CENTERLESS & AUTOMATION GmbH Company Introduction Since more than 20 years, we engage ourselves in centerless-grinding and its optimization. With this big grinding-experience, we can pass on many useful hints to our customers, and also let this experience influence the development and improvement of our machines. We could already take vast amounts of machines in operation and every customer is delighted by our quick and competent service, which we can offer. Our proud are the especially user-friendly NC-controlled centerless-machines. In the world of car part suppliers we are a respected brand. Simplicity, Precision and Speed we could bring down to a common denominator, and this with still keeping the price at a low level. Introduction Consulting & Service Consulting in the Planning Phase Often a part-drawing builds the base for the decision for the purchase of a machine. Due to this reason we invest a lot of time and endurance, to find together with you the best fitting machine for the purpose. If needed a feasibility-test will be made based on some grinding tests. Setup of the Machine The machine will be setup and taken into operation by us in your company. This usually happens in company with one of your employees, who gets some basic introductionary education at the same time. Consulting in the Field If some grinding problems arise during the operation, we together with you and thanks to our long-term experience - can usually solve them quickly. Like that you will be able to continue production in a very short time. Repairing and Service-Workings Our machines are on duty for many years, usually in 24h-operation. If a part gets broken or if some service is needed, one is dependent on quick help. Usually we react within 24h. The most common parts are on stock and can be delivered immediately if needed. 1
Education We are very sorry to tell you, that currently it is not possible for us, to hold some education courses in english. Education 2
CENTERLESS & AUTOMATION GmbH Our Machine Highlights Our machines are built with a high standard of quality. They were developed especially robust, to satisfy small production-tolerances, even under very harsh conditions, like grinding with aggressive grinding-oil, 24h operation or tungston carbide processing. Additionally we continue unceasingly to further develop our machines, to include new technical improvements and suggestions from our customers fast in our products. Our CG-Line machines have many technical highlights, from which the most important ones will now be explained: Machine Bed Highlights The machine bed is made out of best artificially aged MEEHANITE -cast-iron and possesses and excellent stiffness. The prism guides are heat treated and precision ground. This results in an extremely low wearout and a high precision. Spindles Grinding- and regulating-wheel-spindles are made out of high quality alloy steel (SNCM439JIS), precision ground, artificially aged, induction hardened and therefore maintenace free for life-time. The triple hydrodynamic bearing, which sticks out by its longevity allows a very smooth operation. Regulating-Wheel-Servo For driving the regulating-wheel a servo-motor is used, whose speed can be continuously adjusted. By the utilization of the servo-motor, which is directly connected to the spindle via a special belt, speed oscillations and vibrations will be made almost impossible, which results in perfect roundness of the work-piece. 3
Regulating-Wheel Tilt-Angle The tilt-angle of the regulating-wheel is ±5º. This easily allows different feeding speeds for thrufeedgrinding. Regulating-Wheel Swivel-Angle Grinding-Wheel Regulating-Wheel The swivel-angle of the upper slide is ±3º. The centre of rotation lies in the middle of the wheel. The workrest remains unaltered, for it is mounted on the lower slide. With just one screw the cylindricity to the wheel can be quickly and easily adjusted. Regulating-Wheel horizontal Movement The regulating-wheel is parallel movable in relation to the work-rest by 7mm. This allows an easy adjustment of the regulating-wheel to the grinding-wheel (e.g. for parts with heads) Grinding-Wheel Hydraulic Dressing Units Grinding- and regulating-wheel do have hydraulic dressing units, whose speed are continuously adjustable. The guides are precisely hand scraped. This allows a smooth dressing with a high accuracy. Highlights Regulating-Wheel Central Lubrication System To release the user from some burdon, an automatic programmable central lubrication system is mounted. It monitors the pressure and the oil-level and thanks to the piston distributors an exact dosage of every lubricating point is guaranteed. 4
CENTERLESS & AUTOMATION GmbH CG 12 The CG12 is our smallest machine, and is accordingly especially suited to grind small parts (ideal for part-diameters from 1 up to 12mm). Machines It stands out with its very short re-setup times (even from infeed-grinding to thrufeed-grinding). The grinding length should not exceed 140mm for infeed-grinding. CG 16 The CG 16 is perfectly suited for grinding parts with a diameter from 3 up to 20mm (dependant on material). Even at this size, one can already infeed-grind two diameters at once. 5
CG 18 The CG 18 is especially good suited for infeed-grinding of large lots. Owing to the grinding-wheel diameter of 455mm, a long lifetime of the measure and the surface can be achieved, even for fast grinding cycles. Machines CG 1810 The CG 1810 is an intermediate size between the CG18 and the CG1812. Usually it is used instead of the CG18, if one would like to infeed-grind longer parts. 6
CENTERLESS & AUTOMATION GmbH CG 1812 The CG1812 is our standard-machine for thrufeed-grinding. Doesn't matter if long bars or single pieces, everything will be ground fast and flawless. Machines Thanks to the 305mm wide grindingwheel, a continuous removal can be achieved, which yields in superb grinding results. CG 20 The CG20 is like the CG18 especially good suited for infeed-grinding of large lots. Due to the big grinding wheel diameter of 510mm it is ideal for grinding parts with a diameter of 20mm or more. That's why it can guarantee a long lifetime of the measure and the surface, even at these big part-diameters. 7
Technical Data Model CG12 CG16 CG18 CG1810 CG1812 CG20 Grinding Range 1-30mm 2-40mm 2-50mm 2-50mm 2-50mm 2-50mm Grinding Wheel Size 305x 150x 127mm 405X 205X 203.2mm 455X 205X 228.6mm 455X 255X 228.6mm 455X 305X 228.6mm 510X 205X 304.8mm 205x 150x 90mm 255X 205X 111.2mm 255X 205X 111.2mm 255X 255X 111.2mm 255X 305X 111.2mm 305X 205X 127mm 1900 1550 1350 1350 1350 1200 8-150/300 8-150/300 8-150/300 8-150/300 8-150/300 8-150/300 Grinding Wheel Motor 5.5kW 7.5kW 11kW 11kW 15kW 15kW Regulating Wheel Motor 1.3kW 1.8kW 1.8kW 1.8kW 2.9kW 2.9kW 0.75kW 0.75kW 0.75kW 0.75kW 0.75kW 0.75kW Coolant Pump 0.1kW 0.2kW 0.2kW 0.2kW 0.2kW 0.2kW Net Weight (approx.) 1500kg 2300kg 2400kg 2600kg 3200kg 3300kg Regulating Wheel Size Grinding Wheel Speed (RPM) Regulating Wheel Speed (RPM) Hydraulic Pump Machine-Data Machine Floor-Plan E J I K H A D B G C F Model A B C D E F G H I J K CG12 CG16 CG18 CG1810 CG1812 CG20 1350 1450 1530 1530 1530 1555 935 980 1000 1000 1000 1025 25 25 25 25 25 25 1400 1590 1625 1625 1750 1700 1650 1725 1890 1890 1925 2050 1030 1340 1390 1390 1425 1550 630 820 855 855 1000 1050 485 800 800 800 800 800 730 1000 1200 1200 1200 1200 550 590 680 680 680 680 450 550 550 550 550 550 (All units in mm) 8
CENTERLESS & AUTOMATION GmbH NC-Machines NC Version 9 ±1µm-Keys for a fast correction of the grinding-measure by just one key-press Parameters are fast and easily accessible and changeable via the GUI. Infeed-Cycle Outstanding grinding results due to 3 adjustable velocities and their distances (Roughing, Smoothing and Finishing). Setup of the part raw size by simply touching the working piece with the grinding-wheel. Precision For the control of the servos only the newest regulating technology is used. Therefore combined with the precise and firm mechanics it is possible to achieve a very high precision. Interfaces are implemented by default for the communication with various loading units and for the reception of corrections from a partmeasuring-unit.
The User Dream Usually a machine will be developed by engineers with their unfortunately limited userview. Therefore the usabiliy is often missed out. For the engineers the interface is logical and structured, but for the common user in the field it's mostly an ergonomic disaster. We took another path: Due to the help of employees with grinding-experiences of many years and a very close relationship to our customers (Service and Consulting), it was possible for us, to develop a new generation of user-friendly centerless-grinding machines. The core component of this machine consists of a control system, which was especially developed to satisfy the user-needs. Thus also operating errors caused by inexperienced personnel can be drastically reduced: If for the user there is anything unclear about a menu item, he can press the online help and everything about this menu item will be explained in detail and yet still comprehensible. NC-Machines These machines are available with 2-7 controlled axes, which are all very easily configurable. For example the X-Y-Dressing-Profiles can be simply drawn component-wise within the GUI. The user doesn't need any CNC-knowledge, for he will never be faced with even one line of CNC-code. The setup of the machine serves as another example for the simplicity of this control system: After only pressing 2 keys one can already setup the part raw-size. Now, one only has to put the raw part on the work rest blade (between the wheels) and use the portable control unit to move the wheels together until the raw part is slightly jammed between the wheels. Now after pressing Enter one is already done. All part specific parameters can be saved on an USB-Stick and read back again later. Like that it is possible to drastically reduce the changeover time. Due to the usage of an USBStick, it is even possible to create and/or change all parameters on a PC (including the X-YDressing-Profiles). Although the usability was part of the core component in the development of this machine, it also doesn't stand back by the technical aspects. Due to our year-long practical experience also the machine possesses some special technical features: E.g. a vandal-proof piezo keyboard below an Alu-Plate, which withstands even the roughest industrial environments, or a servo-motor for the regulating wheel (variable speed, load independance). Additionally control programs for a lot of standard loading systems are implemented by default (including conveyor belt control). An interface for the integration of a part-measuring-unit for an automated size correction is thereby almost self-evident. 10
CENTERLESS & AUTOMATION GmbH Options NC-Machines All our conventional machines are also available in a NC-Version. All technical data (except the control) remain the same and can be looked up there. Our NC-Centerless-Grinding-Machines are usable for infeed- and thrufeedgrinding by standard (just one switch changes mode), and are available with different options. The basic version is equipped with one axe (working-axe), which moves the regulating-wheel together with the workrest in the direction of the fixed grinding-wheel. Additionally the regulating-wheel speed is adjusted, so that the RPM gets increased synchronous to the grinding-cycle. This results in a better roundness and a smoother surface for the work-piece. The dressing-axe is used for autonomous dressing with measure-compensation. Optionally the dressing-finger can be lifted from the dressing template by the NC, which allows the usage of templates with inclines up to 90 on one side. For complex geometric shapes, a diamond-roller dressingunit is available. Another axe is used for unloading. It is used to let the ground work-piece drop between the work-rest and the regulating-wheel on a conveyor-belt, to transport the part easily out of the machine. To be able to dress complex shapes, X-Y-dressing-units are available for the grinding- and the regulating-wheel. 11
X-Y Diamondwheel Dresser For more complex dressing-shapes, our X-Y diamondwheel dressing unit is the right choice. The diamondwheel can be shaped individually, e.g. to be able to dress certain small radii very precise. The many small point diamonds allow a very lasting lifetime and form stability. Front Face Dresser Grinding the diameter and the front-face at the same time! Options A frequent problem is often the grinding of the diameter and the frontface at the same time on head-parts. Our solution stands out by it's simplicity and efficiency. A brushless motor is responsible for a very calm and smooth dressing. Inductive Linear Encoder On demand conventional machines can be additionally equipped with linear encoders. This allows an easy and verifiable correction during the grinding process. The used inductive technology stands out by an extraordinary ruggedness. 12
CENTERLESS & AUTOMATION GmbH Grinding of Carbid Metals Our machines are excellently suited to grind carbid metals: The hydrodynamic bearing of the grinding-wheel makes it possible, to get very good grinding results even for big removals. Due to the prism-guides of the regulating-wheel-slide, our machines possess a high stiffness, which is of great importance for the handling of carbid metals. If desired, the machines are produced with more torque and reduced grinding-wheel speed, to optimally fit the needs of grinding carbid metals. Carbid Metals Diamond Wheel Dressing Unit A dressing unit for diamond grinding wheels on the machine? This is no longer a wish to dream of, for we found the solution: A solution, that works! Here the diamond-wheel will be dressed by a silicium-carbide-wheel on the machine itself. No more time consuming external dressing of the grinding-wheel, with the corresponding straightness- and roundness-problems! This dressing-unit, with it's corresponding control can handle different tasks: Quick resharpening during thrufeed-grinding Prepare polishing Cylindric dressing for infeed grinding! 13
Accessories We offer a broad range of accessories. If you need some accessories or if you have a certain problem that you don't know how to solve, then don't hesitate to contact us, and we will find a solution together. All accessories needed for the immediate use, will be delivered with the machine as standard: Grinding- and regulating-wheel, each one with flange. Work-rests for infeed and thrufeed-grinding, each one equipped with a carbide blade. Coolant tank with pump. Work-piece pressor for thrufeed-grinding. Wheel-flange-extractor for replacement of the grinding- and regulatingwheel. Toolbox, with all needed tools for maintenance of the machine. Of course, these standard accessories can also be ordered as replacement additionally. Accessories Accessory Examples 14
CENTERLESS & AUTOMATION GmbH Handling & Automation We have a broad range of handling- and automation-solutions for centerless-grinding. The close relationship to our customers and our experience allows us to offer individually tailored solutions, which results in a maximum in efficiency and profitability for a customer. If you would like to get a personal consulting for your centerlessautomation, then don't hesitate to contact us, and we will find a solution together. On the next few pages some standard solutions will be shown as examples. Automation Insertion Loader This loader for infeed-grinding pushes head-parts pneumatically in the machine. The parts are being held during the loading to allow a fast handling. This loader, together with a liftloader, will be usually mounted on a cart, which is movable and height adjustable. Like this the loader can be easily correctly positioned. Additionally it allows an easy access to the machine (e.g. for a wheelchange). 15
Portal Loader For more complex infeed-parts this solution has already proven itself many times. The parts get hold by a vacuum or with the help of mechanical grippers. This solution is also recommended for loading several parts simultaneously. Hopper-Loader Automation Automatic loading system for thrufeed-grinding. It is used for parts with diameters from 3-8mm and a length of 50200mm. Lift Loader This loader for infeed- and thrufeedgrinding lifts the parts with the help of a rake. Due to an adjustable brushless drive, it operates very silent and is very durable. A special feature is the simple setup ability for parts with diameters from 1-25mm and lengths up to 200,300 or 500mm, dependant on which type. 16
CENTERLESS & AUTOMATION GmbH Part-Measurement-System For a fully automated operation, or for a 100% part-measurement such a system will be utilised. It will pass already smallest changes in size to the machine-control and can so manage that all parts stay within tolerance. Simultaneously it can create a measurement-protocol. Automation Bar Loader 17 One of the main applications in centerless-grinding is surely the thrufeed grinding of long bars. Also in this area we can deliver an exceptional solution, which has already proven itself in working reliable even after many years of service.
Conveyor Belts One of the most important accessories for centerlessgrinding are certainly conveyor-belts. Also in this field, we could utilize our long-term experience, to be able to present to you conveyor-belts with outstanding features: Robustness All our conveyor belts are built mechanically robust and withstand also operation in rough environments. Additionally they are cooling-oil and cooling-water resistant. Continuously Electronically Variable The brushless drive is continuously variable by a poti (up to 0.2m/s). Even at low speeds, the motor remains powerful. Smart Control For feeding, the conveyor-belt-control does also handle the control of the feeder (e.g. vibratory feeder) and is so able to manage getting an optimal feeding without gaps. Accessories Coolant Drain Channel Our conveyor-belts do have a coolant drain channel as standard, to keep the working-place around the machine clean. Different Versions To be able to optimally handle the different tasks of a conveyor-belt (e.g. feeding, unloading,...), we provide 4 different versions: Coated teeth-belt Flat textile belt Flat belt with bumps String-belt Options As desired, we can deliver the conveyor-belt together with an appropriate mounting-frame. Also tray-plates can be made, if desired. 18
CENTERLESS & AUTOMATION GmbH Farnsburgerstr. 39 CH-4466 Ormalingen Schweiz Mobile: Tel: Fax: E-Mail: Web: +41 76 3721617 +41 61 9838048 +41 61 9838047 info@centerless-automation.com http://www.centerless-automation.com