CNC solution for Pfauter-Kapp Gear grinder retrofit

A typical success story!

The heat treatment process used to harden gears and pinions distorts them slightly, so before being fitted in gearboxes and other transmission systems, these workpieces must be ground to eliminate this distortion. our customer had a Pfauter-Kapp grinding machine, originally built in 1988, used for this critical step in the production process. The hardware used on the machine was obsolete and hard to maintain and the operating interface was difficult to use and inflexible.

Our solution is based on the Sinumerik 840D platform-the most powerfull CNC on the market, complemented with Simodrive 611D adnd Siemens new digital servo-motors for all axes.  A new user interface was developed in close co-operation with the customer's engineering and production teams. This new operating interface allows flexible and intuitive control of the entire setup and production process. Sinumerik Safety Integrated is now responsible for monitoring the working space and ensuring the safety of the operator during the workpiece setup and operating process.

The words of Mr. Greg Martin, Program Manager at David Brown Gear Industries and TSS Black Belt demonstrate the great outcome of this solution - " The team from CNC Design met our expectations through all phases of the retrofit. I was particulary impressed at the ease in which they grasped the intricacies of gear grinding and were then able to incorporate them into the user interface ... The result so far have shown that we are getting reductions in the areas we were seeking - setup time has typically reduced up to 20%, grinding time has reduced by up to 40%. There have also been reductions in the programming time (now only data entry), the time to change from one program to another...Given the professional manner in whihc the team at CNC Design acquitted themselves and the high level of expertise they showed, we would certainly consider them for any future retrofits"