Breathe New Life into Your Used Machine: A Step-by-Step Guide to Fitting DRO Systems

Let's face it, trusty used machines are the backbone of many workshops. But sometimes, those analog dials just don't cut it anymore. Upgrading to a Digital ReadOut (DRO) system can breathe new life into your used lathe, mill, or surface grinder, boosting both accuracy and efficiency.

This guide will walk you through the process of fitting a DRO system to your used machine. Before we begin, a disclaimer: Every machine is different, and some modifications might be necessary. Always consult your machine's manual and the DRO manufacturer's instructions for specific details.

Step 1: Gather Your Supplies

Here's what you'll need:

• DRO System: Choose a DRO system compatible with your machine's travel distances and axis configuration (X, Y, Z). We offer the popular Newall NMS300, read all about it here.
• Mounting Hardware: This typically includes brackets, scales (linear encoders), and reading heads. Some kits may require additional hardware depending on your machine.
• Tools: Depending on your machine and chosen DRO system, you might need screwdrivers, wrenches, drills, taps, and a level.

Step 2: Prepare Your Machine

• Cleanliness is Key: Give your machine a thorough cleaning, removing any dirt, grease, or debris from the areas where you'll be mounting the scales and reading heads.
• Assess Mounting Locations: Identify suitable mounting locations for the scales and reading heads on each axis (X, Y, Z) you're adding DRO to. Look for flat, clean surfaces with enough space for secure attachment.
• Check for Clearance: Ensure the scales and reading heads won't interfere with the movement of the machine's components or existing controls.

Step 3: Install the Scales

• Mounting the Scales: Follow the DRO manufacturer's instructions for mounting the linear encoders (scales) to the appropriate axes of your machine. This might involve drilling and tapping holes for brackets or utilising existing mounting points.
• Scale Alignment: This is crucial. Ensure the scales are perfectly aligned with the machine's travel direction. Use a level to ensure the scales are straight and parallel to the axis they're measuring.

Step 4: Install the Reading Heads

• Positioning the Reading Heads: Mount the reading heads according to the manufacturer's instructions. These typically need to be positioned close to the scales but without physically contacting them.
• Calibration: Some DRO systems require calibrating the reading heads with the scales after installation. This ensures the displayed measurements are accurate. Refer to your DRO's manual for specific calibration procedures.

Step 5: Wiring and Display Unit

• Connect the Scales and Reading Heads: Following the wiring diagrams provided, connect the scales and reading heads to the DRO display unit using the appropriate cables.
• Power Up and Test: Power on the DRO system and follow the manufacturer's instructions for setting the origin points (reference points) for each axis. Manually move the machine's axes and verify the displayed measurements match the actual travel distances.

Step 6: Fine-Tuning and Enjoy!

• Final Adjustments: Once you're happy with the basic functionality, you might need to make minor adjustments to the scales or reading heads for optimal accuracy. Consult your DRO's manual for any fine-tuning procedures.
• Take it for a Spin: With your newly installed DRO system, you're ready to experience the benefits of digital precision. Enjoy faster setups, reduced errors, and improved overall machining accuracy on your trusty used machine!

Bonus Tip: If you're feeling less confident about tackling the installation yourself, we can quote you for fitting the DRO to your machine. Call us on 09064 32000 or email us at info@millenniummachinery.ie for more information.

Remember: Safety first! Always ensure your machine is properly powered down and secured before performing any installation work.

By following these steps and consulting your specific DRO system's manual, you can successfully breathe new life into your used machine and unlock the power of digital precision in your workshop.