© August Nell jr. August

Machines for Strip Grinding and Polishing

August Nell jr.©

Heinz Berger Maschinenfabrik GmbH & Co. KG Kohlfurther Brücke 69 42349 Wuppertal Deutschland Tel.: +49 202 24742-0 Fax: +49 202 24742-42 [email protected] www.nell.de Table of The plant page 4–5 Contents The Nell system page 6 The modular system page 7

BSM3000-CNC/D and /E page 8–11 Straight finish grinding, scalloped and serrated edge grinding BSM3000-CNC/C page 12 Straight, scalloped edge grinding BSM3000/Sp page 13 Brushing and deburring BSM3000-CNC/P page 14–15 Polishing and deburring BGM1500-CNC/E and /D page 16–17 Straight finish grinding, scalloped and serrated edge grinding BSM1500-CNC/TT and /TTGB page 18–19 Straight micro grinding and gothic arch DEB1500-CNC page 20–21 Grinding and polishing of double-sided razor blades BSM1000-CNC/E page 22 Scalloped and serrated edge grinding BWSL1000-CNC/E page 23 Straight finish grinding, scalloped and serrated edge grinding BSM500-CNC/HK page 24 Plunge grinding and polishing

Dressing Systems page 25 Breakers page 26–27 Spooling Systems page 28 Magazine Systems page 29 Camera / Laser Measuring page 30 Accessories page 31

• 2 • Workpieces

• Blades for the food industry • Household knives • Razor blades • Saw blades • Scalpels • Steel rules • Surgical blades • Technical blades

Industries

• Food industry • Household goods • Printing and paper industry • Razor blade industry • Saw blade industry • Surgical industry • Tooling industry

• 3 • August Nell jr. GmbH

• 4 • The Plant

Single work stations and system components are configured into a complete system. The Nell modular system offers solutions which have been tailor-made to each customer’s requirements. Retooling to add additional system components and/or work stations is possible.

• 5 • The Nell System Founded in Solingen in 1920, the company specializes in precision grinding machines for micro grinding coil material, which is guided on edge through the work stations.

The stock is machined either coil-to-coil or coil-to- breaker unit. The coil material is machined from split stock or edge trimmed stock, previously machined on Julius machines.

The machines are configured as 1- or 2-sided grinding stations with tooling, e.g. grinding wheels, positioned at an angle similar to a butterfly’s wings. The angle spread between the stations can be adjusted by mo- tor from 0 to 35°, depending upon application and configuration.

The stock is fed into the machine so that the cutting angle remains constant. Grinding wheel wear is com- pensated for by feeding the wheel slide unit over pre- cision guideways via ballscrew and AC servomotor. The feed values can be calculated using camera or laser measuring technology.

The use of various tools enable coil grinding, honing, and polishing.

In close consultation with the customer and by im- plementing the latest technology, Nell provides state-of-the-art solutions which are tailor-made for each customer's application.

• 6 • The Modular System

Thanks to Nell’s well-thought-out modular system, complex coil grinding and polishing tasks can be quickly and cost-effectively accomplished with stan- dard modules. After delivery, system components can also be expanded or provided by the customer. The individual modules are described below:

Series BSM Series BGM Series DEB Series BWSL

The belt grinding and polishing lines can be equipped with different dressing systems, breaking machines, spooling systems, magazine systems, camera and laser measuring systems and other accessories. BSM3000-CNC/E and /D

Straight Finish Grinding, Scalloped and Serrated Edge Grinding

Grinding machines from the BSM3000-CNC series are either configured as 1-sided (BSM3000-CNC/E) or 2-sided stations (BSM3000-CNC/D).

• Main motor: 15 kW or 2 x 15 kW • Frequency converter: 18.5 kW for programmable, con- stant peripheral velocity • Peripheral velocity: 30–50 m/sec • Motorized angle adjustment: 0–35° with butterfly wings • Grinding wheel diameter: max. 300 mm (11.81") • Wheel / grinding width: max. 300 mm (11.81") • 2-sided precision spindle bearing • Cutting speed: max. 50 m/sec (1968.51"/s) • Central lubrication • Configured for wet machining with grinding emulsion • Guideways are solid carbide or with carbide inserts • Various dressing systems available for grinding wheel profiles

• 8 • BSM3000-CNC/E and /D

BSM3000-CNC/E

One-Sided The one-sided grinding station is used to grind pencil Machining sharpener blades, abrasor strips and machine blades. • Grinding wheels with 300 mm diameter mounted on precision spindles with two-sided bearings • Grinding wheel width max. 300 mm (11.81") • Employed e. g. for pre-grinding coils where large amounts of material have to be removed from one side

BSM3000-CNC/E – straight finish grinding of blades for the production of abrasors

BSM3000-CNC/E – serrated grinding BSM3000-CNC/E – scalloped grinding BSM3000-CNC/E – straight finish BSM3000-CNC/E – straight finish for the production of doctor blades by for the production of machine knives grinding of blades for the production grinding of blades for the production using a CBN grinding wheel by means of a profiled grinding wheel of industrial blades of pencil sharpener blades

• 10 • BSM3000-CNC/E BSM3000-CNC/D

The double-sided grinding station machines techni- cal blades, doctor blades, surgical blades and similar workpieces. Double-Sided • Two grinding wheels configured on opposite sides Machining • Each spindle can be equipped with 6 grinding wheels, having widths of 20 mm (0.79") each, which are offset for plunging. • This results in a grinding width of 120 mm per side, for a total width of 240 mm (9.45"). • Employed for finish grinding pre-ground or edge trimmed coils (grit 150–320)

BSM3000-CNC/D – Straight blade grinding for the production of industrial blades

BSM3000-CNC/D – Straight blade grinding for the production of doctor blades BSM3000-CNC/D – Straight blade grinding for the production of scalpel baldes

BSM3000-CNC/D • 11 • BSM3000-CNC/C

Straight, Scalloped Grinding

The BSM3000-CNC/C work station is designed for grinding of kitchen knives and similar workpieces.

• Main motor: 22 kW • Frequency converter: 30 kW for pro- grammable peripheral velocity

• Motorized angle adjustment: 0°– 35° • Designed for one-sided removal of large • Grinding wheel diameter: 350–450 mm amounts of material from coils (13.78"–17,72") • Use of cup wheels, 350–450 mm (13.78"–17.72") in diameter • Wheel width: 10–100 mm (0.39"–3.94") • Pre-embossed coils can also be scallop ground • Cutting speed: max. 50 m/s (1968.52"/s • Grinding wheel wear compensation with camera • Central lubrication or ultrasonic technology • Configured for wet machining with grinding emulsion • Guideways are solid carbide or with carbide inserts

• 12 • BSM3000-CNC/C BSM3000/Sp

Brushing

and Deburring The brushing and deburring station BSM3000/Sp machines hair clipper blades, doctor blades, serrated machine cutting tools for food industry and similar workpieces. It is designed as a spiral brushing station with two spindle bearings installed at a radial arm each.

• Main motors: 1,1 kW with tooth belt gear • Frequency converter for continuously adjustable regulation of spindle revolution • Pneumatic synchronized lifting of the brushes and releasing of strip clamping for indexing strip feed • Angle correction by mechanical adjustment of the height • Compensation of the brush wear by mechanical adjustment of the impact • Configured for wet machining BSM3000-CNC/ FPV BSM3000-CNC/P

Polishing and Deburring

The polishing station BSM3000-CNC/P is designed for polishing and deburring of microgrinded blades such as doctor blades, scalpels, technical blades, pencil sharpener blades and similar workpieces.

• Configured as a double-sided polishing station for polishing tools up to 250 mm diameter • The polishing result can be influenced by feeding liquid paste through high-pressure nozzles • A consistent polishing result is achieved by means of an intelligent pressure control for the polishing tools and constant motor power

• 14 • BSM3000-CNC/P • Main motor: 1 kW • Frequency converter: 1,5 kW for programmable, constant peripheral velocity with decreasing wheel diameter, • Peripheral velocity: 6–14 m/s (236.22"–5315"/s) • Motorized angle adjustment: 2°–35° with butterfly wings • Max. strip height: 50 mm (1.97"), alternatively: 100 mm (3.94") • Polishing wheel diameter: 175 mm (6.89") • Scallop configuration, e.g. with 12 polishing wheels, each 5 mm (0.2") in diameter, i.e. total of up to 24 polishing wheels per station • Two-sided spindle bearing • Dressing of the polishing wheels by means of an indexing grinding belt BGM1500-CNC/E and /D

Straight Blade Grinding,

Scalloped Grinding, The grinding machines of the series BGM1500- Serrated Grinding CNC are designed to grind doctor blades, knives for the food industry and similar workpieces.

• Grinding machines of the series BGM are de- signed as one-sided (E) or double-sided (D) strip grinding stations • Strip height: more than 50 mm (1.97") possible • Grinding wheel diameter: 400 mm (15.75") • Width of the grinding wheel: 150 mm (5.91") • Stations applicable for continuous grinding as well as plunge grinding for scallopped and serrated grinding • Dressing system (p. 25) and accessories (p. 31) • Main motor: 15 kW • Frequency converter: 18,5 kW • Motor angle adjustment: 4°–25° • Grinding wheel diameter: 400 mm (15.75") • Grinding wheel width/grinding width: max. 150 mm (5.91") • Double-sided precision spindle bearing • Cutting speed: max. 40 m/s (1574.82"/s) • Central lubrication • Configured for wet machining with grin- ding emulsion • Reception of carbide metal guideways re- spectively guideways with carbide metal inlets • Various integrated dressing systems available for grinding wheel profiles • 18,5 kW for programmable and constant cir- cumferential speed of 30–50 m/s (1181.11"– 1968.52"/s) with decreasing grinding wheel diameter

BGM1500-CNC/E – scalloped grinding with dressed grinding wheel

Grinding station in half shell with motor angle adjustment

BGM1500-CNC/E and /D • 17 • • Grinding spindle configuration up to 8.000 rpm, encoder for position control, precision spindle of highest quality • Spindle bearing: hydrostatic or roller bearing • Programmable, constant peripheral velocity with decreasing wheel diamter • Peripheral velocity: 20–65 m/s (787.41"–2559.1"/s) • Motorized angle adjustment: 0°–35 ° (TT) • Grinding / wheel diameter: 150 mm (5.91") • Spiral wheel diameter: 150–250 mm (5.91"–9.84") • AC servo motor and drive control for grinding wheel synchronization, max. 2° at 8.000 rpm • Central lubrication • Configured for wet machining with grinding emulsion • Guideways are solid caride or with carbide inserts (only solid carbide guideways available with BSM1500-CNC/TTGB) • Various integrated dressing systems available for grinding wheel profiles BSM1500-CNC/TT and /TTGB

Straight Micro-Grinding and Gothic Arch The BSM1500-CNC/TT and /TTGB work stations are designed to deburr finish ground blades. Key applications for the TT and TTGB work stations are grinding razor blade edges with a convex profile (gothic arch) or micro grinding rules with grits up to 1200.

• Use of grinding wheels with 150–250 mm (5.91"– 9.84") diameter • Electronic spindle synchronization with AC servo technique • Mineral composite machine base offers additional vibration damping properties for precision grin- ding

BSM1500-CNC/ TT and /TTGB • 19 • DEB1500-CNC

Grinding and Polishing The solid grinding and polishing station of the series of Double-Sided DEB is configured for the machining of the classic Razor Blades double-sided razor blade with three angles.

The line consists of: • 4 one-sided pre-grinding stations • 2 double-sided finishing stations • 2 double-sided deburring stations • 4 double-sided polishing stations

• Tool wear compensation by means of a AC servo- motor and CNC control unit • Control of strip height • Transportable dressing unit for dressing of grinding wheels • Breaking machine integrated with storing system for up to zu 400 blades/min • Angle adjustable: 3°–13° (grinding machine) ­6°–16° (polishing machine) • Spindle drive: 2,2 kW resp. 0,37 kW • Designed for grinding wheel diameter of 160 mm (6.3"), width of 180 mm (7.1") • Spiral wheels: 152,4 mm (60") Ø, width 127,3 mm (50.1") • Polishing wheel 150 × 50 ×5 mm (5.91" × 1.97" × 0.2")

• 20 • DEB1500-CNC

BSM1000-CNC/E

Scalloped

and Serrated The peripheral grinding station BSM1000-CNC/E is designed for one-sided serrated edge coil grinding Edge Grinding for the production of hair clipper blades and similar workpieces.

• Grinding spindle installed on slide unit with pre- cision guideways • Driven by ballscrew and AC servomotor • Grinding spindle automatically shifted sideways, creating pointed teeth after a second plunge • Main motor: 15 kW • Frequency converter: 18,5 kW for programmable, constant peripheral velocity with decreasing wheel diameter, 30–50 m/s (1181.12"–1968.52"/s) • One-sided precision spindle bearing for grinding wheels, with max. 110 mm (4.33") width and 450 mm (17.72") diameter • Central lubrication • Configured for wet machining with grinding emulsion • Dressing unit for diamond-coated dressing rolls, max. 110 mm (4.33") width • Integrated CNC dressing system available

BSM1000-CNC/E BWSL1000-CNC/E The grinding stations of the series BWSL1000- CNC/E achieve a one-sided straight finish grinding, scalloped and serrated edge grinding at strip ma- terial. The strips are emloyed e. g. in the food industry, the Straight Finish Grinding, paper and packing industry or for the production Scalloped and Serrated of saws.

Edge Grinding • Achieving each edge angle required due to the interpolation of the Y- and Z-angle • Dressing of the grinding wheel by a diamond roller dresser or single point dresser • Integration into a strip grinding line as BWSL

• 23 • BSM500-CNC/HK

Plunge Grinding The BSM500-CNC/HK work station is designed specially and Polishing for grinding and polishing hooked blades.

• Double-sided grinding operation with four grin- ding units which are arranged at different angles • Definition of the grinding wheel geometry by a dressing unit with diamond-coated rolls • Polishing of the blades with felt or leather wheels at a second work station of similar design • Consistent polishing result by means of intelli- gent pressure control for the polishing wheels • Automatic supply of the polishing paste • Main motor: 4 x 2,6 kW • Frequency converter: 4 x 4 kW for prorgammable, constant peripheral velocity with decreasing wheel diameter 30–50 m/s (1181.12"–1968.52"/s) • Dressing motor: 4 x 0,8 kW • One-sided precision spindle bearing • Central lubrication • Configured for wet machining with grinding emulsion and/or polishing paste

BSM500-CNC/HK Dressing Systems

Diamond-coated dressing wheel Diamond-coated dressing wheel for straight dressing of new grinding wheels (not-driven dressing unit)

CNC single-point diamond dressing unit Traveling single-point diamond fleece for dressing grinding wheel

CNC diamond dressing wheel CNC dressing unit for contour dressing of grinding wheel, e. g. for scalloped or serrated profiles with a driven diamond dressing wheel

Diamond roll dressing unit Dressing unit for use with diamond-coated dressing rolls up to 100 mm (3.94") or up to 300 mm (11.82) width for scalloped or serrated grinding

Dressing systems Breakers

• For use as single station or integrated in total system • Blade stacking in magazines, e. g. index table of stacking magazine • Up to 500 breaking cycles per minute • Designed for one-sided our double-sided blades

Storing table, 1500 mm (59.1") diameter for the reception of 65 magazines

Breaking unit with stacking magazine Separate breaking unit with de-coiler

• 26 • Breakers

Spooling Systems

• Spool plate up to 1.200 mm (47.24") outer diameter • 200–600 mm (7.87"–23.62") inner diameter (other dimensions available upon request) • Cycled configuration (gearbox motor 0,12 kW) • Quick clamp device for clamping coils • Spool plate rotatable from vertical to horizontal • Spool equipped with protective guarding • Spool de-coiler for de-coiling from cassette

Spooling de-coiler for de-coiling from cassette

• 28 • Spool plate Spool plate rotatable from horizontal to vertical position by motor Horizontal rotary table magazine for the reception of magazine cassettes

Magazine Systems

Vertical stacking magazine to store double-sided razor blades

Nell offers diverse magazine systems for different applications

• Magazine systems for operator assistance

• Fully automatic blade magazines

• Storing for breakers

• Horizontal rotary table magazine for the reception of magazine cassettes

• Vertical stacking magazine • variable number of swords • pneumatic indexing Vertical stacking magazine to store scalpel blades

Horizontal rotary table magazine • 29 • Camera/ Laser Measuring

For quality control purposes, each work station can be equipped with laser measuring technology and a camera measuring station.

The grinding height is monitored by laser measuring technology, and the symmetry of the grinding width on both sides is monitored by camera.

The results are displayed graphically, evaluated and documented in a closed circuit. Double-sided camera measuring station and laser strip width measuring system Camera measuring of scalloped profiles Camera measuring of grinding width with 4 double-sided camera stations and a total of 8 cameras, evaluation and graphic display on industrial PC

Accessories

The following modules can be integrated additionally in a strip grinding and polishing line:

• Coil transport • Guideways • Strip welding machine • Laser angle measuring equipment • Hardness check unit

Coil transport

• CNC controlled rollers for coil transport with pro- grammable speeds of 0–100 m/min (3.94"/min) • Continuous coil transport for straight grinding and/or programmable indexed operation for grinding scalloped or serrated edges • Tolerance guaranteed at ± 0.015 mm (0.59") during indexing

Guideways

• Guideways in work station areas are solid carbide or with carbide inserts • Coolant supply in grinding area • Default configuration for 2 coil heights, continuously adjustable via slotted hole

Accessories • 31 • Strong Partners Under One Roof ...

The names Heinz Berger, Hau- ment of the BSM 3000 CNC grin- schild, August Nell and Julius 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 or forged tools. Their in-house Thanks to a broad product line, robotic capabilities provide solu- the synergistic effects in our tions to automation and process engineering, R&D and production integration tasks. departments, and a competent customer service team, the Trend-setting innovations 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 Heinz Berger Maschinenfabrik coil stock and tools that demand Hauschild high quality. August Nell jr. The first automatic grinding Julius Maschinenbau machines from Berger in 1957, Werner Peters the development of the Julius edge trimming machine in 1980, Laschet + Partner the first CNC controlled double- scallop polishing machine by Hauschild in 1987, the use of more ... the Berger Group! than 300 robots for automating Berger grinding machines since 2000, as well as Nell’s develop-

Kohlfurther Brücke 69 • 42349 Wuppertal-Cronenberg • Germany Tel.: +49 202 24742-0 • Fax: +49 202 24742-42 [email protected] • www.bergergruppe.de • 32 •