manufacturer: KLINGELNBERG
type: OERLIKON G60
built: 2005
control: SINUMERIK 840 D


EX location

Technical Equipment/Features

workpiece data:
largest workpiece Ø 600 mm
normal module range 2-12  mm
adjustable dividing cone angle -90 bis +90°
axis offset above and below center +/- 100 mm
max. grindable number of teeth 360
grindable spiral angle (in tooth center) without limit
Ø of workpiece holder 203.2 mm / 8"
tool data:  
grinding wheel ∅ 406 mm / 16"
max. height of grinding wheel with base plate 135 mm
max. grinding spindle speed 4.500 1/min
spindle mounting HSK-E63
grinding head (X-axis):  
travel 340 mm
max. travel speed (approx.) 20.000 mm/min
drive type Synchronous servo motor water cooled
spindle pitch 15 mm
grinding slide (Y-axis):  
travel 1.310 mm
max. travel speed 60.000 mm/min
max. acceleration 2,5 m/s2
drive type linear motor water cooled
Axis radial slide (Z-axis):  
travel 300 mm
max. travel speed 20.000 mm/min
drive type synchronous servo motor water cooled
spindle pitch 10 mm
workpiece axis (B-axis):
max. workpiece spindle speed 40 1/min
worm drive ratio 1:75
swivel axis workpiece (C-axis):
max. traversing speed 10800 °/min
max. speed 100 U/min
software package:

• Siemens "Safety integrated" software for safe machine operation
• Generating and plunge grinding up to max. 20 revolutions
• Double generating for max. 10 revolutions
• Dressing according to adjustable number of teeth and round pass related
• automatic test cycles for visual control of the grinding result possible
• variable units for lengths, angles and pressure units
• easy language switching to the available national languages
• easily programmable macro commands for sequence control
• data memory on hard disk for more than 10000 different workpieces
• speed and power consumption of the grinding motor as graphical bar display with power monitoring
• workpiece counter (adjustable by the operator)
• Start of each machine operation / machine movement from any machine position (collision calculation before start)
• Printout of all setting values and database contents via interface
• Technological inputs for economical deep grinding of gears
• Quick start button for serial operation

connection data:  
total connected load approx. 81 kVA
operating voltage 400 V
operating frequency 50 Hz
control voltage 24 V DC
fuse protection 125 A
compressed air connection 6 bar
dimension, weight:
space requirement ca. l x b x h ca. 3,65 x 5,5 x 3,1 m
machine weight ca. 19.500 kg ohne Filteranlage
equipment and accessories:

• Control Siemens 840 D with operating system Windows XP, drives Siemens Simodrive 611, Profibus interfaces.
• Single grinding head with fully automatic grinding wheel threading device for exact determination of the tooth gap position at any workpiece position. No manual adjustment is necessary in series operation.
• System-independent grinding of almost all spiral bevel and hypoid gears pre-toothed in single-part and continuous processes.
• Extremely efficient and precise grinding of spur gear couplings, such as Curvic® couplings.
• Fully CNC-controlled machine concept designed for shortest set-up and changeover times as well as highest gear accuracy and grinding performance.
• Manual data input or read-in via data carrier from the KIMoS calculation program with the possibility of data storage for repeat cases on fixed memory disk or floppy disk.
• Workpiece-specific pre-programmable fully automatic work sequences with automatic threading of the grinding wheel into the pre-machined workpiece profile.
• High grinding performance due to 31 kW grinding wheel drive, intensive wet grinding and eccentric grinding spindle unit to avoid structural damage due to grinding burn.
• Low proportional tool costs through optional use of commercially available ceramic, vitrified bonded SG or CBN grinding wheels.
• Free profile modification possibilities through path-controlled dressing of the ceramic and vitrified bonded grinding wheels by means of a diamond roller.
• Automatic tracking of the cooling oil nozzles during dressing.
• Workpiece spindle with 8 inch mounting
• Automatic emergency retraction in case of overload of the drives
• Lockable maintenance room for hydraulics, pneumatics, lubrication, extinguishing system
• Automatic central lubrication and integrated hydraulic and pneumatic system
• Liquid cooled grinding spindle unit and direct drives
• Hydraulic workpiece and grinding wheel clamping device
• Pressure relief flap with release contact for an extinguishing system
• 1 set of fixators for precise alignment of the machine
• automatic work area door
• documentation in German language, double version
• integrated control cabinet with automatic cooling unit, completely installed with network-compatible full CNC control for all working and setting axes and integrated PLC
• high resolution absolute or incremental encoders for all linear and rotary axes
• liquid cooled motors and spindles for grinding with eccentric and dressing
• 2 machine lights in the work area
• Machine status light
• Exhaust system for the working area
• Program hours approx. 32.000h
• The machine has an interface to an automatic loading unit
(Promot RZ)