SPINDLE REPAIRS OF THE HIGHEST QUALITY FROM KERN
Double the service life of your spindle - reduce spindle failures by half
Spindle repair service from KERN: Working for you for over 23 years
With a worldwide on-site spindle service, we have been an indispensable partner for failure analysis and repair of grinding, milling and turning spindles since 2000. We guarantee fast, flexible and reliable repair, optimization and modification of motor spindles and externally driven spindles of all types and makes. In this way, we ensure the best service life and cost savings.
Our outstanding success with major automotive suppliers demonstrates a high level of expertise in all areas of spindle repair. We also keep an eye on the entire "spindle environment", as this is often where the problems - and therefore the potential savings - lie.
Kessler, Weiss, Chiron, DMG, Grob or special spindle
Large corporations trust our know-how
From the automotive and aviation industries to the wood and plastics sectors, plant engineering and tool and mold making: we work for numerous industries and serve everything from small businesses with two machines to huge machine parks.
We manage a machine park with over 10,000 motorized and milling spindles worldwide.
These customers keep their production running sustainably with our spindle repairs:
The spindle - the CORE of your production
Your machine tools - whether turning, milling or grinding machines - are all dependent on a spindle. If it is defective, the entire production in the company comes to a standstill, which can have far-reaching consequences:
HIGH OPPORTUNITY COSTS
On days when your production comes to a standstill, you lose up to €50,000. But it's not just money that is lost, but also time and human resources.
Dissatisfied customers
Delays in production mean that customers cannot be supplied on time and may not place follow-up orders.
Rising pressure
You need to find a solution quickly in order to be able to supply your customers. In some cases, you may even face legal penalties that you need to prevent.
Why a spindle repair is better than a new or replacement spindle
New spindles from the manufacturer are expensive and usually not immediately available. And replacement spindles are only ever repaired for the short term. This means that the quality is lower than with a spindle repair and there is a real risk that something will break again after just a few months.
LONG SERVICE LIFE
With CNC spindle repair, we ensure that your spindle is as good as new, if not better. The positive feedback and extraordinary satisfaction of thousands of our customers confirm to us every day how durable our repaired spindles are.
Fair prices
According to hundreds of customers, our repaired spindles achieve an exceptionally long service life with consistent precision. Our fair prices therefore promise excellent value for money, especially in the long term.
Minimal effort for maintenance
The use of the highest quality materials and targeted optimizations ensure that wear is much lower and maintenance is cheaper and less costly in the long term.
We repair spindles with roller bearings from almost all manufacturers
Kessler
Mazak
Matsuura
Makino
Fischer
Weiss
Renaud
Omlat
Deuschle
Blohm
Reckerth
Fiege
Fortuna
SLF
SPL
IMT
Voumard
Blombach
StepTec
GMN
Mikron
Grob
Gamfior
Hessap
UVA
IBAG
HüllerHille
Chiron
DMG
Unior
HS-Tec
Cocom
Moore
UKF
Hurco
Hermle
ABA
Bridgeport
Jukomet
Techno and many more.
We repair these types of damage to your spindle
Bearing damage
High temperature development (overheating)
Rotating union defective
Water damage
Winding closure
Measuring system error
Tensioner problems
Lack of resilience
Machine crash
Measuring system error
Winding damage
Strong vibration / noise
Sealing air
External/internal cooling defective
Hydraulic system defective
Air system defective
Engine cooling defective
Cone damaged
Release unit damaged
Clamping system damaged
Wear of the interface
Encoder error
Leakage of oil or coolant
and much more
Request a spindle repair for your spindle now, regardless of the manufacturer.
Comprehensive spindle service:
Our process for repairing your spindle
We repair and overhaul spindles according to a tried-and-tested 6-step principle that has proven itself in practice over the last 20 years. We can optimize all spindle makes and work completely independently of the manufacturer.
Spindle input
For a comprehensive root cause analysis, it is necessary for us to check the spindle in our systems using our tools. You have the option of sending the spindle to us yourself or we can organize collection and, if necessary, removal from the machine at your premises.
Failure analysis
During our comprehensive failure analysis, our spindle fitters first check all electronic and mechanical functions of the spindle. During the disassembly process, we then record every step in detail using images and videos. This enables us to ensure that the spindle is not only functional again at the end, but is even more precise and durable than before.
Spindle report & offer
In our spindle report, we present to you in detail why the spindle has failed and which components need to be refurbished or replaced by us. We then explain the necessary repairs and coordinate these measures closely with you. You will receive a precise repair offer from us that is tailored to your spindle damage.
Preparation
Once you have placed the order for spindle repair with us, we immediately start cleaning all spindle components. Components in need of renewal are either reconditioned, remanufactured or replaced with original spare parts from the spindle manufacturer. We work extremely preventively to increase the service life of the spindle. We also replace parts that have reached a certain age in order to ultimately ensure high machine productivity.
Assembly & optimization
When installing your spindle, we attach particular importance to the careful coordination of all components. At the same time, we thoroughly check the tightness of the cooling circuit and the hydraulic elements in order to detect leaks immediately and rectify them without delay.
Final inspection
At the end of the overhaul, the spindle undergoes a final test on our in-house test field. We use state-of-the-art instruments to simulate the actual operation of the spindle and fine-balance it precisely to the required speed. Our specialists monitor all relevant measured values very closely. The spindle is only returned to you when all parameters match 100%.
Precision work for your spindle repair - down to less than 1 µ
Precise testing and measurement technology
We carry out extensive tests on all motors and motor spindles at our state-of-the-art test facility. To do this, we use the original motor parameter data from the CNC machines in encoder mode and rely on state-of-the-art Siemens inverters for optimum performance. All our spindles are carefully precision-balanced and brought to an excellent precision of 1 µ, which guarantees maximum accuracy.
Cleaning at the highest level
Our Dürr cleaning machine is equipped with a 1 µ filter system. This enables us to restore all spindle parts to as-new condition. The innovative technology not only guarantees the restoration of functional integrity and longevity, but also ensures a flawless visual appearance of the spindle components.
Modern machinery
Our machinery includes a Voumard grinding machine, for which we have even developed our own grinding spindle. With a high speed of 60,000 revolutions per minute, we are able to grind all HSK and SK tool holders precisely. Thanks to this technology, we achieve outstanding precision of less than 1 µ.
Comprehensive additional services
Our range of services includes the additional services of balancing technology (in accordance with DIN ISO 1940), grinding technology, measuring and testing technology. We have a complete range of machinery with the ability to grind tool tapers completely. We complete our full spindle service with the repair of main spindles and tool change spindles for all turning and milling centers (regardless of manufacturer).
Case studies: Our success stories
Reduction of the failure rate by more than 50 %
Reduction of the failure rate by more than 50 %
Precision of the entire machine massively improved
WITH HIGHEST KNOW-HOW for Fritz Studer AG
Precision of the entire machine massively improved
Following the repair, the spindle is now significantly more wear-resistant and can therefore achieve its full performance potential. The failure rate has been greatly reduced, while the quality of the sanding work has improved significantly thanks to perfect concentricity and vibration values below 0.2 mm/s.
Get our exclusive Spindle Report 2023 now!
You will find interesting facts in our exclusive specialist report:
Typical spindle problems and how to fix them
The 3 factors for the efficiency of a spindle
Examples from our customers with specific facts, figures and data
Request a free report
Simply fill out the form to receive the free PDF download directly by e-mail.
FAQ - Frequently asked questions
"How long do you need for a repair?"
As a specialized spindle service, we can carry out express repairs within 6-8 days. Even if it is quick, we will of course look at each element individually, clean it, optimize it or replace it if necessary.
"I'm in a real hurry, can I have my spindle back repaired sooner?"
In special cases, we can also complete a repair in 4 days. To provide you with a really high-quality spindle, it simply takes time, so 4 days is the absolute minimum.
"How do you reduce default rates?"
We have been working with spindles of all makes for over 20 years and know exactly how we can extend the service life by up to 5 times. At the end of a spindle repair, we carry out tests lasting 1-2 days to ensure that the spindle is working perfectly. You can also take a look at the case studies of our customers for more information.
"Why shouldn't I choose a new or replacement spindle?"
New spindles from the manufacturer are expensive and generally not directly available - whether for milling, grinding or turning machines. Replacement spindles, on the other hand, are quickly back in use and cheaper, but are usually of inferior quality, as only the essentials are repaired at short notice.
"How long does a spindle repair take?"
The duration of a spindle overhaul varies depending on the urgency and the condition of the spindle. In urgent cases, we can complete the repair in just 6 to 8 working days and are even prepared to work on Saturdays to shorten the repair time. Generally, the repair takes between 6 and 15 working days, depending on the damage, size and complexity of the spindle.
"How much does a spindle repair cost?"
The cost of a spindle repair cannot be determined across the board, as it depends on various factors. These include the damage, the size, the complexity and the type of spindle (motor spindle or belt spindle without stator). The final price for the repair can only be determined after dismantling and a precise damage analysis. For this reason, fixed prices without a prior analysis are not reliable. However, thanks to our extensive experience in repairing over 3000 different spindle types, we are able to provide you with realistic cost estimates as soon as we have examined the spindle in detail. We will explain to you transparently how the costs for your individual spindle repair are calculated.
"What is the advantage of a spindle repair compared to a new spindle or replacement spindle?"
Spindle repair by a professional offers decisive advantages compared to replacing or purchasing a new spindle. It is generally more sustainable and economical, as the same spindle can be repaired over decades without any loss of quality. We achieve at least the same service life as a new spindle from the manufacturer. Based on hundreds of customer feedbacks and experiences, we have found that our repaired spindles often achieve a significantly longer service life than replacement spindles. At the same time, customers save at least 20 percent of the costs compared to purchasing a new spindle or a replacement spindle from the manufacturer.
"What is the difference between a new spindle and a replacement spindle?
The main difference between a new spindle and a replacement spindle lies in its condition and origin. A new spindle is completely new and has never been used before, whereas a replacement spindle is a spindle that has never been used before . The main difference between a new spindle and a replacement spindle lies in its condition and origin. A new spindle is completely new and has never been used before, whereas a replacement spindle is a spindle thathas been marginally repaired by the manufacturer and not all parts are new or optimized. The replacement spindle is usually more expensive than a repair at KERN, as manufacturers usually specialize in producing spindles rather than repairing or optimizing them comprehensively. and not all parts are new or optimized. The replacement spindle is usually more expensive than a repair at KERN, as manufacturers usually specialize in producing spindles instead of repairing or optimizing them comprehensively.
Do you want to have your spindle repaired and reduce the failure rate by 50 %?
Then get in touch with us now and arrange a no-obligation consultation. You can tell us about your situation and we will explain exactly how we can help you.