Under the banner “Innovate manufacturing,” industry leaders will once again come together at the EMO trade show in Hanover, September 18-23. The EMO is the world’s leading trade show for production technology, providing full-spectrum coverage of the sector. Systems supplier Klingelnberg will be represented in Hall 11, Booth F51. In addition to numerous machine demonstrations, Klingelnberg will also be offering a dedicated lecture series directly at its booth.
In recent years, Klingelnberg has worked continuously with many of its customers to analyze the challenges presented by renewable energies, such as electromobility and wind energy, and incorporate them into the company’s development process. The high standards in regard to noise behavior of gears in electric cars are a key aspect that has come to light based on numerous discussions. This has led to new products and advances in existing products that are designed to manufacture application-specific, high-quality gears on a cost-effective basis, now and in the future.
The highest profile addition to the Klingelnberg portfolio is the Höfler Roll Testing Machine R 300 for torsional acceleration testing of gears. At EMO Hannover, Klingelnberg will also be exhibiting the Höfler Cylindrical Gear Grinding Machine Speed Viper and the series P 152, P 40, and P 26 Precision Measuring Centers.
The metrology on the Höfler Cylindrical Gear Roll Testing Machine R 300 provides a reliable way to determine the root causes of gearbox noise. Due to the short measuring time, it can be easily integrated into any manufacturing process and enables 100 percent quality control of the gears produced. The R 300 is designed for all roll testing processes that are relevant for evaluating the running behavior and noise behavior of gears.
Speed Viper and R 300 combined into one production cell. A 100 percent quality control of the gears can be carried out either as an incoming inspection for assembly or immediately after hard finishing of the gear in production. The advantage of the latter option is that only OK parts are passed on to the next process step, thus preventing any rejects from undergoing the finishing process. The Klingelnberg production cell — consisting of the Höfler Cylindrical Gear Grinding Machine Speed Viper, the CompactLoader and the integrated Höfler Cylindrical Gear Roll Testing Machine R 300 — is ideally suited for this purpose. The production cell can be equipped with all machine models in the Speed Viper series — from the Speed Viper 80² (dual spindle) to the Speed Viper 300.
What’s more, the R 300 is networked with Klingelnberg’s GearEngine®, making it possible to use roll testing data for production evaluation and tolerance management. With the optionally available R 300 production monitor, users always have a documented overview of the current key quality indicators in their production.
P 152 is touted as the solution for medium-sized gears. The increasing cost pressure on large components for wind power requires new technologies that will enable proven principles for high-volume and mass production of smaller components to be transferred over to large components. The newly developed Klingelnberg Precision Measuring Center P 152 closes the gap in the portfolio between the mid-sized and the large precision measuring center model series.
The latest addition to the family is capable of measuring components with a maximum outside diameter of 1 520 mm and workpiece weights up to 8,000 kg with the usual measurement precision. Despite this heavy workpiece weight, no special foundation is required. Klingelnberg has succeeded in scaling the technology concept of the small and mid-sized series to the larger component dimensions. The inherently rigid machine bed with its 3-point support plays a key role here. The bed design and floor support are cleverly designed so that even when loaded with heavy workpiece weights, the angular position of the individual machine axes to each other does not change significantly. The machine bed’s 3-point support enables the integration of an active vibration platform into the machine bed.
P 40 is the universal all-rounder for reducing measurement times in series measurement using a hybrid solution. The introduction of hybrid metrology with optical pitch measurement has significantly reduced measurement times. It is now possible to perform optical pitch measurement on almost all surfaces using the white light sensor technology (HISPEED OPTOSCAN) developed by Klingelnberg and partners, along with other innovative measuring strategies. Two other processes for reliably measuring single pitch deviations are also available.
All Klingelnberg Precision Measuring Centers in the P 26 to P 65 series can be optionally retrofitted with the optical sensor (HISPEED OPTOSCAN). For new machines, the “Ready for Optic” option is also available, providing a factory-installed setup for subsequent retrofitting. Through the systematic use of the standardized Gear Data Exchange (GDE) interface when importing and exporting data and measurement results, Klingelnberg has set a higher standard in metrology 4.0 in the area of measurement results diagnostics and networking of production machines and metrology — a system it calls the Closed Loop.
Compact and tailored to the needs of the automotive industry, the P 26 precision measuring center has been extremely popular with customers for more than 25 years. Its 25-year success story was built on a foundation of new measurement and evaluation methods, the implementation of innovative measuring systems, and uniform quality and reliability.
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