Gear Technology and Automation Systems

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Melissa Drusilla McCarthy
6 years ago
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1 Gear Technology and Automation Systems

Gear hobbing machines For machining workpieces with a pitch diameter of max. 16 metres, Liebherr offers a choice of gear hobbing machines with individual concepts for machine automation.

2 Gear hobbing machines For machining workpieces with a pitch diameter of max. 16 metres, Liebherr offers a choice of gear hobbing machines with individual concepts for machine automation. Workpiece up to Ø mm Workpiece-Ø Axial distance LC 16 / / 27 LC / / LC / / LC / / 27 Workpiece-Ø Axial distance LC 60 2,7 60 LC 1 16 / / / / 27 LC / 400 LC 1400 LC 100 2,7 100 LC 1 16 / / LC 0 16 / / LC / 400 LC 10 2,7 10 LC / 400 Workpiece up to Ø mm LC 20 / 400 LC / LC 0 24 / LC 0 / LC / LC / LC 0 0 / LC / LC / LC 10 0 / Workpiece up to Ø 00 mm 2 Workpiece up to Ø 2,000 mm LC 7 / 12 LC LC 00 7 / LC 80 7 / LC 00 7 / 12 00

LC 10 DC 10 20 / 400 LC DC 20 / 400 LC DC * LC 280 DC 280 400 LC 00 DC

3 Gear hobbing with integrated workpiece chamfering up to Ø 00 mm Workpiece-Ø Axial distance LC 80 DC / 400 LC 120 DC / 400 LC 10 DC / 400 LC DC 20 / 400 LC DC * LC 280 DC LC 00 DC * 00 LC 80 DC * 80 * limited by ChamferCut, DC = integrated ChamferCut unit

Gear shaping machines Gear shaping machines are employed primarily in the production of internal and external gears on workpieces with limited tool overrun.

Gear shaping machines are equipped with cutting tools from our own production which are optimally matched to the process and the machine.

4 Gear shaping machines Gear shaping machines are employed primarily in the production of internal and external gears on workpieces with limited tool overrun. That means that the special workpiece geometry or interference conditions only make machining possible using the shaping process. Gear shaping machines are equipped with cutting tools from our own production which are optimally matched to the process and the machine. 4 Workpiece up to Ø mm Workpiece up to Ø 00 mm Workpiece-Ø Stroke length Axial distance (max. mm) Workpiece-Ø Stroke length Axial distance (max. mm) LS 80 / 80 0 / LS F/E LS 120 / 12 0 / LS 00 F/E LS 10 / 10 0 / LS 80 F/E LS F LS 00 F/E LS E 70 27

Workpiece up to Ø 1. mm Workpiece up to Ø 4.00 mm Workpiece-Ø Stroke length Axial distance (max. mm) Workpiece-Ø Stroke length Axial distance (max. mm) LS F/E 8 / 12 120 240 1.

5 Workpiece up to Ø 1. mm Workpiece up to Ø 4.00 mm Workpiece-Ø Stroke length Axial distance (max. mm) Workpiece-Ø Stroke length Axial distance (max. mm) LS F/E 8 / LS 0 H 440 / LS 700 F/E 8 / LS 0 H / LS 800 F/E 8 / LS H / LS 800 H / 440 LS 000 H / LS 1000 F/E 8 / LS 400 H / LS 1000 H 270 / 440 LS 1 F/E 8 / LS 1 H / 440 LS 1400 F/E 8 / LS 1400 H 270 / 440 LS 100 H / LS 1 H / 440 F = Shaping head slide with mechanic shaping head E = Shaping head slide with electronic shaping head H = Shaping head slide with hydraulic shaping head

Liebherr machines for grinding gears can be individually configured for every customer.

6 Gear generating- and profile-grinding machines The LCS line from Liebherr is an optimal machine concept for the hard-fine machining of bore- and shaft-type gears. The gear grinding machines are suitable for workpieces up to a diameter of 120 mm, plus they are versatile and extremely productive. Liebherr machines for grinding gears can be individually configured for every customer. Workpiece-Ø Axial distance LGG 6 / LGG L 6 / 12 LGG / LGG 280 L 6 / LGG 400 M 6 / The LGF line allows profile grinding of external and internal gears. The basis for this is the directly driven table, which in conjunction with the machine bed made of mineral casting guarantees maximum precision over the entire service life. LGG 400 LM 6 / LCS 8 / 14 / LCS 00 8 / / LCS 80 8 / / LCS 00 8 / / LCS 10 / 20 LCS / LCS / 20 LCS 1 10 / Profile depth Workpiece-Ø Axial distance LGF / / LGF / 120 / LGF / / 6

Skiving Machine Liebherr now offers this complex technology and will be presenting a skiving machine in 2017.

The machine represents excellent quality and productivity when skiving internal and external gears.

7 Skiving Machine Liebherr now offers this complex technology and will be presenting a skiving machine in Everything from a single source: machine, tool and process. The machine represents excellent quality and productivity when skiving internal and external gears. Skiving³ Machine: automation, deburring and tool changer rigidity Tool: design, machining, processing Process: technology configuration, implementation, optimization Max. outer-ø Tooth-Ø LK LK

The chamfering operation is now available as a stand-alone machine.

8 Chamfering and Deburring Machine This method, established for many years and well-known for its very high chamfer quality, is combined with proven machine technology. The chamfering operation is now available as a stand-alone machine. The Chamfercut tools, which can be easily re-sharpened multiple times, create precise chamfers with high consistency, a long tool life and facilitate optimum economy. Workpiece length Workpiece-Ø LD C LD 280 C 280 LD 00 C 00 8

Gear cutting tools Liebherr is a reliable partner offering an extensive range of gear cutting tools which are characterised by quality down to the finest detail and by their long service life.

Services Sharpening and coating Reconditioning of CBN tools WinKolli software Used to test the suitability of gear cutting tools on specific customer applications Tools range Tool-Ø Shaping cutters

9 Gear cutting tools Liebherr is a reliable partner offering an extensive range of gear cutting tools which are characterised by quality down to the finest detail and by their long service life. Many years of experience and sound technical expertise in the field of gear production are the basis for these innovative products. Services Sharpening and coating Reconditioning of CBN tools WinKolli software Used to test the suitability of gear cutting tools on specific customer applications Tools range Tool-Ø Shaping cutters 0,2 0 max. 60 Wafer cutters 0,0 6 max. 0 Solid wafer cutters 0,2 0 max. 60 Rolling dies 1 4 max. 127 Rolling racks 0,7 1, Shaving cutters 0,7 1 max. 20 Rack type cutters 0, x 48 x x 148 x 2 Rolling deburring discs 1 6, max. 280 Rolling chamfering discs 1 6, max. 280 Gauges 0,7 20 max. 60 Calibration tools CBN grinding tools Software XM Calculates all values for common gear thickness test procedures Gauge tooth numbers or measuring ball diameters can be replaced as desired Makes it possible to adjust the measuring equipment available for involute gearing Tooth analysis software Calculates the machining time and technology parameters such as undeformed chip thickness and return stroke collision Used for optimising the shaping process 9

Automation systems Robotic palletisers Liebherr robotic palletisers can be deployed in a variety of ways: For transporting,

Linear robots in five sizes and robotic palletisers with layer pickup in three sizes for workpiece weights of 0.

For all sizes, Liebherr offers a modular system with which the automation system can be adapted to the respective application, e.

10 Conveyor systems Liebherr conveyor systems are adapted not only to the shape, position, weight and size of the range of

Storage systems Storage systems for workpieces can be deployed in a variety of ways: for decoupling on a production line, as a

10 Automation systems Robotic palletisers Liebherr robotic palletisers can be deployed in a variety of ways: For transporting, palletising, goods handling, loading and unloading or storing. Linear robots in five sizes and robotic palletisers with layer pickup in three sizes for workpiece weights of 0. kg to 100 kg solve a wide range of automation tasks. For all sizes, Liebherr offers a modular system with which the automation system can be adapted to the respective application, e.g. cylinder head, engine block or gearbox manufacturing. 10 Conveyor systems Liebherr conveyor systems are adapted not only to the shape, position, weight and size of the range of parts, but to the material as well. Standardised assembly groups provide an ideal enhancement to the programme. Storage systems Storage systems for workpieces can be deployed in a variety of ways: for decoupling on a production line, as a loading and unloading system, or as a classic logistics module with storage functionality. Palletising cell (LPC) Shelf magazine system Decoupling module (EKM) Plastic chain belt (KKB) Pallet accumulating conveyor (PSB) Indexing chain conveyor (TKB) Hinged chain conveyor (SKB) Tooth chain conveyor (ZKB) Accumulating conveyor (SFB) Drag frame conveyor (SRB) Friction roller conveyor (FRB)

HT8 Distribution Box X10-Port1 X10-Port2 X10-Port X127-Port X120-Port DP DP/MP1 Pallet handling systems Pallet handling systems are employed in the automation of machining centres for the production

An intelligent overall concept, which includes both adapting during the main operation and resource and work order scheduling, increases productivity and thereby reduces the unit labour costs.

11 HT8 Distribution Box X10-Port1 X10-Port2 X10-Port X127-Port X120-Port DP DP/MP1 Pallet handling systems Pallet handling systems are employed in the automation of machining centres for the production of individual parts and small batch production. The basis is a workpiece clamped on a machine pallet. An intelligent overall concept, which includes both adapting during the main operation and resource and work order scheduling, increases productivity and thereby reduces the unit labour costs. Pallet handling systems from Liebherr are available in two versions: as a rotation loading system (RLS) or as a linear loading system (PHS). Both versions are modular in design and can therefore be adapted to the respective requirements of the production concept. Robot integration "Random bin picking" substitutes complicated sorting systems, heightens productivity and relieves the strain on personnel. Unloading unsorted workpieces from a transport container requires a complex interaction between image detection system, software and robots. Based on the range of parts, all process-relevant steps have to be adapted to each other in such a way that optimum withdrawal and positioning is achieved. Hardware and software The modular hardware and software system ensures continuity between a mechanical function and the hardware and software functions needed to achieve this. Tested software modules with function description are configured to form a complete solution. Even before a contract is awarded, a detailed customer-specific process description is created (sequence of operation SoO). A standardised software interface makes it possible to incorporate a wide range of processing machines, control and production scheduling systems. 11

12 Machine Tools and Liebherr employs roughly 1 staff in the area of machine tools and automation technology and has production facilities in Kempten and Ettlingen (Germany), Collegno (Italy), Saline (Michigan, USA) and Bangalore (India). They are supported by expert and reliable marketing and service specialists at a large number of locations worldwide. With over sixty years of industrial experience, Liebherr is one of the world s leading manufacturers of CNC gear cutting machines, gear cutting tools and automation systems. The company s innovative products are the result of pioneering ideas, highly qualified staff and state-of-the-art manufacturing systems at each of their locations. They are characterised by economy, ease of use, quality and reliability in combination with a high degree of flexibility. System Solutions in the Area of Machine Tools Included in the production programme are gear hobbing machines, gear shaping machines and generating- and profile grinding-machines, all noted for their high degree of stability and availability. Particular importance is attached to the energy efficiency of the machines. Gear cutting machines from Liebherr are supplied to renowned manufacturers of gears and gearboxes and largescale slewing rings worldwide. They are in demand primarily from the automotive and construction machinery industries and also increasingly from the wind power industry for the manufacture of gears for wind turbines. High Quality Gear Cutting Tools Liebherr manufactures high quality, precision tools for the soft and hard machining of gears and all Liebherr gear cutting machines are fitted with Liebherr tools. The range also includes Lorenz shaping tools and products customised for specific customer applications. Automation Systems for a Broad Range of Applications Liebherr has a wide range of products for linear robots, pallet-handling systems, conveying systems and robot integration for projects in all areas of production and can provide above-average availability of systems. Liebherr-Verzahntechnik GmbH Werk Ettlingen Gear Cutting Tools Hertzstraße Ettlingen, Deutschland +49 (0) Fax +49 (0) tools.lvt@liebherr.com Liebherr-Utensili S.r.l. Gear Technology Via Nazioni Unite Collegno TO, Italien +9 (0) Fax +9 (0) info.lut@liebherr.com Liebherr-Verzahntechnik GmbH Verzahntechnik und Automationssysteme Kaufbeurer Straße 141, D-8747 Kempten +49 (0) , Fax +49 (0) info.lvt@liebherr.com Liebherr-Gear Technology Inc. Gear Technology Liebherr Automation Systems Co. Automation Systems 146 Woodland Drive Saline, MI , USA Fax info.lgt@liebherr.com Liebherr-Machine Tools India Pvt. Ltd Gear Technology /4, 4th Main, 9th Cross, 4th Phase Peenya Industrial Area Bangalore , Indien +91 (0) Fax +91 (0) info.mti@liebherr.com Printed in Germany by Typodruck BK LVT-Verzahntechnik und Automationssysteme _en Subject to modifications. Automation Systems from Liebherr

Gear-Shaping Machines LS F and LS E

Gear-Shaping Machines LS F and LS E Gear-Shaping Machines LS 200 500 F and LS 200 500 E The Machine Concept T-2-G T-2-D-400 The Liebherr gear shaping machines are optimally tailored for universal use. The machine s movable shaping head design