MACHINE KNIFE INDUSTRY MACHINES + ROBOTIC CELLS FOR grinding sharpening polishing CONTENT

MACHINES AND ROBOTIC CELLS

MACHINE KNIVES, WORKPIECES 4–5

GRINDING MACHINES FOR SINGLE WORKPIECES 6–55

Flat and of workpieces in 6–27 plane-side transverse or front-side deep grinding process Flat bevel grinding machines 6–15 grinding machines 16–23

Face, bevel or serrated grinding of workpieces in face, 24–51 circumferential, longitudinal and deep grinding processes Peripheral grinding machines 24–45 Rotary table grinding machines 46–55

ROBOTIC GRINDING AND POLISHING SYSTEMS 56–77  of circular knives 58–61  Sharpening of machine knives 62–65 Accessories 66–75

ROBOTIC PROCESS TECHNOLOGY / AUTOMATION 76–79

Integration of production processes; measuring technique 76–77 Bin-Picking 78–79

STEEL STRIP GRINDING MACHINES 80–105

Smooth grinding 80–85 Straight finish grinding 86–87 Squeegee grinding 88–89 Scalloped and serrated grinding 90–91 Gothic arch grinding 92–93 Serrated grinding simultanously on up to 44 strips 94–95 Plunge grinding and polishing 96–97 Accessories 98–105

METAL-CUTTING PROCESSING MACHINES 106–111 FOR METAL STRIPS

Modular strip edge trimming – lines 106–109–111 Strip edge trimming for heavy-duty use 110–111 REQUEST FOR QUOTATION 112

Questionnaire for technical data Heinz Berger Maschinenfabrik Kohlfurther Brücke 69 Tel. +49 (202) 24742-0 [email protected] GmbH & Co. KG 42349 Wuppertal, Germany Fax +49 (202) 24742-42 www.bergergruppe.de

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Flat and surface grinding on workpieces • Flat and bevel grinding p. 6–15 • Surface grinding on long knives p. 14–15 • Flat grinding p. 16 MACHINE KNIVES

WORKPIECES

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Serrated/scalloped grinding of workpieces • Serrated grinding p. 28–29 • Scalloped and serrated grinding p. 30–43

MECHANICAL PROCESSING The term "machine knives" covers a large number of workpieces of the most varied geometries and OF MACHINE KNIVES sizes.

Due to the multitude of workpiece shapes and the

complexity of some geometries, different grinding processes are used.   3 Bevel/arc and serrated grinding on ciruclar knives • Bevel/arc grinding p. 46–53 • Surface/bevel grinding p. 52–55 • Serrated grinding p. 44–45

4 Straight finish grinding, serrated and scalloped grinding on steel strips • Straight finish grinding p. 80–87 • Squeegee grinding p. 88–89 • Serrated and scalloped grinding p. 90–91 p. 94–95 • Gothic arch grinding p. 92–93 • Plunge grinding and polishing p. 96–97

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GRINDING MACHINES

FOR SINGLE WORKPIECES

GRINDING Grinding with CNC technique SHARPENING For the machining of machine knives the Berger Gruppe offers a wide range of CNC-controlled

SERRATING machines.   Various machining operations can be carried 1 out, such as surface grinding, radii grinding, flat 3 grinding, serrated and scalloped grinding, shar- pening, polishing and hollow grinding.

The machines are primarily used in the cutlery, machine knife, and surgical industries.

Grinding machines are employed as follows: • flat bevel grinding machines • rotary table grinding machines • peripheral grinding machines • rotary index table grinding machines • hollow grinding machines Examples of use (pictures) • contour grinding machines 1. Flat bevel grinding machine of the series BG1/ZA/NT2-CNC for surface grinding of • sharpening machines gardening shears (picture 1) 2. Exemplary structure of a machining cell with flat bevel grinding machine BG/NT2- CNC, robot loading and unloading and rot- ating bar magazine (picture 2) 3. Grinding of circular knives with peripheral grinding machine of the series RFS4-CNC (picture 3)

6 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES  7 back to content FLAT BEVEL GRINDING MACHINES FRONT SIDE GRINDING MACHINES Plane-side transverse or front-side The workpiece is machined with the side faces deep grinding process of a cup . Depending on the dia- meter of the cup grinding wheel, workpieces Surface grinding is a widely used grinding pro- with a grinding length of up to 1 200 mm can cess for the machining of machine knives. It is be processed. mainly used for processing flat and plane work- pieces. Surface grinding can be achieved both If the workpiece is processed in a deep grin- in deep grinding and pendulum grinding. ding process, a large amount of material can be removed and a good surface quality can be The flat bevel grinding machines – also known achieved. as front side grinding machines – process workpieces in plane-side transverse or front- side deep grinding. With a cutting speed of up to 50 m/s, a multi-sided smooth grinding of

machine knives is achieved.   When grinding with the plane side grinding method, the material removal results in a bevel on the wall (drawing p. 9).

Depending on the task and the workpiece, different geometries can be processed.

The solution presented on page 8 involves five workpiece axes and one tool axis. • Expoxy resin bonded grinding wheels with 450–710 mm Ø • Feed speed 30–50 m/s Feed 700–2 000 mm/min

• Ø Q'w = 8–12 [mm³/ (mm s)]

e. g. 4.0 mm • max. Q'w = 25 [mm³/ (mm s)] • max. cutting weight 3–10 g/s

e. g. 2.0 mm

8 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES  9 back to content FLAT BEVEL GRINDING MACHINES DG/NT-CNC Space-saving surface grinding • two to four axes: one tool axis and up to three workpiece axes CNC grinding machine with three or four • smooth grinding on several sides axes and vertical grinding spindle for the • tactile or AE measuring system for grin- surface grinding of machine knives, hand ding wheel wear compensation , scissors, and related parts • grinding length: up to 450 mm • cup wheel Ø: 500 mm • spindle drive: 30 kW

• cutting speed: up to 50 m/s   • 30% less required space in comparison to the horizontal arrangement of the grinding 3 spindle • good stability thanks to a solid welded cons- truction of the machine housing • prevention of vibrations during processing due to a machine housing filled up with mi- neral cast • user-friendly, Windows-based controls with interfaces for robotics, PLC, measuring tech- nology and other applications • “Esprit” CAM interfaces • wear-free main axis drive with linear motor, achieving rapid traverse speeds of 80 m/min (262 ft./min) • precision, backlash-free positioning, using direct measuring system • compact, precision gearbox with high rigidity to control cutting edge angle • as a single or a double machine available due to two separate machine housings

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FLAT BEVEL GRINDING MACHINES BG-CNC Surface grinding Here we differentiate between workpiece and tool axes. Depending on the task at hand, different ver- sions with different grinding lengths, grinding The workpieces are held by means of specific wheel diameters or grinding segments and clamping devices. 3 4

axis geometries are offered.   • grinding length: 1 000 mm • grinding wheel Ø: 80–710 mm • spindle drive 6.5–45 kW • cutting speed: up to 50 m/s • mounting flange for grinding wheel or grin- ding segments • spindle with backlash-free preloaded preci- BG/NT2-CNC: Arrangement of the axes sion bearing, designed for peripheral speed of up to 50 m/s • workpiece and tool feed with four or five axes and one tool axis (design according to task) • digital axis drives on preloaded ball screw Y or precision reduction gear

Examples of use (pictures) BG/ZA/VSS/NT2-CNC: Arrangement of the axes 1. Workpiece holder in combination with elec- tromagent (picture 1) 2. Grinding of screwdriver blades arranged in magazine (picture 2) 3. Grinding with rotation axis and serrating (picture 3) 4.. Grinding of chipper knives with BG/ZA/ VSS/NT2-CNC using segments (picture 4)

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FLAT GRINDING MACHINES FS-CNC Flat grinding of machine knives • four-axle CNC control (1 tool and 3 work- piece axes) CNC controlled vertical precision flat grinding • programmable angle adjustment with elec- machine with up to four axes for flat grinding tronic locking of long knives with a maximum length of • tactile measuring system for grinding wheel 4 5 4 000 mm wear compensation (optional) • grinding length: up to 4 000 mm • magnetic table with 4 magnets of 1,000 × • grinding height: 200 mm (or on request) 250 mm, single magnet with demagnetiza- tion unit • cup/segment grinding wheel Ø: 450 mm • carriage speed 0–60 m/min programmable • segment head Ø: 450 mm • good access to the grinding chamber of the • grinding motor: 30 kW, 1 000 rpm carriage through lateral opening

• cutting speed: up to 50 m/s   • four-axle digital CNC control • vertical guide with precision roller linear 1 guidance • X-axis (carriage) with gear rack in con- nection with servomotor and gear unit • continuous, programmable adjustment • Z-axis (moving of the vertical feed / • automatic interval-controlled central grease plunge grinding) on preloaded ball gea- lubrication with control and fault indication ring spindle by a brushless AC servo- • designed for wet grinding motor, stroke app. 200 mm (7.87") • A'- + A-axis (tool carrier block), swiveling Examples of use (pictures) at grinding angle (option) 1. Access to change segments from the front • coolant supply through hollow shaft in the (picture 1) grinding spindle for internal cooling of the 2. Precision vertical surface grinding machine grinding segments of the series FS-CNC (picture 2) • A-axis/A'-axis: two servomotor gearbox 3. Mounting of grinding segments / segment units, each at the end of the shaft for pre- head (picture 3) cise angle adjustment or with servomotor 4. Surface grinding machine FS-CNC with • carriage driven by precision servo gearbox double version of the A-axis (picture 4) and rack 5. Version with fixed magnet (picture 5) • double-sided cover with bellows • 45 mm precision roller linear guide for the carriage • vertical carriage with ball screw and servo- motor

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ROTARY TABLE GRINDING MACHINES RTS-CNC Surface grinding • cutting speed: up to 50 m/s • two-axle CNC control Grinding machine with vertical adjustable • rotary table speed, variable up to 18 revolu- spindle for efficient surface and angle grinding tions/min in continuous production of pocket knife com- ponents, hand tools and similar parts. • CNC vertical axes • mechanical plates or electromagne- On principle, a distinction is drawn between tic pole plates 600–1,200 mm Ø three different series depending on the grin- • mechanical measuring sensor to gauge ding wheel diameter, the table diameter and the grinding wheel and to adapt to the wear the spindle drive. (option: motor adjustment with digital indi- cation) • grinding wheel-Ø: 600 mm • adapter flange for grinding wheel Ø 600 mm

• grinding motor: 37–55 kW   1 Examples of use (pictures) 3 1. Grinding machine RTS3/2-CNC with device for grinding mower knife edges with auto- matic loading/unloading and rotary module (picture 1) 2. Rotary table grinding machine of the RTS2- CNC series for surface grinding of machine knives for the textile industry; measuring probe with direct measuring system also for interrupted grinding (picture 2) 3. Rotary table grinding machine RTS3-CNC with six single magnets for surface grinding of coils (picture 3)

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ROTARY TABLE GRINDING MACHINES RTS3/2-CNC Economic surface grinding of machine • cutting speed: up to 50 m/s knives • four-axle CNC control • CNC vertical axis Heavy-duty grinding machine with up to two vertically adjustable spindles for economical • 1 000 mm electromagnet with segment surface and bevel grinding, e. g. on large ma- pole pitch for continuous surface grinding chine knives and agricultural knives in continu- • CNC adjustment of the measuring control ous operation • automatic loading/unloading with magazine • two grinding wheels with 600 mm Ø storage

• two 55 kW grinding spindles   1 Examples of use (pictures) 3 1. + 2. Grinding machine RTS3/2-CNC with device for grinding mower knife edges with automatic loading/unloading and rotary module (picture 1 and 2) 3. Surface grinding of mower blades with ro- tary table grinding machine RTS3/2-CNC (picture 3) 4. Surface grinding on agricultural knives with rotary table grinding machine RTS3- CNC with horizontal rotary axis for loading (picture 4)

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ROTARY TABLE GRINDING MACHINES DRG-CNC Flat grinding

Two-axis CNC double rotary table grinding ma- chine with high productivity for flat or tapered surfaces on a variety of workpieces, such as 4 5 table knives, wood chisels, insides of shears, spatulas, connecting rods or machine knives

1   • grinding table Ø: up to 450 mm 6 • spindle drive: up to 45 kW • cutting speed: up to 50 m/s • two-axle CNC control • vertical and horizontal CNC axis • possibility to set nominal part dimensions on the circular tables with up to four inde- pendent gage controls • electromagnets with interchangeable pole plates • mechanical, hydraulic or pneumatic clam- ping fixtures • table diameter 500–800 mm (20″–32″) • automatic interval-controlled grease cen- Example of use (pictures) tral lubrication with monitoring and fault 1. Rotary table grinding machine of the series indication DRG-CNC (picture 1) 2. Grinding of kitchen spatulas (picture 2) 3. Flat grinding of machine knives (picture 3) 4. Grinding of sports knives (picture 4) 5. Grinding of connecting rods (picture 5) 6. Grinding of the inner sides of shears with additional heel (picture 6)

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FLAT BEVEL GRINDING MACHINES PH/PB-CNC Grinding of multi-edged machine knives Equipped with a cup wheel, the PH/PB-CNC achieves a smooth grinding and/or serration CNC-controlled five-axis grinding machine for on machine knives. grinding and serrated grinding of multi-edged machine knives

The grinding machines of the PH/PB-CNC se- ries can be designed both as a face grinding machine with a cup wheel and as a peripheral grinding machine with a peripheral grinding

wheel.   1 • grinding length: up to 450 mm • cup grinding wheel Ø: 450 mm • spindle drive: 22 KW • cutting speed: up to 50 m/s • five-axle CNC control • smooth grinding or serrated grinding • tactile measuring system with compensa- tion of the grinding wheel wear

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Circumferential, longitudinal and deep If the workpiece is processed in a deep grin- grinding processes ding process, a large amount of material can be removed and a good surface quality can be Peripheral grinding machines achieve surface, achieved. bevel or serrated grinding on workpieces. The effective area of the longitudinal grinding is the Peripheral grinding wheels are used if a ser- circumference of the grinding wheel. rated or scalloped grinding and/or a pointing toothing on machine knives is to be achieved Depending on the workpiece and the desired material removal rate, the grinding process is

either pendulum or creepfeed grinding.   • bakelite or ceramic-bonded grinding wheel with 200–600 mm Ø • cutting speed 30–65 m/s • feed rate 100–2 500 mm/min • Ø Q'w = 3–12.5 [mm³/(mm s)].

• max. Q'w = 35 [mm³/(mm s)]. z. B. 5,0 mm z. B. 4,95 mm • max. cutting weight 16,5 g/s

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PROFILE AND SIDE GRINDING MACHINES WSL1-CNC UND BG1/RH/NT2-CNC Surface and hollow grinding on • CNC-controlled peripheral grinding machine cutting edges of workpieces of the series WSL1-CNC with two CNC axes and diamond dressing roll Processing cell for grinding cutting edges of • automatic, camera-controlled feeding for workpieces bulk material (Berger Feeder) • CNC-controlled flat bevel grinding machine • additional spindle for hollow grinding with of the series BG1/RH/NT2-CNC radius < 30 mm

1   Examples of use (pictures) 3 1. Processing cell with feeding of bulk mate- rial via Berger Feeder (picture 1) 2. Measurement of the workpiece position via camera measuring table (pictures 2) 3. Peripheral grinding machine of the series WSL1-CNC with two CNC axes (picture 3) 4. Measurement of the position of workpieces via camera measuring system (picture 4)

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PERIPHERAL GRINDING MACHINES PB/PB-CNC Serrating and deburring of • grinding wheel Ø: up to 400 mm machine knives • grinding wheel width: up to 130 mm

CNC-controlled peripheral grinding machine • spindle drive: 11–18 kW with three axes for serrated grinding and debur- • cutting speed: up to 50 m/s ring of machine blades with a maximum length • three to five-axle CNC control

of 450 mm   • dressing device with driven diamond dres- 1 sing roll 3 • robot loading with feeding via stacking ma- gazine • brushing station for deburring the gear teeth • X-axis travel (feed axis up to 640 mm) • dresser of the grinding wheel with diamond- coated dressing roller or diamond fleece • frequency converter for stepless control of the spindle speed • automatic interval-controlled central grease lubrication with monitoring and fault indica- tion • automatic loading / unloading with robot 4 (option)

Example of use (pictures) 1. Peripheral grinding machine PH/PB3-CNC (picture 1) 2. + 3. Serrated grinding of machine knives with PH/PB3-CNC (pictures 2 and 3) 4. Peripheral grinding machine PH/PB-CNC with swivel axis for cross toothing on hand saws (picture 4)

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PERIPHERAL GRINDING MACHINES WS-CNC Serrated grinding, plunge grinding and • grinding wheel Ø: 300 mm through-feed grinding • grinding wheel width: up to100 mm

CNC peripheral grinding machine with up • spindle drive: up to 11 kW to three axes for infeed grinding of gears on • cutting speed: up to 45 m/s machine knives, blades, shears and similar • three- to five-axle CNC control shaped workpieces

1   • CNC control with display for operator gui- dance / programming of up to three axes 3

• horizontal movement of the grinding wheel

via servo motor and preloaded ball screw

• simple, direct programming via the input of parameters / workpiece data

• interval-controlled dressing of the grinding

wheel via diamond-coated profile roller or

programmable single-grain diamonds

• automatic compensation of travels after each dressing cycle as well as adaptation to preset peripheral speed via frequency converter integrated in the control system • programmable positioning at straight grin- ding wheel Examples of use (pictures) • grinding wheel mounted on cross ta- 1. + 2 Serrating of machine knives with ble for plunge grinding and through- WS4-CNC (pictures 1 and 2) feed grinding (WS6-CNC) 2. Production of saws, cross toothing with ad- ditional vertical and swivel axis (picture 3)

30 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES  31 back to content PERIPHERAL GRINDING MACHINES WSM-CNC Serrated and scalloped grinding • grinding wheel width: up to 360 mm (14″) • grinding wheel Ø: 300 mm CNC peripheral grinding machine with up to • spindle drive: 18 kW three axes for infeed grinding of gear teeth on knives (e.g. bread or steak knives), scissors, • cutting speed: up to 45 m/s

machine knives or comparable workpieces • up to three-axle CNC control   • CNC controlled with display of all operating • automatic compensation of the travels information on monitor screen after each dressing cycle as well as adap- tation to the preset circumferential speed • horizontal wheel motion by AC servo motor via frequency converter integrated in the driven by preloaded precision ball screw control • simple, direct programming via the input of • vertical workpiece movement to the grin- parameters/workpiece data ding wheel possible • interval-controlled dressing of the grinding wheel via diamond-coated profile roller, dressing roller made of tool steel or pro- grammable single grain diamond • programmable movement of the workpiece on a straight grinding wheel (e.g. steak knives) using a six-axis robot

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PERIPHERAL GRINDING MACHINES WSL-CNC Scalloped and serrated grinding Depending on the application, the following se- ries are offered for the machining of machine The grinding station of the WSL-CNC series knives: is used as a module in different machines to • WSL2-CNC (p. 36 f.) achieve a scalloped and serrated grinding. 2 • WSL3-CNC (p. 38 f.) Fixed single point dresser for The grinding machines of the WSl-CNC series • WSL4-CNC (p. 40 f.) achieve any desired cutting edge angle by inter- programmable dressing polation of the Y and Z axes. • WSL5-CNC (p. 42 f.)

• BWSL-CNC ­   3 Clamping for toothing of cir- cular knives up to 200 mm Ø

4 Swiveling of the grinding sta- tion to achieve relief grinding, additional clamping device for larger relief

34 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES  35 back to content PERIPHERAL GRINDING MACHINES WSL2-CNC Scalloped and serrated grinding on • grinding length: up to 750 mm hedge trimmer blades • grinding wheel Ø: 450 mm

CNC peripheral grinding machine for proces- • grinding wheel width: 120 mm sing hedge shear blades up to 750 mm • spindle drive: 22 kW • cutting speed: up to 45 m/s The processing cell is equipped with two two- axis peripheral grinding stations of the WSL2- • two-axle CNC control CNC series as well as a loading and unloading

robot.   • CNC feed axis for displacing/indexing the hedge trimmer blades with 750 mm stroke • CNC axis for programmable cutting angle adjustment from 30°–45 • Grinding spindle with precision-bearing shaft and mounting flange for grinding wheels • dressing/profiling the grinding wheel with diamond-coated profile roller 80 mm Ø; drive 1.5 kW • dressing intervals programmable with auto- matic compensation of wheel wear • grinding station each equipped with a verti- cal slide for grinding movement and a hori- zontal slide for moving against workpiece/ profile roll • loading and unloading via robot

36 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES  37 back to content PERIPHERAL GRINDING MACHINES WSL3-CNC Knives with smooth, scalloped or • up to seven axes (four CNC axes for moving pointed serrated cutting edge the peripheral grinding wheel) • magnetic clamping table for long knives up CNC grinding machine with up to seven axes to 1 800 mm length for processing knives up to 1,800 mm long and • double-sided CNC angle adjustment of the for serrating circular knives up to 250 mm dia- magnetic clamping table meter (optional) • direct drive of the grinding wheel • grinding length: up to 1 800 mm • diamond dresser • grinding wheel Ø: 450 mm: (usable up to 250 mm Ø) • orthogonal creepfeed grinding or plunge- cut grinding • grinding wheel width: up to 100 mm • grinding spindle on CNC turntable for relief • special motor 15 kW with precision-bearing grinding of gears shaft and mounting flange for grinding wheels • programmable, constant peripheral speed with decreasing pulley diameter 30–45 m/s

• cutting speed: up to 45 m/s   Scalloped and serrated grinding • dressing/profiling of the grinding wheel with diamond-coated profile roller 140 mm Ø, drive 0.75 kW; dressing intervals pre-pro- grammable with automatic compensation of wheel wear • dressing with single grain diamond • grinding station each equipped with one vertical slide and one horizontal slide: • Y axis = vertical slide for grinding move- ment • Z axis = horizontal slide for moving against workpiece/profile roll • CNC-axis traversing via AC servo motor with preloaded ball screw spindles • achieving any desired cutting edge angle by interpolation of Y and Z axis • automatic interval-controlled central grease lubrication with monitoring and fault indica- tion

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PERIPHERAL GRINDING MACHINES WSL4-CNC Serrated grinding – • cutting speed: up to 45 m/s straight or with relief grinding • five CNC axes

Double-sided CNC grinding machine for serra- • dressing device with diamond dressing wheel for individual tooth profiles (rapid ting machine knives with relief grinding prototyping) • grinding length: up to 600 mm • vertical and horizontal axis with CNC ad- • grinding wheel Ø: 450 mm justment for relief grinding • grinding wheel width: 110 mm • spindle drive: 18.5 kW

1   • grinding table with additional X-axis in 30° inclined bed design 3 • encapsulation of the milling station • grinding station series WSL-CNC • grinding of knives with straight or serrated cutting edge at programmable angle • dressing of grinding wheels for frequently used tooth profiles with dressing device for mounting diamond-coated dressing rolls • optionally with two-axis CNC dresser for user-friendly programming of tooth forms via menu • this allows fast grinding of almost any tooth profile on long knives, even for small Examples of use (pictures) quantities or prototypes (especially pointed 1. Peripheral grinding machine of the series or wavy gears) WSL4-CNC for serrated grinding of machi- • serrating of circular knives possible by ad- ne knives (picture 1) ditional rotation axis (C axis) 2. Serrated grinding of machine knives with re- • additional B axis (± 20°) for generating a lief grinding (pictures 2) relief grinding (WSL3-CNC) 3. Peripheral grinding machine of the series WSL4-CNC with encapsulation

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PERIPHERAL GRINDING MACHINES WSL5-CNC Serrated grinding of machine knives • grinding length: up to 650 mm • grinding wheel Ø: 500 mm The presented peripheral grinding machine is • grinding wheel width: 130 mm designed for serrated grinding of saw blades with a length of up to 650 mm. • spindle drive: 90 kW • cutting speed: up to 50 m/s • five-axle CNC control

1   • workpiece length: 150–650 mm 3 • workpiece thickness: 0.4–1.3 mm • grinding station with one vertical slide, two horizontal slides, one rotational axis -40°–0° and one axis for programmable adjustment of the coolant nozzle • exchangeable dressing system • automatic central lubrication system • coolant supply with programmable CNC height adjustment • loading and unloading via robot • loading and unloading magazines for saw blades

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PERIPHERAL GRINDING MACHINES RVZ-CNC Serrated grinding on circular and cutter • workpiece Ø: up to 1 000 mm knives • grinding wheel Ø: 300 mm • spindle drive: 7.5 kW CNC-controlled serrated grinding machine for processing circular and cutter knives as well as • cutting speed: up to 45 m/s for grinding panel seats on circular saw bodies • four-axle CNC control for the programming of the machine and the tooth profile

1   • diamond roll and single grain dresser 23 • following the contour on straight grinding wheel • automatic diameter measurement • serrated grinding of cutter knives (option) • grinding the panel seats on the base bodies of circular saws in deep grinding • CNC servo motor gear unit • single point dresser • diamond Roller Dresser • grinding spindle with precision-bearing shaft • grinding station designed for wet proces- Examples of use (pictures) sing 1. Serrated grinding of circular knives (picture 1) 2. + 3. Peripheral grinding machine RVZ-CNC (pictures 2 + 3) 4 Different geometries (picture 4)

44 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES  45 back to content ROTARY TABLE GRINDING MACHINES RMS-CNC Cutting edge grinding of round and • workpiece Ø: up to 1 000 mm cutter knives with arc grinding method • grinding wheel Ø: 400 mm • spindle drive: up to 11 kW CNC grinding machine with three or four axes for grinding cutting edges and chamfers on • cutting speed: up to 45 m/s circular knives using a cup wheel for high chip • three-axle CNC control removal and programmable angle setting for

subsequent machining   • rotation speed of the workpiece adjustable 100–240 rpm • headstock with cup grinding wheels with 450 mm Ø • tactile stone wear compensation • automatic diameter measurement • simple, direct programming with input of workpiece data/parameters • CNC controlled adjustment of the angle range 0°–30° with hydraulic clamping • automatic wear compensation of the grin- ding wheel • clamping of workpieces via permanent magnet, electromagnet, mechanical or pneumatic device

46 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES  47 back to content 1 Mounting of the circular knives with additional seventh axis integrated in robot control

RUNDTISCH-SCHLEIFMASCHINEN RMS-CNC / RSP Cutting edge grinding of circular knives • headstock with cup grinding wheels with with arc grinding method 450 mm Ø • tactile stone wear compensation Robot with grinding spindle and two-axis CNC • automatic diameter measurement grinding machine for cutting edge grinding on 2 circular knives Production cell with four-sided

safety fence   3 Measurement of the diameter for regrinding

4 Different models

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ROTARY TABLE GRINDING MACHINES VR-CNC Cutting edge grinding of circular knives • cutting speed: up to 50 m/s with arc grinding method • two-axle CNC control • tactile measuring system for stone wear CNC grinding machine for grinding cutting edges compensation of the cup grinding wheel and bevels on circular knives with a maximum diameter of 400 mm using a cup wheel for high • polishing station for polishing the cutting edge chip removal • camera measuring system for measuring • workpiece Ø: 50–400 mm the outer diameter and residual thickness • grinding wheel Ø: 300–400 mm of the cutting edge

• spindle drive: 15 kW • robot loading and unloading system (option)   • simple, direct programming with input of 1 workpiece data/parameters 3 • manually adjustable cutting edge angle up to 45° • automatic grinding wheel wear compensa- tion • clamping of workpieces via permanent magnet, electromagnet, mechanical or pneumatic devices • rotation speed of the workpiece adjustable • robot-controlled loading system with stack magazine • simultaneous, additional deburring possible with bevel grinding

Examples of use (pictures) 1. Grinding machine VR2/NT-CNC (picture 1) 2. Rotary table grinding machine VR0-CNC combined with chamfer polishing machine FPV for bevel grinding and polishing (picture 2) 3. Pick-up of the workpiece by means of a clamping (picture 3) 4 Arc grinding of circular knives (picture 4)

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PERIPHERAL GRINDING MACHINES RFS-CNC Surface and bevel grinding of circular • linear motor in main axis for oscillating the knives workpiece spindle • direct probing measuring system for thick- CNC peripheral grinding machine with six axes ness measurement or tactile measuring sys- for the grinding of surfaces, cutting edges and tem for stone wear compensation 4 5 contours on circular knives, saw blades or • automatic grinding wheel radio control blanks with oscillating or plunge grinding pro- • CNC diamond roll dresser (optional) cess • horizontal movement of the grinding wheel • workpiece Ø: 50 mm (RFS2-CNC) up to via AC servo motor with preloaded ball screw 1 100 mm (RFS5-CNC) • automatic compensation of the travels after • grinding wheel Ø: up to 600 mm each dressing cycle and adaptation to the • spindle drive: up to 75 kW preset circumferential speed via frequency converter integrated in the control • cutting speed: up to 63 m/s

• up to three-axle CNC control   • simple, direct programming via input of Examples of use (pictures) 1 workpiece data/parameters 1. Surface grinding of circular knives with RFS- • processing of subsequent grinding in one CNC (picture 1) clamping in connection with an additional grinding axis 2. Peripheral grinding machine RFS2-CNC with robot loading and unloading (picture 2) • circular knives taken up in rotating workpie- ce holder and held by mechanical clamping 3. Peripheral grinding machine RFS2-CNC devices via permanent magnet or electro- with cleaning system (picture 3) magnet 4. Peripheral grinding machine RFS3-CNC • rotating workpiece holders infinitely variable with robot loading and unloading (picture 4) via servo motor or frequency converter 5. Peripheral grinding machine RFS4-CNC with • different dressing systems, permanent or robot loading and unloading (picture 5) interval controlled • processing of interrupted grinding in con- nection with measuring system "Marposs"

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PERIPHERAL GRINDING MACHINES RFS/RT-CNC Surface and edge grinding of circular knives

Four-axis CNC grinding machine for surface and edge grinding on circular knives with up to 4 5 300 mm diameter with high concentricity and surface grinding accuracy • workpiece Ø: up to 500 mm • grinding wheel Ø: up to 500 mm • spindle drive: up to 22 kW • cutting speed: up to 63 m/s

• four-axle CNC control   • workpiece spindle driven on rotary table 1 with high-precision torque motor • linear motor in main axis for oscillating the workpiece spindle with magnetic or mecha- nical clamping • direct probing measuring system for thick- ness measurement of circular knives • automatic grinding wheel radio control • high concentricity and surface grinding ac- curacy • magnetic clamping, mandrel with clamping plate or tie rod with clamping plate • needle nozzles with KSS pressure cooling > 9 bar Examples of use (pictures) 1. Peripheral grinding machine of the series RFS2/RT-CNC (picture 1) 2. Pick-up of workpiece (picture 2) 3. + 4 Machine assembly with workpiece/ tool (pictures 3 + 4) 5. Drying of circular knives (picture 5)

54 GRINDING MACHINES FOR SINGLE WORKPIECES GRINDING MACHINES FOR SINGLE WORKPIECES  55 back to content ROBOTIC GRINDING AND POLISHING SYSTEMS

GRINDING AND POLISHING The Berger Gruppe offers solutions for robotic processing of workpieces with different sizes and WITH ROBOTIC TECHNIQUE geometries.

The focus is on partly standardized robot cells with

different conceptual approaches.   Depending on the nature of the workpiece, the robotic cell is equipped with different proces- sing stations. Either the workpiece or the tool can be guided by the robot.

If the tool is robot-guided, the workpiece can be aligned via CNC axes so that all-round machi- ning is possible without additional changeover time. • robot grinding and polishing stations either integrated into existing production lines or designed as separate cells • standard interfaces to all common robot manufacturers such as ABB, KUKA, Stäubli and Fanuc • programming in touch-in mode or with a CAD/CAM interface • integration of measuring systems for com- pensation of workpiece tolerances in posi- tion and dimensions • various machining stations with different tools (e.g. grinding belts, grinding stones, po- lishing wheels) available

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ROBOTIC GRINDING AND POLISHING SYSTEMS

Resharpening / sharpening of circular or crush cut knives

The modular RSP/2S robot grinding station shown here is designed for processing circular knives with a diameter of 70 to 200 mm.

The outer diameter is measured with a laser measuring station.

1   3 4

• Single-sided machining station with dia- Examples of use (pictures) mond grinding wheel of the P3/T series (see also machining stations p. 69 f.) 1. Processing station P3/T (picture 1) • Stacking via stacking magazine with subse- 2. Robotic cell RSP/2S for processing circular quent deposit on mandrel knives (picture 2) • Workpiece spindle for holding the circular 3. Stacking via stacking magazine (picture 3) blade for continuous after measu- 4. Workpiece spindle with workpiece (picture 4) ring the outside diameter

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ROBOTIC GRINDING AND POLISHING SYSTEMS

Serrating of circular knives A robot takes the workpiece from a stacking magazine, feeds it to the stations for machining The robot grinding station shown here is de- / measuring and deposits it in another stacking signed for serrated grinding and brushing of magazine. circular knives. 4 5

A peripheral grinding machine of the WS4-CNC series and a brushing station of the SM2 series are integrated in the robot cell.

1   • processing robot with vacuum robot gripper Examples of use (pictures) for picking up round knives up to 35 kg/piece • peripheral grinding machine WS4-CNC 1. Serrated grinding of circular knives with pe- ripheral grinding machine of the WS4-CNC • max. grinding width 100 mm series (picture 1) • grinding wheel Ø 300 mm 2. Robot feding of a circular knife (picture 2) • measuring station with probe to determine 3. Stacking magazine for circular knives with the outer diameter cylinder for lifting the workpiece (picture 3) • 2 vertical stacking magazines for holding 4. Measuring station to measure the outer dia- circular knives up to 1 000 mm Ø meter (picture 4) • magazine for holding round knives of 5. Processing station SM2 with two spiral 300 mm Ø with a stacking height of 500 mm. brushes (picture 5) • processing machine of the SM2 series for the reception of spiral brushes

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ROBOTIC GRINDING AND POLISHING SYSTEMS

Sharpening of machine knives

The modular RSP/2B robot grinding station shown here is designed for sharpening machine knives.

The robot cell consists of two belt grinding sta- tions and a processing robot. The workpieces

are provided by a conveyor belt.   1 3 4

• conveyor belt of 2 000 mm length for cor- Examples of use (pictures) rect positioning of the workpieces • separating and centering station 1. Robot processing cell for sharpening ma- chine knives (picture 1) • vertical bar magazine 2. Belt grinding station of the series BSS10 • processing and loading/unloading robot (picture 2) • parallel gripper for workpiece fixture inclu- 3. Conveyor belt for workpiece positioning ding 180° rotation module (picture 3) • two one-sided belt grinding stations of the 4. Robot gripper with 180° rotation module BSS10 series (picture 4)

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ROBOTIC GRINDING AND POLISHING SYSTEMS

Sharpening and polishing of The cell is equipped with three processing machine knife blades stations from the P3 series. A stacking ma- gazine is used for loading and separating the The robot cell shown is designed for sharpe- workpieces. The workpieces are deposited on ning and polishing machine knife blades and a rotary transfer magazine after processing. similarly shaped workpieces.

1   • indexing rotary table magazine, 1 200 mm Ø for 80 workpieces 3 • vertical stacking magazine for loading and separation of the workpieces • robot with stirrup bearing for measuring of new blades or position check in the gripper • three single-sided machining stations of the P3 series • cooling water system

Examples of use (pictures)

1. RSP/3P/1M robot processing cell for pro- cessing machine knives (picture 1) 2. Integration of three processing stations of the P3 series for sharpening and polishing the workpiece blades (picture 2) 3. Simulation via RobotStudio (picture 3)

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ACCESSORIES

3 4

PROCESSING STATIONS Various processing stations such as polishing and grinding stations or CNC controlled sharpening FOR ROBOTIC CELLS machines can be integrated into a robot cell and combined with each other.

.   Belt grinding stations BSS Examples of use (pictures) 1. One-sided belt grinding station BSS12 with Belt grinding stations of the series BSS are de- revolver head (picture 1) signed for use in robotic cells. 2. One-sided belt grinding station BSS14 with • pneumatic belt tensioner pressure control (picture 2) • belt breakage control 3. One-sided belt grinding station BSS20 with horizontal belt (picture 3) • preparation for customer provided suction 4. One-sided belt grinding station BSS22 with • preparation for connection 400 Volt/50 Hz, oscillating movement (picture 4) single control cabinet or central control point • minimum quantity cooling (optional) • robot control with 16 belt speeds pro- grammable (optional)

Model BSS10 BSS12 BSS14 BSS20 BSS22 Main control (kW) 4,0 4,0 4,0 4,0 4,0 Contact roll Ø (mm) 80–400 100–200 150–400 50–150 50–150 Contact roll width (mm) 10–130 10–130 10–130 10–130 10–130 Weight (kg) 150 180 350 200 200 Dimensions - Length (mm) 850 900 1 200 1 500 1 500 - Width (mm) 650 800 600 600 600 - High (mm) 2 100 2 100 2 100 1.500 1 500

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ACCESSORIES

Grinding and polishing stations

The Berger Gruppe offers grinding and polishing stations of various types. Polishing, grinding and belt grinding stations can be combined in a robo- tic cell. 3 4

Picture below: Polishing wheel change system in- tegrated in a robot grinding and polishing system

for hollow goods   Polishing stations P1 (picture 1) 5 • polishing wheel Ø: 500 mm • polishing width: 100 mm • drive: 5.5 kW, 750 rpm • optional with frequency converter

Grinding and polishing stations P3 (picture 2)

• grinding and polishing wheel Ø: 300 mm • wheel width: 100 mm

• drive: 3 kW, 2,800 rpm Polishing stations P3/T (picture 5) • spindle speed frequency controlled • mounting cup wheel, Ø 200 mm • drive 1.5 Kw; 1,400 rpm Polishing stations P5 (picture 3) • spindle speed frequency controlled • polishing wheel Ø: 500 mm

• polishing width: up to 300 mm Grinding stations SS1 (picture 4) • drive: 7.5 kW, 2,000 rpm • grinding with headstock • spindle speed frequency controlled • grinding wheel Ø: 450 mm (cup wheel) • spindle drive: as required 15–22 kW

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Cleaning systems As an alternative, the workpiece can also be placed in one position by the loading/unload- Berger grinding machines can be combined ing robot. Here the workpiece is cleaned and with various cleaning systems. The workpiece dried and then stacked in a sliding magazine. is positioned in the transport chain.

Cleaning and drying take place in different

stages.   Cooling systems Additionally can be installed:

In combination with Berger machines, a large • flow monitor for monitoring the coolant flow level number of different cooling water installations for grinding emulsion are offered. The design • magnetic switch (water stand-/stop) of these systems depends primarily on the re- • float switch for level monitoring quirements for water quantity, water pressure • cooling unit for constant temperature of and degree of purity. coolant

Use of different cleaning stages: • magnetic pusher • paper and/or fleece filter • ultra-fine filter

These components can be combined as requi- red. Depending on requirements, water reco- oling must also be taken into account.

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ACCESSORIES

Magazine systems A wide range of magazine systems is available such as: Robot cells as well as machining cells with CNC grinding machines can be equipped with • indexing rotary magazine different feeding and magazine systems for • indexing chain magazine for conical material 7 8 stackable and non-stackable workpieces. • indexing vertical rotary magazine

The design of the loading/unloading magazi- • circulating bar magazine nes depends on requirements such as • guidance of bulk material via • required magazine capacity • circular conveyor • shape of the workpieces • Berger Feeder • variety of workpiece shapes • integration into previous production stage

• orientation of the workpieces   5. Chain magazine: feeding of wrenches to 1 2 Examples of use (pictures): rotary table grinding machine HDS3-CNC 1. Berger Feeder: disordered feeding (here of (picture 5) garden shears parts) via conveyor belt in 6. Indexing rotary table magazine: unloading connection with camera system (picture 1) magazine for non-stackable workpieces – (see also p. 26: feeding of tongs and pliers in this case garden shears parts (picture 6) with Berger Feeder) 7. Stacking magazine: for flat material (here 2. Circulating chain magazine: loading maga- garden shears parts), loading capacity from zine for tongs and pliers (picture 2) 500–2,000 mm, adjustable length stops 3. Circular conveyor: disordered feeding of (picture 7) workpieces (picture 3) 8. Step feeder: feeding of screwdrivers for pro- 4. Schäfer box: removal of the workpieces cessing in the roller impact centre (picture 8) (here shears and scissors) from Schäfer box (picture 4) 3 4

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ACCESSORIES

Dressing systems Examples of use (pictures)

Depending on the machine type or the applica- 1. Two-axis CNC dresser for profiling the tion, there are different dressing systems for grinding wheel (e.g. with RFS-CNC, p. 52) (picture 1) grinding wheels or polishing discs, such as the 7 8 two-axis CNC dresser for profiling the grinding 2. Driven diamond-coated dressing device for wheel or the diamond-coated dressing roller consistent bolster quality (e.g. BG-CNC) (picture 2) for peripheral grinding machines of the WSM2- CNC. 3. Diamond-coated dressing roll designed for peripheral grinding machines of the WSM2- CNC series (picture 3) 4. Movable single grain/contour dresser (e.g.

WSM2-CNC) (picture 4)   1 2 Workpiece holder 9 The Berger Gruppe offers a wide range of me- chanical, hydraulic and pneumatic clamping devices for grinding and polishing machines for individual workpieces.

Examples of use (picture)

5. Clamping device with additional clamping finger (picture 5) 6. Pressure roller programmable via CNC con- trol (picture 6) 7. Electromagnetic workpiece holder integ- rated in flat bevel grinding machine of the 3 4 series BG-CNC (picture 7) 10 8. Workpiece holder for side surface grinding machines of the BG-CNC series (picture 8) Full enclosure

The Berger Gruppe offers full enclosure for flat bevel grinding machines, peripheral grinding machines and glazing machines. (pictures 9 + 10)

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ROBOTIC PROCESS TECHNOLOGY / AUTOMATION

INTEGRATION AND Integration of production processes AUTOMATION Various production processes can be integrated into a robotic cell, such as deposition , bending presses, and countersinking, har-

dening systems, painting systems and packaging  machines.  Measurement technology 2 Development of standard measuring systems for different applications for the acquisition and compensation of automated dimensions/ contours or position detection • measuring systems for automated contour detection and measurement of workpieces (picture 1) • separation and position detection on mea- suring table (picture 2) • evaluation software for position detection (picture 3)

3

76 ROBOTIC PROCESS TECHNOLOGY / AUTOMATION ROBOTIC PROCESS TECHNOLOGY / AUTOMATION  77 back to content BIN PICKING

Handling of non-sorted workpieces

A camera system with high-resolution cameras – in this case from Keyence – detects the position of the workpieces, which are lying disorderly in a skeleton box or Schäfer box, and passes the data

to the handling robot.   • provision and feeding of disordered work- pieces with bin-picking from two KLT boxes • docking stations for KLT containers with re- peatable positioning via stops • bin-picking robot ABB • double gripper with two magnetic grippers with adjustable magnetic force for remo- ving workpieces from KLT box • 3D robot vision CV-X (Keyence) • camera-controlled turning and centering station • 3D position detection via camera measu- ring system with high-resolution cameras • automatic calculation of the optimal robot path • special robot gripper depending on the workpiece • loading robot with adjustable magnetic force for loading and unloading the grinding machine and loading the cleaning and dry- ing station

78 ROBOTIC PROCESS TECHNOLOGY / AUTOMATION ROBOTIC PROCESS TECHNOLOGY / AUTOMATION  79 back to content 2

STEEL STRIP GRINDING MACHINES

CUTTING EDGE GRINDING Series BSM-CNC and BGM-CNC ON STEEL STRIPS One or two-sided smooth grinding of cutting edges

on steel strips   • smooth grinding of cutting edges with 1 angles from 0–30° 3 • single or double sided grinding • camera measurement of the ground sec- tion width • laser strip height measurement • CNC dressing systems with stationary and driven tools

Examples of use (pictures) 1. One-sided steel strip grinding station of the series BSM3000/E-CNC 2. Steel strip grinding machine of the BSM- CNC series designed for steel strip grinding for the production of pencil sharpener bla- des 3. Breaking unit with sliding magazine

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STEEL STRIP GRINDING MACHINES BSM3000/E-CNC One-sided processing

The one-sided grinding station is used e. g. for grin- ding pencil sharpener blades, curette bands and machine blades. 3 4 • grinding wheels with 300 mm Ø mounted on a double-sided precision spindle • grinding wheel width max. 240 mm • used for pre-grinding, e.g. for high material re-

moval rates on one side of the strip   Example of applications (pictures) 5 1. Straight finish grinding for the production of curettes (picture 1) 2. Serrated grinding with CBN grinding wheel to produce cutting rules (picture 2) 3. Scalloped grinding for the production of machine knives by means of a profiled grin- ding wheel (picture 3) 4. Straight finish grinding for the production of industrial blades (picture 4) 5. Straight finish grinding for the production of pencil sharpener blades (picture 5) 6. Steel strip grinding station of the series BSM3000/E-CNC (picture p. 82)

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STEEL STRIP GRINDING MACHINES BSM3000/D-CNC Double-sided processing

The double-sided grinding station processes cut- ting lines, technical blades, scalpel blades and si- milar shaped workpieces. • integration of two opposite grinding spindles • both spindles equippable with six grinding wheels of 20 mm width • spindles for plunging mounted offset against each other • effective grinding width of 120 mm per side (or 240 mm in total) • used for finish grinding on pre-ground or pre-

chamfered strips (abrasive grit 150–320)   1 Examples of use (pictures) 1. Straight finish grinding of cutting edges for the production of industrial blades (picture 1) 2. Straight finish grinding of cutting edges for the production of cutting lines (picture 2)

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STEE STRIP GRINDING MACHINES BSM1500/TT-CNC Straight micro-grinding • design of the grinding spindle for up to 8 000 rpm, encoder for position synchro- The BSM1500/TT-CNC machining station is nization, precision spindle of the highest used for deburring finely ground blades. The quality steel strip grinding machine works with six • spindle bearing arrangement: hydrostatic or CNC axes. roller bearing • programmable, constant peripheral speed Core application of the station is the micro- with decreasing grinding wheel Ø grinding of cutting rules with grits up to 1 200. • peripheral speed: 20–65 m/s • mounting of grinding wheels with 150– 250 mm Ø • motorized angle adjustment: 0–35°. • electronic synchronization of the spindles • grinding width/wheel width: max.: 150 mm with AC servo technology • spiral grinding wheel Ø: 150–250 mm • additional vibration damping through mi- neral cast filled machine body for precision

grinding of highest quality  

• AC servo motor/drive control unit for syn- Examples of use (pictures) chronisation of the grinding wheels, max. synchronous deviation 2° at 8,000 rpm 1. Steel strip grinding plant consisting of two grinding stations BSM3000/E-CNC, one • central lubrication grinding station BSM3000/D-CNC, one • design for wet machining with grinding grinding station BSM1500/TT-CNC, one de- emulsion coiler, one recoiler, two camera measuring systems and one laser measuring system • mounting of guides made of carbide or with (picture 1) carbide inserts 2. Deburring of steel strip for the production • integration of different dressing systems of precision knives for the food industry for profiling the grinding wheels possible (picture p. 86)

86 STEEL STRIP GRINDING MACHINES STEEL STRIP GRINDING MACHINES  87 back to content STEEL STRIP GRINDING MACHINES BDG1500-CNC Squeegee edge grinding

The BDG1500-CNC series steel strip grinding system consists of up to five vertical strip grinding stations and is designed for the production of doctor blades and similarly shaped workpieces.

It grinds a bevel on both sides and a straight edge grin-

ding with 90° to the workpiece.  

• cutting speed: up to 50 m/s • design for wet machining with grinding emulsion • pull-through speed: 5 m/min • central lubrication • CBN cup wheel Ø: 125 mm • direct measuring system integrated in the • precision-bearing grinding motor spindle guides of Z- and Y-axis driven by a special motor • frequency converter for programming the spindle speed

88 STEEL STRIP GRINDING MACHINES STEEL STRIP GRINDING MACHINES  89 back to content STEEL STRIP GRINDING MACHINES BSM3000/2E/BS-CNC Scalloped and serrated grinding of • serrated grinding on steel strips with angles steel strips of 0–30 • camera measurement of the serration The presented steel strip grinding machine is • camera strip height measurement designed for scalloped and serrated grinding of steel strip. • CNC dressing systems with stationary and

driven tools   • recoiler with spool plate Ø 1 250 mm • two single-sided grinding stations of the BSM3000/E-CNC series • deburring station BSM3000/SP-CNC • strip drying • camera and laser measuring system • strip pull-through system • cooling water supply • central lubrication

90 STEEL STRIP GRINDING MACHINES STEEL STRIP GRINDING MACHINES  91 back to content 2 3

STEEL STRIP GRINDING MACHINES BSM1500/TTGB-CNC Gothic arch grinding of razor blade • gothic arch in the cutting area with con- strips tinuous angle progression from 6°–8° to 12°–15° The presented steel strip grinding machine • grinding spindle with high-precision hydro- achieves a gothic arch on cutting edges of static bearing 4 5 steel strip. • CNC dressing system on machine • grinding of steel strip with 0.075–0.1 mm

thickness (razor blade strip)   • mounting of spiral grinding wheels with • central lubrication 1 150–250 mm Ø • design for wet machining with grinding • electronic synchronization of the spindles emulsion with AC servo technology • mounting of carbide guides • additional vibration damping through mi- • integration of different dressing systems neral cast filled machine body for precision for profiling the grinding wheels possible grinding of highest quality • design of the grinding spindle for up to Examples of use (Bilder) 8 000 rpm, encoder for position synchro- nization, precision spindle of the highest 1. Steel strip grinding line of the series quality BSM1500/TTGB-CNC for grinding razor blades (picture 1) • spindle bearing arrangement: hydrostatic 2. Cleaning station for metal strips (Bild 2) • programmable, constant peripheral speed with decreasing grinding wheel Ø 3. Dryer integrated into a cleaning station (picture 3) • peripheral speed: 20–65 m/s 4. Camera measuring system for measuring • grinding width/wheel width: max. 150 mm the strip height (picture 4) • spiral grinding wheel Ø: 150–250 mm 5. Gothic arch grinding on razor blade strips • AC servo motor/drive control unit for syn- (picture 5) chronization of the grinding wheels, max. synchronous deviation 2° at 8 000 rpm

92 STEEL STRIP GRINDING MACHINES STEEL STRIP GRINDING MACHINES  93 back to content STEEL STRIP GRINDING MACHINES SVZ-CNC Serrated grinding simultaneously on The line consists of two vertical decoilers, a up to 44 multiple strips steel strip grinding station SVZ-CNC and a re- coiler. The grinding machine of the SVZ-CNC series • grinding width: 120 mm achieves serating on metal strips. • grinding length in package: 66 mm On the machine shown here, up to 44 strips • max. strip width: 30 mm with a maximum strip thickness of 1.5 mm are • grinding wheel Ø: 500 mm

processed simultaneously.  

Four CNC axes: • diamond-coated profile roll, bearings on both sides of the dressing roll • Z-axis: horizontal axis for the grinding move- ment, drive with linear motor and direct mea- • precision-bearing shaft with 30 kW main suring system for highest precision drive • Y-axis: vertical axis for moving in the direc- • pre-programmable dressing intervals with tion of the workpiece, drive with ball screw automatic compensation of the grinding and servo motor wheel wear • C-axis: programmable axis for a relief grin- ding from 0°–18° • X-axis: cycle feed of the strip, drive with li- near motor and direct measuring system for highest precision

94 STEEL STRIP GRINDING MACHINES STEEL STRIP GRINDING MACHINES  95 back to content BANDSTAHLSCHLEIFMASCHINEN BSM500/HK-CNC Plunge grinding and polishing leather wheels in a second, similarly con- structed processing station The processing station BSM500/HK-CNC is • constant polishing result ensured by in- specially designed for grinding and polishing of telligent pressure control of the polishing hook blades. wheels • double-sided grinding operation with four • automatic feeding of the polishing agent grinding units, each arranged at different grinding angles • definition of the grinding wheel geometry via dressing unit with diamond-coated rolls

• polishing of the cutting edge using felt or   • main engine: 4 × 2.6 kW 1 • frequency converter: 4 × 4 kW for pro- grammable, constant peripheral speed with decreasing grinding wheel Ø 30–50 m/s • dressing motor: 4 × 0.8 kW • one-sided precision spindle bearing arrange- ment • central lubrication • designed for wet processing with grinding emulsion or for use of polishing paste • breaker with sliding magazine (picture 1) • horizontal decoiler plate (picture 2)

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ACCESSORIES

FOR STEEL STRIP GRINDING MACHINES

BREAKERS The breaking machines can be integrated into existing steel strip grinding plants or used as a

separate breaking unit with decoiler.   1 33 44

• use as single station or integration of blade Example of applications (pictures) breaking machines into a total system 1. Magazine table Ø of 1 500 mm for holding • stacking the blades in magazine units up to 65 magazines (picture 1) • up to 500 breaking cycles per minute 2. Breaker with horizontal rotary table for hol- • designed for one- and double-sided blades ding magazine cassettes (picture 2) 3. Breaker with sliding magazine (picture 3) 4. Separate breaker decoiler (picture 4)

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ACCESSORIES FOR STEEL STRIP GRINDING MACHINES Magazine systems Example of applications (pictures) 1. Horizontal rotary table magazine for holding The Berger Gruppe offers various magazine magazine casettes (picture 1) devices for different applications 2. Vertical stacking magazine for storing • horizontal rotary table magazines for hol- double-sided razor blades (pictures 2) 3 4 ding magazine cassettes 3. Vertical stacking magazine for storing • magazine for breakers scalpel blades (picture 3) • magazine devices for operator assistance 4. Horizontal rotary table magazine (picture 4) • pneumatic indexing • variable number of swords • vertical stacking magazines

• fully automatic blade magazines   1 2 Dressing systems Example of use (pictures) 1. Diamond coated dressing roll (picture 1) Various types of dressing systems for steel strip grinding machines are part of the Berger 2. CNC single-point diamond dresser (picture 2) Gruppe product range such as 3. CNC diamond wheel dresser (picture 3) • diamond-coated dressing roller for straight 4. Diamond roll dresser (picture 4) dressing of new grinding wheels (non-driven dressing unit) • CNC movable single grain diamond or dia- mond fleece for dressing the grinding wheel • CNC dresser for contour dressing of the grinding wheel, e.g. for shaft or tooth pro- files with a driven diamond dressing wheel • dresser for the use of diamond-coated dressing rolls 100–300 mm wide for scal- 3 4 loped or serrated grinding

100 ACCESSORIES FOR STEEL STRIP GRINDING MACHINES ACCESSORIES FOR STEEL STRIP GRINDING MACHINES  101 back to content 5

ACCESSORIES FOR STEEL STRIP GRINDING MACHINES Spooling systems Example of use (pictures) • guidances in the area of the working stations 1. Vertical decoiler integrated into a steel strip serrating line (picture 1) • spool plate outer Ø max. 1 200 mm 2. Spool plate (picture 2) • inner Ø 200–600 mm (other dimensions available by agreement) 3. Spool plate rotatable from horizontal to ver- tical position by motor (picture 3) • cycled configuration (gear motor 0.12 kW) 4. Spool decoiler for decoiling from cassette • quick release for clamping the coils (picture 4) • motor-driven swivelling of spool plate from 5. Aspiration of cooling lubricant mist integra- vertical to horizontal ted in steel strip grinding machine (picture 5, • spool equipped with protective cover p. 103, above)

• spool decoiler for decoiling from cassettes   1 2 Pulling system (picture 6) 6 • transport of the strip material via CNC con- trolled rollers with programmable speed of 0–100 m/min • both continuous strip feed for straight finish grinding as well as indexing mode for serra- ted or saw cut can be programmed • guarantee of tolerance values of ±0.015 mm for indexing

Strip welding (picture 7) 3 4 • strip width: 2–50 mm (wider on request) 7 • strip thickness: • up to 1 mm (Plasma Arc Welding) • 0,4–4 mm (Butt Welding) • cutting the beginning and end of the strip (option) • grinding off the bead seam (option)

102 ACCESSORIES FOR STEEL STRIP GRINDING MACHINES ACCESSORIES FOR STEEL STRIP GRINDING MACHINES  103 back to content ACCESSORIES FOR STEEL STRIP GRINDING MACHINES Cleaning systems • cleaning by means of a high-pressure mo- dule (high-pressure cleaner) followed by a The steel strip grinding machines of the Berger drying unit Gruppe can be combined with various cleaning • impurity separator systems. The cleaning systems are designed • particle filter for cleaning coils in a continuous process. • high pressure circuit • cleaning and drying with a max. speed of 50 m/min • differential pressure measurement at the

filter   Coolant systems

The design of coolant systems used in grinding machines depends on the requirements for wa- ter quantity, pressure and purity of the water.

Options: e.g. flow monitor, magnetic switch or float switch

These components can be combined depen- ding on the requirements. Water recooling has to be taken into account depending on the re- quirements.

Additionally can be installed: • flow monitor (for monitoring the level of the coolant flow) • magnetic switch (water level/stop) • float switch (level monitoring) • cooling unit for constant temperature of the coolant

104 ACCESSORIES FOR STEEL STRIP GRINDING MACHINES ACCESSORIES FOR STEEL STRIP GRINDING MACHINES  105 back to content STRIP EDGING BY METAL-CUTTING

OF STEEL STRIPS

FROM CUTTING EDGE Strip processing by metal-cutting TO FUNCTIONAL EDGE If the slit edge is the operational edge in the final product, the condition of the slit edge is inadequate

for the down-stream operation.   During strip edge trimming with the JULIUS In contrast to rolling, the material is not chan- system, the burr is removed from the strip ged during strip edge trimming by metal-cut- edge and any desired contour is chamfered to ting. The structure of the material surface is the strip edge. retained.

The resulting swarfs are removed via scrap Through precise adjustment of the tools and conveyor systems. a sophisticated system of arrange- ment, even complex chamfers and contours This means that no burrs can come off during are machined to the strip edge without impai- further work processes such as punching or ring the surface structure. profiling.

106 STRIP EDGING BY METAL-CUTTING STRIP EDGING BY METAL-CUTTING  107 back to content THE MODULAR SYSTEM – LINES SERIES BHR Modular strip edging The following modules can be integrated into a strip processing line: The modular concept allows different modules • strip edge trimming machines to be integrated into a full operational line. • strip surface treatment machines It facilitates other modules to be added later if • traverse winding and multi-coil systems and when demand changes. • strip tension technique • levelling machines

• measuring devices  

Example of a modular strip edge trimming line • QUINTO strip edge trimming machine (drawing here above) with (f. l. t. r.): • stripper • decoiler with strip tension technique and • speed measurement multi-coil system • S-block and dancer • brushing machine • pneumatical guiding arm • flat levelling machine • recoiler with traverse winding system • UNO deburring device with brushing machine and disk brake • pressing arm and turnstile • two calibrating rolls • vertical levelling machine

108 STRIP EDGING BY METAL-CUTTING STRIP EDGING BY METAL-CUTTING  109 back to content THE MODULAR SYSTEM – LINES SERIES BHR/BKB/S Strip edge trimming by metal-cutting They are designed for processing under high for heavy-duty applications loads with high material removal.

With large swarf removal cross-sections and While maintaining the most precise tolerance high performance, the stress during machining values, they can also work a complex contour of the strip edges is very high. with wide chamfers on thick and/or hard strips.

For this case, the Berger Gruppe has developed the strip edge trimming machines of the BHR/S

series.   A new concept of support arrangement has optimized the swarf removal. It is now possible to work with a thick swarf and eliminate a ma- ximum of material in one pass.

The arrangement of the hydraulic clamping in the guide rails on both sides and the use of ad- ditional cylinders have increased the capacity so that the machine can work vibration-free even under high loads. • strip width: max. 2 000 mm • strip thickness: 0.15–8 mm • contours: all contours/chamfers • speed: up to 300 m/min • strip material: all machinable materials

110 STRIP EDGING BY METAL-CUTTING STRIP EDGING BY METAL-CUTTING  111 back to content REQUEST FOR QUOTATION

QUESTIONNAIRE FOR TECHNICAL DATA

STRONG PARTNERS

Company UNDER______ONE ROOF ...

Contact ______The Berger Gruppe develops and builds Newest technologies of broadband con- CNC-controlled grinding machines for nectivity and digitalization of production E-Mail ______various industries such as the cutlery, purposes set the stage for Berger de- Phone/Fax ______tool, surgical and automotive industries. velopments of interfaces for Industry 4.0 applications with linked sensor techno- Every year 10–12 new types of machines logy, signal analysis and integration of or new production processes are com- Automated Guided Vehicles (AGV) for Workpiece pleted from a total of 80–110 new plants. the machines. Lot size As a robot system house from ABB and Batch size KUKA, the company mainly uses robots Number of typesto automate its machines. Sample WORKPIECE Drawing The robots are used both for handling

Contour andmilling for workpiece or toolSerrated guidance. grinding The Back grindingfeeding technology of theScalloped components grinding Flat grindingto be machined is decisiveSharpening for the use / ofRe-sharpening  Flat bevelautomation grinding Smooth grinding of steel strip Hollow grinding Serrated grinding of steel strip

PROCESSING The development of workpiece provision Polishing Strip processing by metal-cutting and interfaces for other production steps Automatic loading/unloading is an important area of workcentral for the com- decentralized Autonomy, capacitypany. magazine Coolant system Flow Control for coolant supply Magnet valve for coolant flow start/stop Chiller for coolant system Coolant tank single-shell double-shell Exhausting device Connection central decentralized

MACHINE Full enclosure Safety fenceOUR PRODUCT CATEGORIES Tension Preferences control Andron Bosch Siemens Preferences robot ABB KUKA Starting up customer‘s site Transport Grinding machines Grinding machines Polishing machines Robotic process Robotic grinding and Strip processing machines Metal cutting for single workpieces for steel stripGuaranteefor single extension workpieces technology/automation polishing systems by metal-cutting machines

Heinz Berger Maschinenfabrik Kohlfurther Brücke 69 Tel. +49 (202) 24742-0 [email protected] GmbH & Co. KG 42349 Wuppertal, Germany Fax +49 (202) 24742-42 www.bergergruppe.de

112 Please send the questionnaire to [email protected].  back to content