From standard to high-performance: The MCV 1016 Speed. Case study of a general overhaul with a custom spindle unit
What does a general overhaul and machine modernization actually involve? Take a look at how we transformed a worn-out machine into a high-performance, technologically advanced MCV 1016 Speed – the first of its kind.
Initial condition and project brief
The MCV 1000 machine, manufactured in 1996 and operated by Slevarna a modelarna Ransko, was a typical example of a worn but structurally solid machine. The project was initiated in cooperation with Mr. Pochop from Nove Ransko. The client opted for a full rebuild – a combination of general overhaul and modernization. The aim was to preserve the solid structural foundation, fully utilize the machine’s potential and create a machining center based on the original core but upgraded to meet modern production demands.
We sincerely thank the management of Nove Ransko and especially Mr. Pochop for their trust and cooperation. We value the opportunity to carry out this transformation and appreciate their support for VOPSS as a Czech supplier.
Scope of work: From frame to final detail
The general overhaul involved full disassembly, refurbishment, and replacement of mechanical and electronic components.
Only the main cast iron parts and parts of the enclosure were retained – everything else was either thoroughly renewed or replaced.
Key upgrades:
- New in-line spindle unit – 32 kW, 15,000 rpm
- New KSK Precision ball screws and Rexroth linear guides on X, Y, Z axes
- New KSK Precision ball screws and Rexroth linear guides on X, Y, Z axes
- Complete new wiring, new servomotors with absolute encoders
- Heidenhain TNC620 control system, including panel, MPG, axis motors, and scales
- 4th axis readiness, new tool changer with arm, centralized lubrication for guides and screws, telescopic covers, flushing, pumps, and cooling system
- Full geometric alignment, functional testing, and performance trials
At the heart of the modernization: A new VOPSS spindle unit
The uniqueness of this project lies in the custom-built electrospindle unit developed and manufactured by the VOPSS team.
With a power output of 32 kW and 15,000 rpm, the original machine was elevated to a completely new level – now known as the MCV 1016 Speed. As the name suggests, this is a machine built for speed and performance.
The in-line motor-spindle design allows easy replacement or adaptation of the spindle for specific technologies – from roughing to finishing.
Thanks to efficient cooling of both the motor and bearings, minimized thermal changes, and precision bearing housing in the spindle tube, the machine gained increased stability and extended lifespan of key components.
In this project, we applied everything we’ve learned over the years – from design to control to precision. The result is a unique combination of performance, availability, and tailored design.
Project Manager
The result: A machine equivalent to new
Following modernization, the customer received a high-performance machining center with parameters comparable to brand-new machines – but at a significantly lower cost.
The delivery also included accessories such as:
- Chip conveyor with customized discharge height
- Heidenhain TS460 and TT460 probes
- Fume extraction, electrical cabinet air conditioning, 20-bar tool cooling
Operator training, function demonstrations, and final machine handover were all part of the project.
An investment that pays off
Thanks to our comprehensive approach and in-house development of key components, we transformed an aging machine into a system that meets current technological standards.