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 machining 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: Milling L=1400 mm W=3000 mm H=1500 mm External grinding Ø up to 600 mm; Length up to 3000 mm GEAR COMPETENCE the most important factors in the production of • Turning and milling centres Bevel gears: 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 hobbing 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 broaching • 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 Bevel gear 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 SPUR GEAR 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.