www.hauschildgmbh.de [email protected] Fax: Tel.: +49 20224742-0 42349 Wuppertal Brücke69 Kohlfurther GmbH &Co. KG Heinz Berger Maschinenfabrik Hauschild +49 20224742-42 © Hauschild ©

polishing anddeburring forSolutions grinding, of workpieces Contents

GRINDING LINES Grinding of cutlery edges KBR 4–5 Grinding of tines ZS 6–7

DOUBLE SHAFT POLISHING MACHINES Polishing of the outer edge DWP/2K 8 Handle neck DS 9 End machining EB 9 Polishing CNC controlled PS-CNC 10–11 Polishing of and DWP + EWP 12–15 Clamping and exchanging ET + UT 16 Polishing of cutlery DWP/2S + 2M 17 Mechanical polishing (transfer lines) DWP800 18 Polishing CNC controlled (transfer lines) PS-CNC 19 Polishing of blades PC-CNC 20–21 Further applications 22–23

ROTARY TABLE GRINDING MACHINES Sharpening of knife blades KBM 24–25

ROBOT TECHNOLOGY Robot grinding and polishing sytems RSP 26–27 Sharpening of knife blades RSP1B2P 28 Serrating of knife blades RSP1B 29 Flat grinding of knife handles RSP2B1M 30 Polishing of knife handles RSP3P 31 Grinding and polishing of hollow-ware RSP2B1P 32–33 Machining of cast iron pots RSP2B1F 34–35 Finishing of aluminium cast parts RSP3S 36–37 All-around machining of tweezers RSP4B1P 38 Rough and final polishing of hip joints RSP2P 39 Further applications RSP 40

COMPONENTS Sorters SE 41 System integration 42 Process automation and handling technolopgy 43 Belt grinding station BSS 44 Polishing and grinding stations P + SS1 45 Magazine systems 46 Measuring technology / programming 47

• 2 • Workpieces

• Knives • Forks • Spoons • Pliers • Wrenches • Spectacle frames • Kitchen knives • Professional knives • Pans • Taps • Bone plates • Bone nails • Surgical instruments

Industries

• Cutlery industry • Hand industry • Producers of spectacle frames • Producers of professional and kitchen knives • Producers of household goods • Hollow-ware industry • Surgical industry

• 3 • Grinding of cutlery edges

KBR The transfer line KBR6 realizes a complete edge machi- ning all around the workpiece with a machine which consists of two one-sided and two double-sided belt grinding stations. The KBR6/robot is a further development of the transfer line KBR6. A six-axle robot is integrated into the system processing complex geometries at handle and . This unique solution offers the possibility to machine completely all kind of cutlery forms in one line.

In the following, two versions of machining with the KBR transfer line are demonstrated: Machining of spoons and forks (pictures at the right side and here above) • Complete solution for cutlery items by the integra- tion of end machining • Automatic loading and unloading • Number and configuration of the working stations variable depending on the scope of work

Machining of wrenches (picture at the left side) • Six belt grinding stations: two stations for the ma- chining of the ring and four stations for the machi- ning of the side parts • Intermediate transfer from ring to wrench machining • Manual or automatic loading possible • Conventional and CNC controlled equipment available

• 4 • Cutlery Cutlery • 5 • Grinding of tines

ZS

The grinding line of the series ZS machines forks with two, three or four tines. By the use of a folded grinding belt the run-out radius is ground cleanly.

The system consists of three belt grinding stations, one rotary table and one separate automatic loading and un- loading station with stacking device. PLC control system and operator device with display enable a simple and quick set-up. Two different grinding procedures can be preset: • Grinding of one tine interspace per station • Rough grinding of all tines in the first station, final grin- ding in the second station and polishing in the third station

• 6 • Cutlery Technical data ZS/R3

Dimension of the grinding belt: max. 3500 mm (137.8 in) long 60 mm (2.4 in) wide Total connected load: 3×3 kW Weight of the machine: 2300 kg (5071 lb) Dimensions (L x W x H): 2300 mm × 2300 mm × 2200 mm (90.6 × 90.6 × 86.6 in) Cutlery • 7 • Polishing of the outer edge

DWP/2K

The polishing machine type DWP/2K polishes the edges of cutlery and handles in two steps: • Polishing of the edges, the top of the bowl and the tran- sition Insertion of the workpiece from the first clamping tool into the second clamping tool via exchange table • Polishing of the outer edges of the handle

• 8 • Polishing of the outer edge Handle neck

DS

The double shaft polishing machine of the series DS is used for rough and final polishing of the narrow edge area of the handle neck (transition between handle and bowl) of spoons, forks and similar workpieces. Technical data DS600 DS1000 • Perfect machining of the transitions thanks to transver- sely working polishing Working width: 600 mm (23.6 in) 1000 mm (39.4 in) • Parallel machining top down Main drive: 4 kW 7,5 kW • First-rate results, shortened processing times and re- Weight: 2400 kg (5291 ib) 2600 kg (5732 lb) duction of the polish roll wear due to an exact scanning of the workpiece shape

Polishing of the outer edge End machining EB

The single shaft polishing machine of the series EB is an end facing machine. Depending on its configuration, it can be Technical data EB600 EB1000 used for rough or final polishing of spoons, forks or similar items. Working width: 600 mm (23.6 in) 1000 mm (39.4 in) • Machining in two clampings Main drive: 7,5 kW 11 kW • First-rate results, shortened processing times and re- Weight: 3400 kg (7496 ib) 3600 kg (7937 lb) duction of the polish roll wear due to an exact scanning of the workpiece shape

Cutlery • 9 • Machining of the surface Polishing CNC-controlled

PS-CNC

The CNC-controlled double shaft polishing machine of the series PS-CNC is equipped with a control system which enables a programming and storing of all process parameters. Thanks to its short changeover time of a few minutes the machine can also run small series.

Polishing of nails 360° • Continuously speed-controlled polishing shaft drive • Polish injection control • Automatic correction of polishing shaft wear • Shaft contact pressure corrected according to load • Entry of data and data output to in- tegrated or external printer or directly to production • Demonstrator programs • Extension of PS-CNC/LG for spoons and forks to the machining of rotationally symmetrical workpieces (e.g. nails or handles) possible

• 10 • Cutlery and bone nails Technical data PS1000-CNC/LGM Basic frame: welded construction Dimensions (L x W x H): 2060 mm × 1250 mm × 2000 mm (81.1 × 49.2 × 78.7 in) Weight (incl. hydraulic power pack): ca. 3500 kg (7716 lb) Working width: ca. 1000 mm (39.4 in) Edging of the output shaft: 55–230 mm (2.2–9.1 in) Long stroke (upper/lower shaft): 0–300 mm (11.8 in) each Machining of handles 360° Cross stroke (upper/lower shaft): 0–60 mm (2.4 in) each Wrench size of hexagonal shaft for the reception of the polishing wheel: 12–32 mm (0.5–1.3 in) Polishing roll drive (upper shaft): 11–15 kW Polishing roll drive (lower shaft): 11–15 kW Motion of long and cross stroke axes: hydraulic Drive of hydraulic power pack: 5,5 kW Polish application: 4 high pressure spraying guns Polishing of plates Control: programmable from memory Adjustment: by operator via screen by plain text and ˝Teach-ln˝-mode Data memory: hard disk and UBS flash drive

Cutlery and bone nails • 11 • Rough and final polishing of spoons and forks

DWP For rough and final polishing of spoons and forks the EWP following double shaft and single shaft polishing machines are assembled to one production line: • DWP/1S • DWP/VS • DWP/2S • EWP/1S The number of machines and the configuration of the line depend on the kind of machining and the required capacity.

• Working width 1000 mm (39.4 in) • Clamping and exchange table • Different tongs for the machining of bowl and handle • Perfect machining of the top of the bowl due to the integration of a pressure pad in DWP/1S • Compound slide rest on maintenance-free idle pulley • Upper polishing shaft balanced by a counter weight • Integration of automatic polish feed and polish shot interval • DWP/1S, DWP/VS, DWP/2S and EWP/1S usable as single machines

• 12 • Cutlery Technical data DWP/1S DWP/VS DWP/2S EWP/1S

Basic frame: welded construction Length: 2000 mm (78.7 in) 2000 mm (78.7 in) 2000 mm (78.7 in) 2000 mm (78.7 in) Width: 1600 mm (63 in) 1300 mm (51.2 in) 1600 mm (63 in) 1800 mm (70.9 in) Height: 1500 mm (59 in) 1300 mm (51.2 in) 1500 mm (59 in) 1600 mm (63 in) Weight: 1800 kg (3968 lb) 1700 kg (3748 lb) 1800 kg (3968 lb) 1435 kg (3164 lb) Working width: 1000 mm (39.4 in) 1000 mm (39.4) 1000 mm (39.4) 1000 mm (39.4) Polishing wheel Ø: 150 mm (5.9 in) 230 mm (9.1 in) 150 mm (5.9 in) 100 mm (3.9 in) Long stroke: 0–320 mm (12.6 in) 0–320 mm (12.6 in) 0–320 mm (12.6 in) 0–250 mm (9.8 in) Gear motor: 0,55 kW 0,37 kW 0,55 kW 0,37 kW Cross stroke: 0–60 mm (2.4 in) 0–80 mm (3.2 in) 0–60 mm (2.4 in) 0–60 mm (2.4 in) Gear motor for cross stroke: 0,55 kW 0,37 kW 0,55 kW 0,37 kW Contact pressure: 6 bar 6 bar 6 bar 6 bar Control: PLC (option) PLC (option) PLC (option) PLC (option) Cutlery • 13 • Rough and final polishing of spoons and forks

The double shaft polishing machine type DWP/1S is emp- loyed for rough and final polishing of cutlery bowls. • Pressure pad for perfect machining of the bowl top • Perfect machining of the edges thanks to a DWP/1S pneumatically swivelling clamping tool • Shaft contact pressure by pneumatic cylinder (three different contact pressures selectable) • Upper polishing shaft swivelled forwards and back- wards manually • Movement of long and cross stroke by hydraulics or electro-mechanical gear motor

The automatic single shaft polishing machine of the series EWP machines the inner and outer side of cutlery bowls. • Elimination of distortion marks at difficult bowls EWP/1S • Bowls swivelled on work roll by rotatable piece holder • machining result at the deep area and at the edges of the bowls due to the swivel movement of the piece holder with changing rotating direction of the machine

The double shaft polishing machine type DWP/VS is used DWP/VS for rough and final polishing of the transition between bowl and handle.

The double shaft polishing machine type DWP/2S machines DWP/2S bilaterally handles of spoons, forks or similar pieces as well DWP/1S with pressure pad as blades of monobloc knives.

• 14 • Cutlery 1 2 3

7 4

9 8 6 5

Example of a polishing line of the series DWP: Clamping of the workpiece at clamping table* (1), rough polishing of the transition of the workpiece at the first DWP/VS* (2), polishing of deep bowls at EWP/1S* (3), polishing of bowls at DWP/1S* (4), final polishing of the transition at the second DWP/VS* (5), final polishing of bowls at the second DWP/1S* (6), turning over of the workpiece at the exchange table* (7), rough and final polishing of handles at both DWP/2S* (8 + 9)

DWP/VS DWP/1S with pressure pad

DWP/2S – Rough polishing DWP/2S – Final polishing Cutlery • 15 • Clamping and exchanging

ET For different machines/workpieces automatic and manual UT clamping and exchanging tables are available. • Clamping of up to 32 workpieces per line by the auto- matic clamping tables of the series ET/LG • Clamping table equipped with vacuum bar, mobile insert with distance bassets and magazine • Clamping time of max. 15 seconds minimizing the dead time at surface finishing machines • Exchange table of the series UT/LG to turn the cutlery items in the workpiece holders for the subsequent ma- chining of handles • Exchange table of the series UT/LG used at single grin- ding and polishing machines with manual loading

Exchange table

Clamping table, detail view Clamping table

• 16 • Cutlery Polishing of cutlery knives

Depending on the driving speed and the lining of the output shaft, the double shaft polishing machines type DWP/2S and DWP/2M are emp- loyed for the automatic bilateral rough or final polishing of cutlery knives.

DWP/2S • Polishing of blades of monobloc knives, mounted knives and knife DWP/2S blades before setting into hollow handles • Clean machining of the knife blade transition to the bolster during DWP/2M final polishing due to the alternate shaft rotation • Cross-table with maintenance-free idlers conceived for feeding the workpieces to the polishing rolls

DWP/2M • Polishing of knife handles at monobloc knives, mounted knives and hollow handles • Swivelling up to 110° in connection with oscillating tools • Complete processing of the whole knife handle due to the knife handle end machining device • Cross table with maintenance-free idlers for feeding the workpieces to the polishing rolls • Application of polishing emulsion required for machining the knife handles by high pressure spray guns • Simple operation due to easy handling of the electronical control Cutlery Cutlery knives • 17 • Transfer lines Mechanical polishing

DWP800

Hauschild offers mechanical and CNC-controlled transfer lines for grinding and polishing of knives, forks and spoons. The mechanical transfer line DWP800 is a special wear- minimizing design and solid machine construction with low maintenance costs considered for the long term.

Mechanical transfer line type DWP800 • Tilting arms for easy access to the machine, e. g. when the shafts have to be changed • Wear compensation of the polishing rings during the machining of the internal side of the bowl due to the adjustment of the upper shaft • Usual rectangular machining of the internal side of the bowl replaced by circular machining by means of a con- trol unit • Wear reduction of the polishing wheel of 30% as the sharp bowl edges are not passed over

• 18 • Cutlery Transfer lines Polishing CNC-controlled

The CNC-controlled transfer line of the series PS-CNC con- PS-CNC sists of six to eight CNC-controlled double shaft polishing machines, two rotary tables, an automatic clamping table, an automatic exchange table and an automatic unclamping table. • Flexible working axes • Storage-programmable logic controller • Nearly maintenance free • Low-vibration run • High performance • Working width of 1000 mm (39.4 in). CNC-controlled transfer line type PS1000-CNC

Cutlery • 19 • Rough and final polishing of knife blades

PC-CNC

The CNC-controlled double shaft polishing machine of the series PC-CNC is designed for rough and final polishing of knife blades up to a length of 650 mm (25.6 in). Due to the innovative conception of automation it is possible to run in continuous process or to use separate fixtures.

CNC controlled double shaft polishing machine type PC1000-CNC • Working width of 1000 mm (39.4 in). • Movement of the polishing machine CNC controlled • Continuous feeding of the workpieces (see pictures at the right side and here above) • Use of polishing wheels with a diameter of up to 300 mm (11.8 in) • Integration of a linear chain conveyor containing five clamping tongs

• 20 • Professional and kitchen knives Professional and kitchen knives • 21 • Double-shaft polishing machines Further applications

• Grinding • Polishing • Deburring / Brushing • Sharpening of knives • Serrating Polishing of knives with double shaft polishing machine DWP

• 22 • Polishing of with double shaft polishing machine type DWP/1S Polishing of spoon edges with a single shaft polishing machine type EB1000

Grinding of wrenches, machining of the open-end and the lateral edge with transfer line type KBR6

Polishing of handles with double shaft polishing machine type PS1000-CNC Polishing of spectable frames with double shaft polishing machine type PS1000-CNC Other workpieces • 23 • Sharpening of knife blades with rotary table grinding machine

KBM-CNC

The CNC controlled sharpening machine of the series KBM- CNC machines a market-ready sharpening of higest quality at knife blades. The workpieces are sharpened in eight of ten fixtures while the rotary table is turning continuously.

• Manual or automatic unloading/loading of the knives • Completion after a 360°-turn in eight stations • Scanning of the edge by CNC sensor in two measuring stations to detect warped knives and differences in form/position of each knife blade • Digitalization and storing of the measured values • Grinding of the blade with six belt grinding stations at a manually adjustable angle (12°–25°), three times from above and three times from below • Use of different belt qualities – depending on the requirements

• 24 • Professional and kitchen knives Technical data KBM6-CNC • 10 pneumatically activated fixtures for knives • 6 belt grinding stations arranged at 36° each around the rotary table CNC-rotary table-Ø: 150 mm • 2 pneumatically activated CNC-gauge sensores for bilateral con- Processing time/knife: 8–10 s tour measurement of each knife Blade thickness : 0,2–0,45 mm (0.08–0.18 in) • Siemens PC-control 840DI Changeover time: 15–30 min • Gauging results digitized and stored relative to each part fixture Result of sharpening • Workpiece orientated programming CP-value (Initial Cut Perform.): 90–105 mm (3.5–4.1 in) TCC-value (Total Catra Cut): 250–400 mm (9.8–15.8 in) • Beginning and end of grinding programmable, independently of (with standardized paper tape test (CATRA)* the probe reading, to achieve a “soft” start at the handle and run-

* Sharpening results were calculated based on approx. 30 different knife types of different qualities, out at the end of the blade. with a sample size of 30–400 knives from each type

CNC measuring sensors Test of sharpness

Professional and kitchen knives • 25 • Robots grinding and polishing systems

Machining cells with robots used to machine workpieces • Robot grinding and polishing stations either integrated RSP into existing production lines or built as a separate cell • Standard interfaces for all established manufacturers of robots such as ABB, Kuka, Stäubli and Fanuc • Programming in the touch-in processor with a CAD/ CAM interface • Integration of measuring systems used in the compen- sation of workpiece location and measurement tole- rances • Various machining stations with a variety of tools (e.g. grinding belts, grinding stones, polishing discs) are available

• 26 • Robot grinding and polishing system for the machining of grippers with a measurement station, a grinding belt station, a grinding stone station, a cleaning and drying station

• 27 • Robotic sharpening of knife blades

By using this universal conception, edges of blades and knives can be sharpened and polished up. RSP1B2P • Sharpening realized alternatively by a belt grinding or wheel grinding station • Polishing of the blade by a one-sided polishing station, e. g. in connection with a buff • Measuring of the workpieces • Optimization of the gripper • Optimization of contour programming for sharpening and polishing of knives

• 28 • Robotic serrating of knife blades

RSP1B

By means of a robot (e. g. IRB 140F/ABB ) the knife blade is generated at a straight, profiled tooth wheel. The programming of the blade contour is effected accor- ding to the features of each workpiece.

Professional and kitchen knives • 29 • Robotic flat grinding of knife handles

RSP2B1M

Especially for bilateral flat grinding of knife handles two belt grinding stations of the type BSS14 are erected opposite to each other. The stations are connected to a special attachment for bi- lateral parallel flat grinding of handles.

Robot grinding station RSP for flat grinding of knife handles by means of two belt grinding stations type BSS14 erected opposite to each other

Robot grinding station RSP for grinding of knife handles by means of a Indexing rotary table with adjustable stops for the reception of approx. 160 work- profiled grinding wheel pieces • 30 • Professional and kitchen knives Robotic polishing of knife handles

RSP3P

For the polishing of knife handles one-sided polishing machines are employed. According to the model, the use of polishing wheels with a width of 100 mm respectively 300 mm are recommended. The polish is supplied in a liquid or in a solid texture.

Professional and kitchen knives • 31 • Robotic grinding and polishing of hollow-ware

RSP2B1P

Special solution for polishing the lateral area of pots by means of two abrasive belts and one polishing wheel

• 32 • Robot grinding and polishing system type RSP2B1P consisting of two belt grinding stations and one polishing station for the machining of the lateral area of cooking pots – automatic changing of the gripper for quick changeover

• 33 • Robotic machining of cast iron pots

RSP2B1F

Modular robot grinding and polishing station for the machining of cast iron pots Feeding by conveyor belt, prepositioning on camera measuring table

• 34 • Compensation of workpiece tolerances using a camera measuring system Deburring of the inner side of the handle by means of high frequency motor spindle

Finishing of the outer face with belt grinding station BSS14

Hollow-ware • 35 • Robotic finishing of aluminium cast parts

RSP3S

The robotic deburring of die parts can be achieved with a variety of tools. Above all, rotating power tools such as milling burrs and grinding pencils, grinding flap discs or brushes are used. Tools are selected depending on the re- quirements of precision, the materials, the surface and the amount of material which has to be removed. Either the tool or the workpiece can be guided during machining. • Integration of different tools in three pneumatically powered milling spindles and a brush spindle using a turret • Tool changing time: 0,4 s • Machining of the programmed curves in the geometrical order • Very short processing paths • Integration of up to four tools • Integration of a 3D measuring sensor for the calibra- tion of complete workpieces or individual contour ele- ments checking the position of the workpiece during processing • Increase of the lifetime of tools and improvement of the surface when deburring due to a spray nozzle installed on the tool turret

Tool turret with three pneumatically powered milling spindles, a brush Interchangeable workpiece holder (device) with defined reference points spindle and a 3D measuring sensor • 36 • Cast parts Machining of cast parts with a tool turret

Precise and defined deburring is decisive e. g. for the machi- Special milling tools were developed to realise with alumi- ning of cylinder heads as die cast parts. The deburred edges nium these uniform and narrow trimmed edges reliably. should be 0,3 to 0,5 mm (0.01 to 0.02 in) wide to guarantee The milling tools have a long lifetime and are designed in a maximum size of the sealing surfaces. that way that the penetration into the workpiece is limited. For the programming of the robot, an offline software is included in the scope of delivery. It selects the drawing data and assembles the curves which have to be deburred as radii and lines.

Robot deburring cell with guided tools for aluminium die cast parts

Cast parts • 37 • Robotic all-around machining of surgical tweezers

RSP4B1P

The robotic grinding and polishing systems of the series RSP can be equipped with different processing stations such as belt grinding stations, polishing machines or stone grinding stations. For the producion of surgical tweezers the robotic line can be composed in that way that an all-around machining of the workpiece can be performed.

Robotic grinding and polishing station RSP • Machining of the tip and the spring of the tweezer at belt grinding station • Gripper station for all-around machining • Close grinding of the tip of the tweezers at grinding wheel

Gripper station for all-around machining: Machining of the spring of the tweezer at belt grinding station

• 38 • Tweezers Robotic rough and final polishing of protheses and hip joints

RSP2P

The robotic grinding and polishing station of the series RSP machines hip joints, prohteses and similar workpieces. • Robotic grinding and polishing station either integrated into an existing production line or errected as a separate processing station • Programming in the touch-in processor with a CAD/CAM interface • Integration of measuring systems for the compensation of workpiece location and measurement tolerances • Various machining stations with a variety of tools available (e.g. grinding belts, grinding stones, polishing discs)

Tweezers • 39 • Further robotic applications

Robotic grinding of mounted surgical scissors Grinding of single shear blades / hair dressing scissors Polishing of nail scissors with scotch brite

Grinding of forceps components Grinding of surgical forceps in mounted condition Polishing of mounted forceps

Resurface welding of the carbide coating of Robotic deburring of blades for eye surgery Robotic machining with laser marking of workpieces surgical scissors

Grinding of lancets Machining of single-use microscissors Machining of filter baskets

Deburrring of forged secateur pieces Convex grinding of wrench surfaces Grinding of torque wrench tools

• 40 • Further workpieces Magazining of workpieces. approx. 120 workpieces / min (depending on the workpiece)

Sorters

SE Series SE sorters magazine workpieces made from cut mate- rials or insert them into a magazine. Workpieces are taken from a silo and fed one at a time over a conveyor belt. A camera identifies the location of the workpiece. The loca- tion data is transmitted to a robot control. The robot grabs the workpiece and positions it correctly for magazining.

Further workpieces Sorters • 41 • System integration

Integration of • Bending presses • Painting plants • Packing machines • Overlay welding • Hardening machines • Drilling / Abating

Integration of two milling centres, two bending presses, and a type BG1 grinder in connection with an indexing vertical rotary table magazine

Painting, oiling, packing of jigsaw blades

• 42 • System integration Robotic feeding / robotic welding Manufacturing cell for cable cutters for the grinding of inner and outer surfaces, indentation and deburring

Process automation Handling technology

Automation of production processes and automatic feeding of widely varying workpieces

Process automation – handling technology • 43 • Belt grinding

station BSS design series belt grinding stations equipped with the following are designed especially for use with robot machining cells: • Pneumatic belt tensioning BSS • Belt damage monitoring • Preparation for extraction system to be provided by customer • Fittings for 400Volt/50Hz connection, single switch cabinet or switch point • Minimum quantity cooling (optional) • Robotic control with 16 belt speeds programmable (optional)

Doublesided belt grinding station type BSS1 Model BSS10 BSS12 BSS14 BSS20 BSS22

Main engine (kW) 4,0 4,0 4,0 4,0 4,0

Contact rollers Ø (mm) 80–400 100–200 150–400 50–150 50–150

Contact roller width 10–130 10–130 10–130 10–130 10–130 (mm)

Weight (kg) 150 180 350 200 200

Space requirement - Length (mm) 850 900 1.200 1.500 1.500 Onesided belt grinding station type BSS12 with - Width(mm) 650 800 600 600 600 turret - Height (mm) 2.100 2.100 2.100 1.500 1.500

Onesided belt grinding station type BSS14 with pressure control

Onesided belt grinding station type BSS 20 with horizontal abrasive belt

Onesided belt grinding station type BSS22 with Type BSS10 single-sided belt grinding station, equipped with different front buildings depending on the type oscillation of processing (picture V1)

• 44 • Belt grinding stations Polishing and grinding stations

Polishing station P1

• Polishing wheel diameter: 500 mm • Polishing width: 100 mm • Drive power: 5,5 kW, 750 U/min • Optional with frequency converter

Polishing station type P1

Grinding and polishing station P3

• Grinding / polishing wheel diameter: 300 mm • Grinding / polishing wheel width: 60 mm • Drive power: 3 kW, 2800 U/min • Spindle rotation speed-controlled

Polishing station type P3

Polishing station P5

• Polishing wheel diameter: 500 mm • Polishing width: up to 300 mm • Drive power: 7,5 kW, up to 2000 U/min • Spindle rotation speed-controlled

Polishing station type P5

Spindle head SS1

• Grinding wheel diameter: 450 mm (cup wheel) • Spindle drive: according to requirements 15–22 kW

Belt grinding stations Grinding station type SS1 • 45 • Magazine systems

The design of the loading / unloading magazine depends on various requirements:

• Required magazine capacity (e.g. one hour or one complete shift) • Shape of the workpiece (forged, conical, or flat) • The variety of workpiece shapes / dimensions that should be processed • Integration in the preceding stage of production (e.g. stamping) or subsequent processing (e.g. polishing, dry-fining) • Orientation of the pieces (e.g. disordered in a glide grinding line)

Indexing rotary table Ø 1,500 mm with adjus- Conveyor belt system for workpiece separating and Vertical stacking magazine for circular blades table stops, holds approx. 160 workpieces positioning on camera table

Stacking magazine for flat material, load ca- Circulating chain magazine with 24 load bars each Circulating bar magazine for forceps pacity 500–2,000 mm, adjustable length stops 300 mm e.g. for grippers

Indexing chain magazine for conical material Indexing vertical rotary tablemagazine with 6 or 12 Berger feeder used to feed loose material, location or forged workpieces, load capacity 2,000 mm loading and 3 or 4 unloading bars used to hold shears or detection by way of a camera system, positioning in with adjustable length stops shear blades in the ring grinder by robot • 46 • Magazine systems Camera measuring system used to measure parts

Mechanical measuring sensor used to measure parts

Camera measuring system used to measure contours Camera measuring system for robots used to identify the location of forceps

Measuring technology Programming

Programming of control panel in connection with an external computer

Development of standard measuring systems for various applications for the measurement and compensation of automated measurements / contours Menu-driven interfaces are available for complex system Interface robot in connextion with external controls. computer / control panel

Magazine systems Measuring technology • 47 • Strong partners under one roof ...

The trade marks Heinz Berger, 2000, as well as Nell’s develop- Hauschild, August Nell and Julius, ment of the BSM 3000 CNC grin- Werner Peters and LP-Laschet ding machine for micro-grinding stand for highest quality in the coil stock with camera control – field of machining and refining all important milestones for the metal coils and tools, e.g. house- Group and key driving forces for hold and machine blades, cutting the metalworking industry. tools, surgical instruments, cast Thanks to a broad product line, or forged tools. Their in-house the synergistic effects in our robotic capabilities provide solu- engineering, R&D and production tions to automation and process departments, and a competent integration tasks. customer service team, the Trend-setting in Berger Group provides complete the fields of robotics and CNC solutions – particularly for custom machines for grinding and poli- requirements – all from a single shing tools, as well as state-of- source. the-art technology for strip edge trimming by metal-cutting and surface finishing, are available for coil stock and tools that demand Heinz Berger Maschinenfabrik high quality. Hauschild The first automatic grinding August Nell jr. machines from Berger in 1957, the development of the Julius Julius Maschinenbau edge trimming machine in 1980, Werner Peters the first CNC controlled double- LP – Laschet scallop polishing machine by Hauschild in 1987, the use of more than 300 robots for automating Berger grinding machines since ... the Berger Group!

Kohlfurther Brücke 69 • 42349 Wuppertal-Cronenberg • Germany Tel.: +49 202 24742-0 • Fax: +49 202 24742-42 [email protected] • www.bergergruppe.de • 48 •