WELTER WELTER INNOVATIVE DRIVE TECHNOLOGY INNOVATIVE DRIVE TECHNOLOGY

At our production sites in Lahr /Black Forest and at our factory SPIROTEC in Valff /France we employ more than 120 qualified and highly motivated employees on latest machine tools.

Of course we are always at your disposal for any further questi- ons.

WELTER zahnrad GmbH How to contact us: WELTER Karl-Kammer Straße 7 D-77933 Lahr/Schwarzwald Frankfurt Nuremberg Phone: +49 (0) 78 21/923 -0 Fax: +49 (0) 78 21/923 -129 Saarbrücken z a h n r a d Email: [email protected]

WELTER WELTER maschinen GmbH

Karl-Kammer Straße 7 Rhine D-77933 Lahr/Schwarzwald France Karlsruhe Phone: +49 (0) 78 21/94 28-0 Munich Fax: +49 (0) 78 21/49 45 Stuttgart maschinen Email: [email protected] Strasbourg

WELTER Lahr GermanyG Valff SPIROTEC

Freiburg/Breisgau

Rhine Mulhouse SPIROTEC S.A.R.L. Bale 13, Rue Large We deliver F-67210 Valff Zurich drive technology for: Téléphone: +33 (0) 3 88 08 26 13 Switzerland Mining technology, Marine technology, Télécopie: +33 (0) 3 88 08 71 21 SPIROSSPIROTTECECC Rolling stock, Construction machines, Mail: [email protected] Raw material production and power generation, WELTER Machine tools WELTER

www.welter-lahr.com www.welter-lahr.com In addition to the selection of suitable raw We perform complete on latest CNC Turning Ø up to 3000 mm; Length up to 3000 mm material, the heat treatment process is one of machines in our mechanical workshop: L=1400 mm W=3000 mm H=1500 mm External grinding Ø up to 600 mm; Length up to 3000 mm COMPETENCE the most important factors in the production of • Turning and milling centres Bevel : Klingelnberg Palloid Ø up to 500 mm, module 2-8 highly stressed geared parts. • 5 axis machining Klingelnberg Cyclo Palloid Ø up to 2500 mm, module 2-33 Gleason Ø up to 2500 mm, module 2-33 So we treat our products in the most advan- • Boring and milling machines ced process-controlled furnace units: • External and internal grinding machines Toothing cylindrical gears: External Ø up to 180 mm, module 2-40, internal Ø up to 1300 mm, module 2-14, herringbone gearing (Sykes) PRODUCTION OF GEAR WHEELS • Gear and gashing milling Ø up to 2500 mm, module 2-40 • Gas carburizing in shaft and batch furnaces • Gear shaping • Gas and plasma nitriding Gear grinding: External Ø up to 2000 mm, width up to • Gear grinding 950 mm, module 2-34, internal Ø 200 - 1800 mm, module 2-10 • Bath and short-term nitriding • Grooving and • Low-distortion press hardening Worm gears: Gear Ø up to 3000 mm, module 1-34 AND ENGINEERING Worms: Grinding Ø up to 500 mm, module 1-34 • Levelling up to 100 t

Heat treatment Manufacturing Dimensions

In 1946 the mechanic master Richard Welter laid the foundation for our company under modest circumstances with a small shop. Due to the consequent realization of his demand “Highest quality and performance” nowadays WELTER is one of the well-known companies of the machine tool building and drive technology. At the sites Lahr/Black Forest and Valff/France we manufacture tailor-made machine tools and customer-specific gears on latest production and heat treatment machines with about 120 highly qualified employees. Our worldwide operating customers in the branches mining technology, vessel’s technology/marine technology, rolling stock, construc- tion machines, raw material production and power generation as well as machine tools comply with highest demands and therefore appreciate their long term partnership with us. We also act as partners in the automobile, commercial vehicle and agricultural equipment industries, as well as with gearbox manufacturers. We hope you’ll place your trust in us as well!

The international reputation of our compa- • Material certifications according to ny is based on our continuous efforts to DIN EN 10204 TOOTHED achieve quality. We rely on long-term • Heat treatment protocols experience, expertise and reliability of our • Annealing records employees. • Dimension records QUALITY • Gear measurement diagrams Since 1999 we are certified according • Certificates for classification societies to DIN EN ISO 9001/2008. such as ABS, DNV, GL, BV, etc. The quality of our products is systemati- • Certificates according to cally planned, monitored and tested during DB quality inspection I production. The results are documented in measure- ment reports and certificates:

Gear Manufacturing Engineering sets Overhauls, maintenance, modernization and new building of Klingelnberg Cyclo-Palloid and Palloid, Gleason, Kurvex, gear cutting machines. Face couplings The frames of well-known manufacturers form the basis for the new machine after through overhaul and maintenance. Due to Gear Wheels the equipment with latest control and measurement technique Spur and helical gears (external and internal), as well as overhaul of all guideways and drives the “New one” double helical and herringbone gears offers state-of-the-art efficiency. Worm gearsets The integration of new technologies or additional axes allows CAVEX, Duplex, standard profile economic and technically perfect production of all components. WELTER

www.welter-lahr.com Special tools are used for hard cutting; Achieving best possible properties regarding 5-axis milling offers new options in processing the tips consist of polycrystalline boron strength and stiffness and minimized noise gear teeth. Beside the known profiles including nitride. The HPG-S method guarantees emission requires comprehensive adaptati- their modifications it is possible to realize any complete removal of the distortions after on of the gear geometry and the flank geometries at highest precision which were FROM 50 TO 3000 MM heat treatment at which exactly defined topography. We take into account the impossible to manufacture before. The load capacities and outstanding surface continuously increasing demands of our procedure is well suitable for green cutting as qualities can be achieved which is having customers by being able to realize almost well as for hard cutting. Combined with latest positive effects on the reliability and all necessary modifications, such as measuring technology it is possible to perfectly quiet running. crowning and depth crowning, tip relief and adapt gear teeth of the new part to existing BEVEL GEAR PRODUCTION root relief as well as exact root radius with (run-in) gear teeth. Cost and procurement lead our grinding technology. times for expensive spare parts are considerab- ly reduced.

HPG method / skiving Bevel Gear Grinding 5-axis CNC milling

According to the manufacturing processes For demanding applications not only the capacity calculation is • Klingelnberg Cyclo Palloid important, but also the definition of the flank geometry is of • Palloid determining importance for noise and temperature behaviour. We • Gleason will be glad to support you in calculating and designing as well as • Kurvex in the production of your gears. Our experts are using high ® ® • Oerlikon performance software packages e.g. KISSOFT and KIMOS for • 5-axis machining satisfying your demands. • up to 3000 mm, module 2-33 Max. Ø: 1400 mm Max. Ø: 900 mm Max. Ø: 3000 mm We manufacture spiral bevel and hypoid bevel gears in almost any required qualities and types • from subcontract machining up to fully-finished system components tension • from precision gears to high load face couplings T1= 1910 Nm • batch sizes from 1 to several hundreds and from module 0.8 to 33

Bevel gear Optimized HPG-S bevel gear sets for rail application Single flank test

We deliver drive technology for: Marine technology Raw material production and power generation Construction machines Mining technology Rolling stock Machine tools WELTER

www.welter-lahr.com 5-axis milling offers new options in processing For us shaped internal geared wheels of Economic production at highest precision. We gear teeth. Beside the known profiles including quality 7 according to DIN are state-of-the-art. meet these requirements in particular in de- their modifications it is possible to realize any Our specialists guarantee the required quality manding branches such as railway technology, geometries at highest precision which were and economic production depending on the vessel’s technology and mining. At this, we at- THE GEAR TEETH ARE IMPORANT impossible to manufacture before. The proce- most important technical parameters. tain highest fatigue strength. dure is well suitable for green cutting as well The considerably increased requirements in Our customers estimate the reliability of our as for hard cutting. Combined with latest me- transfer accuracy and smoothness of gears employees and the quality of our work. In key asuring technology it is possible to perfectly also demands considerably higher quality of questions you are welcome to rely on our tech- adapt gear teeth of the new part to existing the internal gear - we offer you the quantum nical knowledge. (run-in) gear teeth. Cost and procurement lead PRODUCTION leap for noise optimized precise gears. times for expensive spare parts are consider- ably reduced.

5-axis machining Internal gears Tooth Profile Grinding

Herringbone pinion toothed Internal gears Helical and Double Helical Gears by 5-axis milling

Highly loaded pinion gear for tunneling machines Spur wheel for locomotive drive

We produce pinion gears, pinion shafts, wheels, internal geared As your partner for drive solutions, we offer you: We deliver drive technology for: wheels and lots of special parts of spur gear or helical gear type, • A comprehensive program of toothed wheels and Rolling stock with internal and/or external gears, with milled, shaped, components Mining technology planed or ground gears. • Competent advice for drives and repair solutions Marine technology Dimensions in a diameter range of up to 3000 mm and • Tailored customer solutions Construction machines Raw material production shaft lengths of up to 3000 mm are feasible. • New developments and optimisation of drive solutions and power generation Already some years ago customer-specific quality requirements Machine tools in gear and surface quality have induced us to produce on latest tooth flank grinding machines of the leading machine tool manufacturers. The reproduction of necessary profile requirements such as depth crowning, tip and/or root relief as well as root radius, etc. guarantees smooth running adapted to the special application, which may give you the decisive competitive edge e.g. regarding increasing requirements for reduced noise emission.

WELTER

www.welter-lahr.com CUSTOMER-SPECIFIC Worm gear-milling Worm-grinding Worm-Testing WORM GEAR PRODUCTION

We produce worm gear sets according to customer designs of The tooth profile of the CAVEX® wheel sets is decisive for the CAVEX® wheel sets are designed for highest loads. We optimise high variability with all common standard profiles. By the new long service life and the high strength of the wheel sets. Due to the profile of the gear using latest calculation tools. As the CAVEX GmbH & Co. KG with the CAVEX® wheel set program we the hollow flank profile it is possible to fully use the material reliability of the CAVEX® wheel sets is of great importance even offer a range of worm gears which has proven successful for properties of the high quality bronze of the wheel and the cased- under rough operating conditions. Each wheel set is entirely decades. Due to its power density and the long service life hardened worm, since the contact stresses are considerably quality proofed. After geometrical testing of worm and wheel ® CAVEX wheel sets are always the first choice of experienced reduced and the lubrication of the gear is considerably improved the contact pattern is checked. We deliver engineers for demanding machines and plant designs such as in all operating conditions. drive technology for: • Packaging machines A particularly high root width of teeth is achieved due to the Raw material production • Food processing machines hollow flank profile. Therefore, the wheel sets are extremely and power generation • Rolling mills (scissors, winders, roller tables) resistant to high impact load at little speed. Mining technology • Mixers and agitators Marine technology • Shipbuilding The range of products of CAVEX® CAVEX® profile Rolling stock Construction machines toothed wheels includes: Comparison of standard In machine tools with increasing requirements in accuracy and Machine tools and hollow flank profile stiffness have prevailed in lots of applications of the DUPLEX • Centre distance 40 - 1400 mm wheel sets. In this wheel set the worm is realized with a variable • Gearing from 1 to 180 pitch and thus allows a wheel set with a clearance free setting. • Module from 1 to 40 In this way, the conditions for highly precise production are • Number of worm starts from given. 1 to 12 • Increased accuracy • Reduced backlash • Finished dimensions according to customer requirements CAVEX® Conventional • Special models

WELTER

www.welter-lahr.com This is the right address for you! Engineering Purchase and trade of machine tools ENGINEERING You have a problem with your gear cutting machines and need You have a special machining task - we assume the engineering We are always looking for used gear cutting machines for new service, immediate advice and support in repair and mainte- tasks. We develop new assemblies such as capping heads, hobs customer projects. If you are planning to sell your machine, nance of the machine? and other drive elements on modern CAD - sets for the existing please contact us. You are yourself looking for a used or moder- machine up to a complete new machine such as the modern nized machine tool? We always keep a choice of machines We are your partner for all system solutions. In the engineering WITH WELTER bevel gear cutting machine KF 1400 and the bevel gear testers available - with a focus on gear cutting. Furthermore we have we are dealing with overhaul, maintenance, modernisation and UHT 1000 and EFPG 2000. At this our target is always to react access to thousands of used machine tools being a member of new development of gear cutting machines. Our machines on the current signals of the market and to achieve optimum the professional association Fachverband des Deutschen Ma- increase the productivity of your production and the performance by using latest technologies and electronics. schinen- und Werkzeuggroßhandels e.V. (FDM). TO THE TOP quality of your products.

Modernization New production machines Bevel gear cutting and measuring machines

Modernization For this we use the basic components (cast constructions) of the well-known machine manufacturers as basic machines which we reconvert to CNC gear cutting machines after thorough redesign/renewal and optimisation by implementing latest technologies.

Significant advantages of an overhaul: • Significant cost advantages compared to a new machine • The efficiency, the value and the productivity are adapted state-of-the-art • Comfortable operation • Little downtimes P900 CNC Gear shaping machine WS 1500 CNC including new shaping head KF1400 • Use of latest technologies • Warranties • Availability of spare parts

Maintenance & Service: • Major and partial overhaul • Measurement of machines • Geometry with grinding/ scraping of the slideways • Modernisation of controls, electrics • Reconverting to special machines • Preventive servicing and maintenance • Delivery of spare parts

Gear hobbing machine WS 3000 CNC Gear shaping machine MCS 60 Single flank testing machine EFPG 2000

WELTER

www.welter-lahr.com WELTER WELTER INNOVATIVE DRIVE TECHNOLOGY INNOVATIVE DRIVE TECHNOLOGY

At our production sites in Lahr /Black Forest and at our factory SPIROTEC in Valff /France we employ more than 120 qualified and highly motivated employees on latest machine tools.

Of course we are always at your disposal for any further questi- ons.

WELTER zahnrad GmbH How to contact us: WELTER Karl-Kammer Straße 7 D-77933 Lahr/Schwarzwald Frankfurt Nuremberg Phone: +49 (0) 78 21/923 -0 Fax: +49 (0) 78 21/923 -129 Saarbrücken z a h n r a d Email: [email protected]

WELTER WELTER maschinen GmbH

Karl-Kammer Straße 7 Rhine D-77933 Lahr/Schwarzwald France Karlsruhe Phone: +49 (0) 78 21/94 28-0 Munich Fax: +49 (0) 78 21/49 45 Stuttgart maschinen Email: [email protected] Strasbourg

WELTER Lahr GermanyG Valff SPIROTEC

Freiburg/Breisgau

Rhine Mulhouse SPIROTEC S.A.R.L. Bale 13, Rue Large We deliver F-67210 Valff Zurich drive technology for: Téléphone: +33 (0) 3 88 08 26 13 Switzerland Mining technology, Marine technology, Télécopie: +33 (0) 3 88 08 71 21 SPIROSSPIROTTECECC Rolling stock, Construction machines, Mail: [email protected] Raw material production and power generation, WELTER Machine tools WELTER

www.welter-lahr.com www.welter-lahr.com