HÖFLER 円筒歯車研削盤 Speed Viper

HÖFLER CYLINDRICAL GEAR TECHNOLOGY – GRINDING MACHINES

LEADING IN CYLINDRICAL GEAR TECHNOLOGY Innovative Cylindrical Gear Machining for Flexible Requirements All around the world, manufacturers of gears and gear- boxes ensure their leading edge in gear machining with innovative, advanced technology by Klingelnberg. The Höfler Cylindrical Gear Technology division allows us- ers to manufacture cylindrical gears with diameters from 20 millimeters up to 10 meters economically and with high precision. Moreover, thanks to decades-long exper- tise and great innovative strength, Klingelnberg is able to maintain a leadership position not only through its high research and development standards, but also its in-house application engineering services. Klingelnberg offers advanced technology and efficient machines for cylindrical gear manufacturing. The com- Winner of the iF Design pany sees itself as a solutions provider that supports its Award 2018 customers from gear design to quality assurance, in order to produce top quality gearing. Klingelnberg’s software system for production management from process design to quality control is called Closed Loop – and is now also available for cylindrical gears. Its core component is the powerful duo, Gear Designer and Gear Operator – two newly developed soft- ware solutions that accurately simulate the entire manufacturing process using a digital twin of the workpiece to be ground, providing optimal sup- port for gear design and manufacturing. Höfler cylindrical gear machines are developed with real-world applications in mind and satisfy a whole host of application industry requirements. Customers include all gearbox manufacturers in the precision engineering, aviation and automo- tive industries, as well as manufacturers of large gears for the energy industry. HÖFLER cylindrical gear generating grinding machine Speed Viper 300 2

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OUTSTANDING GRINDING TECHNOLOGY The New Force in High-Productivity Generating Grinding The Höfler cylindrical gear grinding machine Speed Viper – which focuses on high-productivity generating grinding in large-series manufacturing – draws on the successful concept   Highly productive generating of the Viper 500 series. It is available in four different configu- grinding thanks to intelligent ma- rations based on individual requirements: Speed Viper 300 in a chine software and a robust ma- single-spindle configuration, as well as Speed Viper² 180 and chine base 80 in a dual-spindle configuration. Depending on the model, Speed Viper is designed for maximum workpiece diameters of 80, 180 and 300 mm. In addition to gears, it can also grind   Large component range to 300 mm extra-long shafts. This is possible thanks to a distance between workpiece diameter and 1,100 mm centers over table of up to 1,100 mm. workpiece length The Speed Viper² dual-spindle concept achieves minimal auxil-   Long tool life thanks to large tool iary times, fulfilling the productivity requirements of the auto- motive industry. The grinding worms, with an outside diameter diameters of 275 (320) mm and a of 275 (320) mm and a width of 200 mm, ensure a long tool life. tool length of 200 mm An automatic tool clamping system with an integrated balanc- ing unit also contributes to shortened tooling times as an op-   Minimal auxiliary times tion. In addition, the Speed Viper with partial or full automa- tion can be equipped with an automation interface that meets   Flexible automation concept the VDMA 34180 and ISO 21919 standard.   Innovative operating concept The Gear Operator machine software and a process-oriented navigation system via wizard technology make operation easy,   Optimal energy efficiency (e2) even in the most complex applications. And last but not least, ultra-modern drive and control technology guarantees maxi-   Short set-up times thanks to auto- mum energy efficiency. matic tool clamping system (opti- nal) Z1 CNC axes C4 Z2 Speed Viper 300 Speed Viper² 180/80 B2 X Radial axis X Radial axis B2 C2 Y Shift axis Y Shift axis C3 Z Stroke axis Z Stroke axis Z3 Z1 Counter support Z1/Z2 Counter support C5 A Swivel grinding head A Swivel grinding head B Grinding spindle B Grinding spindle B2 Dressing spindle B2 Dressing spindle C Workpiece spindle C1/C2 Workpiece spindle C3 Dressing device swivel C5 Rotating tower Speed Viper 300 Swivel loader Speed Viper2 80 C4 Loader swivel Z3/Z4 Loader stroke axes 4

Speed Viper – More Than Just a Generating Grinding Machine Generating Grinding Maximum productivity at cutting speeds up to 100 m/s Polish Grinding (optional) Efficient gearing through the use of segmented tools with a total width of 200 mm Topological Grinding (optional) Grinding of twist-free tooth flanks as well as targeted twists, incl. Closed Loop processing Beveloid Gearing (optional) Grinding of beveloid gearing, with freely definable flank modifications as needed for improved running behavior and optimized load carrying capacity 5

HIGHLIGHTS Speed Viper is fit for Industry 4.0 Bevel Gear Technology for Mass-Production of “The gear cutting industry is in transition” – and Klingelnberg is poised to em- brace the challenges ahead. The Speed Viper development team, consisting of Cylindrical Gears engineers from the bevel gear and cylindrical gear product lines, has developed a unique machine design that combines know-how from the OERLIKON Bevel Gear Manufacturing cylindrical gears Technology and HÖFLER Cylindrical Gear Technology brands. Thus Speed Viper on a large scale – for Klingelnberg, combines outstanding grinding technology and an innovative operating concept this meant taking technology with the unique Klingelnberg Closed Loop process. The structural design of the and expertise from bevel gear machine is based on experiences gleaned from the successful C 30 and G 30 bevel production and applying it to gear machines as well as the VIPER 500 cylindrical gear machine. Speed Viper’s the cylindrical gear industry. The success factors include: result from the interdisciplinary   High productivity   High quality thanks to   Maintenance-friendly development team is reflected in through minimal rugged mechanical machine design com- Speed Viper: productive time and engineering and the bined with expert service auxiliary time Klingelnberg Closed   Systematic linking of gear Loop concept design and production   Integration of Speed Viper into the Klingelnberg produc- tion system   Use of the Closed Loop system, which has been proven the world over for bevel gears, for cylindrical gears Result: Speed Viper uses bevel gear DNA for large-scale production of acoustically optimized cylindrical gears. HÖFLER generating grinding machine Speed Viper 300 with CompactLoader Innovative Machine Design for Maximum Productivity   Cutting speeds up to 100 m/s   Rugged machine design, made of vibration-damping cast polymer   Optimal automation capability for minimal auxiliary times   Use of long-life tools   Compact design with minimal travel paths in the process   High-performance, aerodynamic nozzle for efficient coolant supply 6

Maximum Flexibility in the Grinding Process   Speed Viper platform covers a broad range of components (large travel paths)   Integrated, automated configuration of table drive parameter based on workpiece inertia   Tool diameters between 210 mm and 275 (320) mm   Thermally stable machine design   Flexible automation interface   Automatic tool clamping system for minimal set-up times (optional) Convenient, Intuitive Operating Concept   Systematic linking of gear design and production   Intuitive operator guidance through user-oriented operating concept and easy-to-follow menu design   Modern control panel with touchscreen display and clear screen lay- out   Integration of Klingelnberg Closed Loop system   Analysis, planning and control functions in parallel with production time, thanks to multitasking capability of Gear Operator software   Machine configuration successfully completed in just a few steps Easy, Fast and Service-friendly Maintenance   Rugged design of machine components   Pivoting control cabinet   Logical arrangement of power supply   Easy accessibility of modules to be serviced   Real-time remote maintenance via Ethernet connection 7

HIGHLIGHTS Acoustically Optimized Cylindrical Gears in Large-scale Production   Linking of gear design with production for acoustically optimized gears   Rugged machine base (large guide width) for minimal gearing devia- tions in the process   Dynamically optimized drives   Two-plane balancing system for minimal excitation in the process   Systematic implementation of the Klingelnberg Closed Loop system, which provides feedback to the grinding machine about the manu- factured quality Closed Loop Quality Control in Line with Industry 4.0   Central gearing and process design   Networked connection in the Klingelnberg production system (GearEngine®)   Knowledge management with central production data acquisition   Digitization of gear production through automated machine correc- tion Energy Efficiency (e²) for Maximum Savings   Flow-optimized coolant supply   Pressure sensor on high-performance nozzle for fastest possible pro- cess start, as soon as adequate coolant is available   On-demand optimization of drive control for permanent reduction of energy loss   Systematic gear design with testing of producible geometries allows production of ultra-precise tooth geometries for optimized gear run- ning behavior 8

Gear Operator – Process-oriented Operator Guidance with Wizard Technology Powerful and Reliable   Reproducible quality through central manage- ment of relevant tool and process parameters   Maximum productivity through custom machin- ing and loading cycles   Workpiece and device-dependent axis drive opti- mization   Process analysis and control in parallel with grind- ing using independently operated control and display pages   Collision management based on a dynamic 3D machine model   Automated quality control in Klingelnberg Closed Loop system Convenient and Clearly Laid-out   Siemens Sinumerik One control unit with touch- screen display   Intuitive user interface with process-oriented operator guidance   Clarity through constantly visible menu struc- ture and immediately responsive program logic   Convenient setup with customized configura- tion of operating sequences   Effective context-sensitive help with text, image and video material Flexible and Expandable Enhanced process reliability: Service and maintenance: Technologies:   Digital identification of tools   Remote maintenance via   Finish grinding and polishing and clamping fixtures Klingelnberg Service Gate   Topological grinding of specific   Automatic allowance and stock   Comprehensive machine and twists removal control process analysis with Gear Analyzer   Generation grinding of   Contact monitoring during beveloid gearing dressing   Preventive maintenance with automatic axis test 9

USER-FRIENDLY SOFTWARE CONCEPT Real Productivity Gains with Gear Designer and Gear Operator The quality demands on transmissions and gears continue Gear Designer imports the “function-oriented gear geometry” to increase. Masking noises in the transmission environ- defined by the design engineer and carries out a production ment – such as noise from the combustion engine – are di- simulation. The resulting “production-ready gear geometry” minishing or are being eliminated altogether as in the is determined, taking the tool geometry and process kinemat- electric drive. Add to these the demands on transmission ics into account. This is then analyzed and further optimized engineers to develop designs that are as resource-efficient by the design engineer. Once the “process-ready gear ge- as possible. Lightweight design and the use of low-viscosity ometry” has been approved, it is transferred to GearEngine® transmission oil mean that gear quality must improve in or- and the central management there. Gear Operator loads the der to achieve comparable or improved acoustic behavior. data record and interactively assists machine operators in their tasks. In-series optimization of the gear geometry takes In transmission and gear design, the use of calculation soft- place via the Closed Loop quality control process. Gear varia- ware for tooth contact analysis is commonplace. Optimiza- tions are identified relative to the approved “production- tion of gear modifications involves the elastic behavior of ready gear geometry,” and the process is corrected accord- the shaft bearing system. In many cases, the gear geometry is ingly. This follows the Klingelnberg philosophy that has been optimized by simulating many variants, taking the tolerance used successfully in bevel gear production for many years. fields into account. The objective of this variation calculation is to define a gear that is as rugged as possible. Result: A virtual twin is created, which provides an achievable image for every process step. This makes it possible to clealy Klingelnberg has come up with a software package that analyze deviations and identify the causes. It also eliminates draws on its successful production system for bevel gears. uncertainties in the machine and cutter head setting and Gear Designer and Gear Operator are unique software solu- checking device with regard to the achievable quality and the tions that were developed to implement the Closed Loop pro- quality actually achieved. cess for cylindrical gears. The first Closed Loop is located at the interface between transmission calculation and production engineering. 10

The Speed Viper Concept Gear Operator GearEngine® Data management Machine settings Nominal data & tolerances Correction data Gear Designer Measured values Producible gear geometry Function-oriented gear geometry www.speedviper.com 11

EXPERTISE IN COUNTLESS INDUSTRIES Automotive Industry in Transition “Electromobility” and “Industry 4.0” are hot topics currently sion concepts, but also to significantly increased demands on under discussion in the automotive industry. As an automotive the vibration and noise characteristics of the transmission. supplier, Klingelnberg is also tackling these issues, in an effort Whereas input speeds in IC engine-powered passenger cars to develop specific solutions for the demands of the future. do not exceed 6,000 rpm in most cases, motors with speeds significantly greater than 20,000 rpm are used in the electric Demands on the automotive industry: powertrain. This brings gear runout and cumulative pitch er- Owing to the characteristics of the speed-torque curve rors – previously only significant as the cause of side bands or in the electric motor, it is possible to adapt the product tooth mesh harmonics – into the acoustically relevant range. range to suit the tractive power requirement curve in ve- hicles using fewer gears than is the case with the combus- Klingelnberg solution: tion engine. But industry professionals all agree that gear With GearEngine® and its Closed Loop approach, Klingelnberg transmissions will continue to be indispensable, even in an has developed a exceptional solution for the process chain in cy- electrified powertrain. This is necessary to meet require- lindrical gear manufacturing. Owing to the quality-determining ments for driving comfort, efficiency and vehicle costs. influence of hard finishing, the networking of Speed Viper with the Klingelnberg Precision Measuring Centers is a crucial step in Current electric drive concepts for passenger cars frequently ensuring the quality of the production process. With the analy- comprise of an electric motor with single-shift transmissions, sis options of the P machine software, particularly the waviness consisting of two cylindrical gear stages or one plane- analysis option, the causes of noise problems can be quickly pin- tary stage and one cylindrical gear stage. In light- pointed. Thus the right tools are available for automotive gear weight commercial vehicles, concepts with production – and not just for electric powertrain transmissions. up to two shifts are used, and the starting point in heavy-duty commercial Conclusion: vehicles is currently six to eight Klingelnberg solutions deliver useful tools for gear produc- shifts, which are shifted au- tion in the automotive industry of today and tomorrow, thus tomatically via the drive providing the right answers to questions arising in the areas of control based on the “electromobility” and “Industry 4.0”. driving situation. The elimination of the internal com- bustion engine will lead not only to changes in transmis- 12

Commercial Vehicles The developments in commercial, construction, and ag- ricultural vehicles have never been as exciting: Specific industry solutions, payload optimization, sophisticated safety systems and not least fuel efficiency are just a few of the key trends. Each new vehicle generation must fulfill the requirement of providing more safety and comfort while achieving lower total overall operating costs. The use of Klingelnberg solutions makes it possible to mass-produce cylindrical gears with the required quality. Contract Gear Manufacturers Contract gear manufacturers in particular have to be able to react flexibly to market conditions on a daily basis and produce a whole host of different gear components. From standard solutions to high-tech applications – Klingeln- berg offers its customers tailor-made machine designs. These are supplemented by comprehensive engineering and other services, including everything from in-house machine certification at Klingelnberg, to machine-atten- dant and software training, right through to production support. Industrial Gear Units The industrial gear unit sector comprises many different applications, all of which place great demands on the reli- ability of gear wheels. The cylindrical gears for these sec- tors are often produced by companies specializing in small batch sizes and a variety of products. A rigid machine de- sign and flexible, cost-effective tool systems are the keys to success for ranking among the market leaders in these sectors. Robot Industry Digitization, automation, and robotics are key issues in mechanical and plant engineering. From the autonomous lawn-mower to the articulated robot in the operating room: In addition to sophisticated software, every robot runs on high-precision hardware – and that starts with the smallest toothed gear. With Klingelnberg system solu- tions for cylindrical and bevel gears, the right “mechanical backbone” for every robot type can be built in the smaller diameter ranges. 13

TECHNICAL DATA SPEED VIPER 300 SPEED VIPER2 180 SPEED VIPER2 80 Workpiece diameter (max.) Ø 300 mm Ø 180 mm Ø 80 mm Grinding stroke 500 mm Distance between center above table 370 – 1,100 mm 295 – 895 mm (min. – max.) Module (min. – max.) (0.5) 1 – 5 mm (0.5) 1 – 3 mm Swivel angle +/- 45° Grinding worm diameter Ø 200 – 275 (320) mm Grinding worm width (max.) 200 mm Grinding spindle 25 kW Grinding worm speed 7,200 rpm Cutting speed 100 m/s Table diameter Ø 180 mm Ø 120 mm Table load (max.) 50 kg 35 kg Table hole (diameter x depth) Ø 87 x 196 mm Ø 59 x 150 mm Table rotation speed (max.) 2,300 rpm 3.000 min-1 Axial feed rate 12,000 mm/min Total connected load 40 kVA Machine dimensions (L x W x H) approx. 3,085 x 2,160 x 3,420 mm approx. 3,455 x 2,160 x 3,420 mm Filter unit dimensions (L x W) approx. 3,400 x 2,160 mm Net weight approx. 16,500 kg approx. 18,500 kg The dimensions of the standard version are for orientation only. Swivel ranges for doors, operating panels etc. are not taken into account here. The final space requi- rement depends on the individual configuration of the machine. 14

Installation Dimensions SPEED VIPER 300 SPEED VIPER2 180 SPEED VIPER2 80 SPEED VIPER 300: FRONT VIEW Workpiece diameter (max.) Ø 300 mm Ø 180 mm Ø 80 mm Grinding stroke 500 mm Distance between center above table 370 – 1,100 mm 295 – 895 mm (min. – max.) Module (min. – max.) (0.5) 1 – 5 mm (0.5) 1 – 3 mm Swivel angle +/- 45° Grinding worm diameter Ø 200 – 275 (320) mm Grinding worm width (max.) 200 mm Grinding spindle 25 kW Grinding worm speed 7,200 rpm Cutting speed 100 m/s Table diameter Ø 180 mm Ø 120 mm SPEED VIPER 300: TOP VIEW Table load (max.) 50 kg 35 kg Table hole (diameter x depth) Ø 87 x 196 mm Ø 59 x 150 mm Table rotation speed (max.) 2,300 rpm 3.000 min-1 Axial feed rate 12,000 mm/min Total connected load 40 kVA Machine dimensions (L x W x H) approx. 3,085 x 2,160 x 3,420 mm approx. 3,455 x 2,160 x 3,420 mm Filter unit dimensions (L x W) approx. 3,400 x 2,160 mm Net weight approx. 16,500 kg approx. 18,500 kg All dimensions in mm 15

BEVEL GEAR TECHNOLOGY I CYLINDRICAL GEAR TECHNOLOGY I MEASURING TECHNOLOGY I DRIVE TECHNOLOGY KLINGELNBERG Service The KLINGELNBERG Group is a world leader in the development and manufacture of machines for bevel gear and cylindrical gear production, and precision measuring centers for gearing and axially symmetrical components, as well as the production of customized high-precision drive components. In addition to the headquarters in Zurich, Switzerland, further development and production facilities are located in Hückeswagen and Ettlingen, Germany. The company also maintains a presence with Sales and Service offices and numerous marketing agents. On this basis, Klingelnberg offers users a comprehensive range of services for all aspects of toothed gear design, manufacturing, and quality inspection. The spectrum includes technical consulting, on-site machine acceptance, operator and software training as well as maintenance contracts. KLINGELNBERG Solutions Klingelnberg solutions are used in the automotive, commercial vehicle, and aviation industries, as well as in shipbuilding, the wind power industry, and the general transmis- sion manufacturing industry. With numerous R&D engineers around the globe and over 200 registered patents, the company consistently demonstrates its capacity for innovation. FOLLOW US AND STAY UP TO DATE: KLINGELNBERG AG KLINGELNBERG GmbH KLINGELNBERG GmbH Binzmühlestrasse 171 Peterstraße 45 Industriestraße 5–9 8050 Zürich, Switzerland 42499 Hückeswagen, Germany 76275 Ettlingen, Germany Fon: +41 44 278 7979 Fon: +49 2192 81-0 Fon: +49 7243 599-0 Fax: +41 44 273 1594 Fax: +49 2192 81-200 Fax: +49 7243 599-165 You can also find your local contact for sales advice at https://klingelnberg.com/en/contact WWW.KLINGELNBERG.COM • INFO@KLINGELNBERG.COM 16 EN 03/2025 - Subject to technical modifications without notice.