is proven and carefully controlled,“ Stephen Barclay says.

That principle shaped the technical scope. A completely new electrical cabinet was installed, along with all cables, sensors, and drive modules. Drive motors were replaced with the latest-generation Siemens units, physically smaller, equal in power, and significantly more energy efficient, across two 16 m machines operating around the clock.

The CNC was upgraded to the latest Siemens platform, resolving the obsolescence issue that triggered the project while introducing the latest Sinumerik motion-control packages, including MDynamics and Engineered Motion Control. Spindles and other major mechanical components were deliberately left unchanged. ”It was their decision not to replace the spindles with a different design,“ Stephen Barclay explains. ”They preferred to exchange them for refurbished and repaired versions. This ensured that the critical mechanical components remained in good condition, while avoiding changes that could have affected their process.“ One upgrade went beyond the original project scope. Both machines moved from Starrag’s standard Kinematic Management System (KMS) to Starrag’s upgraded Volumetric Compensation System (VCS), which corrects geometric deviations throughout the machine’s working volume from within the CNC rather than relying solely on mechanical accuracy. The benefits include improved tool-tip positioning during fully interpolated 5-axis movement and enhanced surface quality, exceeding the equal-to-or-better performance standard Starrag was contracted to achieve.