MOTION_2012-1_en

Ecological and effi cient Sustainable production using innovative

solutions and machines of the SCHLEIFRING Group

MOTIONTHE CUSTOMER MAGAZINE OF THE SCHLEIFRING GROUP

AVIATION TURBINES: BLOHM and MÄGERLE increase effi ciency

CALIFORNIA: Pioneer in climate and environmental protection in the USA

100 YEARS: Fritz Studer AG celebrates its birthday

I S S U E 1 / 2 0 1 2

L_S.01_TItel_ENG.indd 1 22.06.12 14:02

www.winterthurtechnology.com

GRINDING WITH WINTERTHUR: ROBUST SOLUTIONS FOR LEAN PROCESSES

SwitzerlandWinterthur Schleiftechnik AG8411 WinterthurTel.: +41 (0)52 234 41 [email protected]

UKWinterthur Technology UK Ltd. Sheffield S3 9QX Tel.: +44 (0)114 275 42 [email protected]

USAWinterthur Wendt USA Inc.Webster, MA 01570Tel.: +1 (508) 949 10 [email protected]

L_S.02-03_Editorial_ENG.indd 2 13.06.12 10:26

E D I T O R I A L

Assuming responsibility

Dear Readers,

There is great discussion in society, politics, and in-

dustry on the topic of sustainability – a term related

to numerous requirements and expectations. With

regard to new energy concepts, the way we handle

scarce resources, and the reduction of the energy

consumption, the question is how and where energy

conservation potential can be developed. Who con-

siders themselves responsible? And who has the

expertise and the potential to develop and offer

market-ready and effi cient solutions?

The SCHLEIFRING Group rises to this challenge. We

strive for the highest possible product quality and the

conservation of energy and resources. This is appli-

cable to production processes, the grinding machines

and their application for the customer. Our engineers

are systematically developing new technologies and

procedures consuming less energy at maximum pro-

ductivity, conserving resources, and reducing emis-

sions to a minimum. Therefore, all SCHLEIFRING

companies are allowed to use the “Blue Competence”

brand. That is what we are proud of.

Since day one, we have been driven by pioneering

spirit and innovative energy, with success – as can

be seen using the example of Fritz Studer AG. In 100

years of company history, the company has risen to

become the worldwide market leader in the fi eld of

cylindrical grinding technology.

I hope you will enjoy reading the magazine.

3MOTION 01/12

Yours sincerely,

Stephan Nell

CEO Körber Schleifring AG

L_S.02-03_Editorial_ENG.indd 3 13.06.12 10:26

4 MOTION 02/11

CONTENTS

184 MOTION 01/12

L_S.04-05_Inhalt_ENG.indd 4 13.06.12 10:27

C O N T E N T S

5MOTION 01/12

IMPRINT

Publisher: Körber Schleifring AG, Hamburg Chief editor: Peter Lütjens Realisation: JDB MEDIA GmbH, Schanzenstraße 70, 20357 Hamburg, Deutschland, www.jdb.de

Project management: Jan Hawerkamp Art direction: Claudia Schiersch Editorial board: Marc-Oliver Prier (dir.), Ira Schroers, Barbara Schulze, Klaus Vogt, Maresa Wolbert Layout: Stef fi

Pflugbeil (dir.), Sandra, Haberlandt, Yvonne Vahland Graphic editors: Julia Poppe (dir.) Proofreading, editing and translation: Ü-Werk GmbH Photos: dpa (1), iStockphoto (4), Getty

Images(Titel+2), JDB(1), Kilian J. Kessler(2), laif(1) Lithography: Fire Dept. GmbH, Hamburg Printing: NEEF + STUMME premium printing GmbH & Co. KG, Wit tingen

N E W S

28

32

Current events from the companies

TO O L S & T EC H N O LO GY

28

43

06

08

14

18

26

22

32

34

36

40

COV E R S TO RY

Acting sustainably

Energy- and resource-conserving

manufacturing solutions of the

companies of the SCHLEIFRING Group

Country special: California

The Golden State wants to become

greener with ambitious environmen-

tal guidelines

100th birthday

How Fritz Studer AG developed from a

pioneer to become the market leader

50 years of STUDER know-how

Kunio Kitamura led the brand to

success in Japan

Success factor: employees

About the training and further

education of skilled employees

in the companies of the

SCHLEIFRING Group

Backpacking through the world

MAEGERLE manager Hans Seifert

regularly hikes along the rough coasts

of Canada

Tapping savings potentials

MOTION in conversation with Prof. Dr.

Konrad Wegener from the ETH Zürich

Increasing output, reducing energy

Solutions by BLOHM and MAEGERLE

increase the effi ciency of aviation turbines

System and solution provider

Partners WALTER and EWAG intensify

their cooperation and offer services and

solutions from a single source

Ideas with huge effects

WALTER reduces the energy consumption

of the HELITRONIC POWER machines

News to use

Practical production tips

M A R K E T S & T R E N DS

M OT I O N S & M O R E

L_S.04-05_Inhalt_ENG.indd 5 13.06.12 10:27

6

N E W S

MOTION 01/12

WALTER

Grinding and measuring to perfection

At the GrindTec 2012 in March, Walter

Maschinenbau GmbH presented

new software and hardware solutions

for tool grinding and optical measure-

ment engineering.

Optimised kinematics

Using the new high-performance tool

grinding machine HELITRONIC VISION

LONG, rotationally symmetric precision

tools such as milling cutters, drills, step

drills, woodworking tools and profi le

tools consisting of materials such as

HM, HSS, ceramics, cermet, and CBN

can be ground up to a total length of 700

millimetres. The concept is based on the

tried and tested and highly precise

HELITRONIC VISION tool grinding ma-

chine with linear drives and torque mo-

tors. However, the kinematics of the

HELITRONIC VISION LONG were modi-

fi ed. In this way, using the same working

HELITRONIC VISION LONG:

new kinematics and low-vibration

grinding precision

envelope, manufacturing tools with diameters from three to 200 millimetres and

outside diameter grinding length of up to 580 millimetres are possible. The poly-

mer concrete machine base and the patented portal design for extreme rigidity

convert the high dynamics of the digital drives to low-vibration grinding precision.

The motor output is 35KW / 10,000 rpm. Grinding wheels with a maximum diam-

eter of 254 millimetres are replaced by means of a wheel changer

(can optionally be extended to 24 stations). A 6 axis Fanuc CNC

robot is used to load and unload the tools.

Measuring range extended

Option “L” for the measuring machines HELICHECK PRO and

HELICHECK PLUS is also new. This option can be used in order to

measure tools up to a total length of 730 millimetres. All tried and

tested features and characteristics, as well as the diverse

and powerful options of HELICHECK PRO and HELICHECK

PLUS are also available for the “L” option. The former meas-

uring length of 300 millimetres was extended considerably

with the measuring range extension for the “L” option and

provides tool manufacturers or re-sharpeners with the

perfect investment in the future for the virtually unlimited

extension of their product ranges. Taking the HELICHECK PLUS L

as an example, this means that micro, standard or extremely long

tools can be measured on only one measurement system in the

future. The characteristic variable decisive for the accuracy of a

measurement machine is also E1 = (1.4 + L/300) μm and once again

guarantees the high capability of the HELICHECK measurement

machines from WALTER.

[email protected]

HELICHECK PLUS L

Measure tools with

a length of up to

730 millimetres

L_S.06-07_News_ENG.indd 6 20.06.12 11:45

7MOTION 01/12

THE ORBIT HAS ARRIVED

Double premiere with BLOHM and JUNG in Göppingen

Two good reasons to celebrate at

once: on 23 and 24 February 2012,

Blohm Jung GmbH opened the new sales

and service centre at its offi ce in Göp-

pingen. The highlight of the premiere

was the offi cial presentation of the new

ORBIT series (see also MOTION 2/2011).

The series comprises three machine

sizes with grinding ranges between

500 × 200 millimetres and 800 × 400 mil-

The CT960 general-purpose internal

cylindrical grinding machine from

STUDER is designed for a broad

range of applications. Thanks to its

stability and interpolating axes,

grinding radius transitions at

dies in polished quality is

possible. The machine has

now been optimised further

in many aspects. The com-

pletely re-engineered tur-

ret is equipped with a new

highly-dynamic direct

drive. This drive reduces the swivel

and, thus, the non-productive times and

allows for positioning the grinding

spindles from -5 to +30° in an infi nitely

variable manner.

A new coolant distributor tidies up the

interior. Furthermore, the Z table has

been reviewed and re-engineered, the

higher rigidity of which has positive

effects on the entire axis system. The

dressing system has also been re-

viewed and re-engineered in the base

pedestal and the bearing so that even

higher accuracies can be achieved

when dressing the grinding wheels.

Grand opening: sales representatives examine machines in the new showroom

of Blohm Jung GmbH at the offi ce in Göppingen

The ORBIT has arrived: BLOHM offi cially presented

the new series in February

limetres. Here, the customer is provided

with the choice between two control

variants: one professional CNC control

unit, as well as the tried and tested BLO-

HM EasyProfi le control unit, both deliv-

ered with controlled drives in all axes.

From the new sales and service centre,

the BLOHM and JUNG brands will offer

everything from a single source in the

future: starting with consultations and

STUDER CT 96 0

Innovations for ideal grinding results

[email protected]

[email protected]

New in the concept of the CT960:

the turret with a highly dynamic

direct drive

overhauls, via a logistics centre and

spare parts distribution up to the service

hotline and application engineering. Em-

ployees and partners from all over Eu-

rope came to Baden-Wurttemberg and

got to know the new showroom.

Equipped with state-of-the-art technol-

ogy, machine presentations and training

sessions can be conducted here.

L_S.06-07_News_ENG.indd 7 25.06.12 16:17

8 MOTION 01/12

Maximum value with minimum resources: in times ofscarce resources, energy- and resource-conservingmanufacturing is focused on more strongly. The companiesof the SCHLEIFRING Group actively support this development.

C OV E R S T O RY

Future technology:

in machinery and plant

engineering, the signs

are pointing to

Blue Competence ®

SUSTAINABLE PRODUCTION

Ecological and effi cient

Maximum value with minimum resources: in times ofscarce resources, energy- and resource-conservingmanufacturing is focused on more strongly. The companiesof the SCHLEIFRING Group actively support this development.

C OV E R S T O RY

SUSTAINABLE PRODUCTION

L_S.08-13_Titelgeschichte_ENG.indd 8 18.06.12 14:18

9MOTION 01/12

I ncreasing emissions with adverse effects for human beings and

nature, decreasing resources of fossil combustibles accompanied

by increasing energy prices – the world is changing. Everybody knows

that action must be taken. The climate protection goals of interna-

tional environmental policy are correspondingly ambitious. Sustain-

ability is no longer a trend or niche topic, but it is decisive for our future.

Intensive efforts are being made to optimise energy and resource ef-

fi ciency in industrial production as well. According to a study con-

ducted by Fraunhofer, “Energieeffi zienz in der Produktion” (Energy

effi ciency in production), up to 30 percent of energy consumption in

industry can be saved in the medium term. Alone for the product

classes considered within the framework of the study, this amounts to

210 petajoules per year. This corresponds approximately to half of the

energy consumption of all private households in Germany or to the

output of four power plants with 1.4 gigawatts each.

Less energy, maximum productivity

Therefore, in order to develop sustainable living and production con-

ditions, it is necessary to have partners from industry and technology

work intensively on the topic of resource effi ciency. The SCHLEIFRING

companies are number 1 in the world in the fi eld of grinding. This

market position carries responsibilities with it. As the leading manu-

facturers of machine tools, these companies assume responsibility

and are also pioneers in their industry in terms of sustainable produc-


the-art and energy-effi cient inverters and energy recovery modules provides

further savings potential. Moreover, there is no energy-intensive pressure prepa-

ration of air or oil if hydraulically and/or pneumatically operated auxiliary axes (for

example handling systems, door openers, and tool changers) are replaced with

electrical drives. That is not all; the basic energy consumption of a manufacturing

facility is increased signifi cantly if auxiliary units are not activated automatically

with the machine but only if required.

Most of the energy consumption can be attributed to the cooling system and the

cooling lubricant supply. In this regard, engineers of the SCHLEIFRING Group used

adapted line cross-sections with minimised fl ow losses (low number of bends, no

bottlenecks) or a concentrated, laminar steel at the nozzle (for example for needle

valve nozzles) in order to allow lower pump pressures and reduced fl ow rates. This

reduces the energy consumption of pumps, cooling plants, and preparation fa-

cilities. The use of speed-controlled and/or consumption-controlled cooling lubri-

cant pumps, not pumping against closed valves at full power as up to now, also

reduces the consumption.

The possible extent of the savings potential which results from the combination

of structural measures is demonstrated by Walter Maschinenbau GmbH (see page

28). In an example application for the timber industry, the engineers managed to

reduce the production-related energy consumption of the HELITRONIC POWER

machines for a certain component family by up to 44 percent.

Effi cient procedures

Short process chains, fewer machines, lower space requirements and reduced

transport and storage expenditures – combined machining demonstrates

its potential economic and energy-saving effects in these fi elds. The integration

of processes such as grinding, turning, and milling makes it possible to signi-

fi cantly increase the effi ciency of production. This is illustrated by an example

from the turbine industry. In cooperation with MTU Aero Engines, Blohm Jung

GmbH developed a manufacturing line consisting of a total of seven modifi ed

BLOHM PROFIMAT MC 610s (see page

18). The concept combines different

machining processes, including simula-

tion and measurement. The production

solution not only results in an enhance-

ment in the fi elds of quality and effi -

ciency of low-pressure turbines, but

also requires less space, minimises

non-productive time, and reduces pow-

er consumption.

Likewise, software solutions for tech-

nology support help save energy and

resources. Special databases such as

HEUREKA for MIKROSA machines or

StuderTechnology instantly allow opti-

mised machining processes with sig-

nifi cantly reduced machining time.

For example, StuderTechnology reduc-

es machining time by approx. 25 per-

cent. A detailed process simulation

regarding the confi guration of a ma-

chine for new production assignments

tion. They develop technology and

processes which consume less energy

for maximum productivity, conserve

resources, and reduce emissions to a

minimum level. These factors helped

all the SCHLEIFRING companies qualify

for the label of “Blue Competence ®”

awarded by the VDMA (German Engi-

neering Federation) with diverse ac-

tivities and efforts. This registered

trademark must only be applied if en-

ergy- and resource-effi cient solutions

are implemented demonstrably for pro-

duction processes and products.

Good design, good result

These comprehensive measures for

ecological product and production de-

sign and for innovative environmental

technology include the optimisation of

the machine periphery and of the ma-

chining technology. One example is the

replacement of traditional fi nal drives

with direct drives. Here, a lower number

of components, minimised friction, and

lower moved masses result in energy

savings. Furthermore, the process times

are shortened on the basis of the higher

velocities. The use of synchronous mo-

tors with increased effi ciency, state-of-

C OV E R S T O RY

MOTION 01/1210

Innovative grinding technology for effi cient

engines: BLOHM and MÄGERLE are acknow-

ledged partners of the turbine industry


11

Grinding machines can be optimised for a

more resource-conserving design with

these solutions, amongst others:

n Replacement of direct drives such as

linear or torque motors (fewer

components, less friction, fewer

moved bulk quantities)

n Use of synchronous motors with

increased effi ciency, state-of-the-art

and energy-effi cient inverters, as

well as energy recovery modules

n Optimised electrical installation

such as bus systems, low-watt and

LED technology

n Use of pressure reservoirs and

consumption-controlled pumps for

hydraulic assemblies.

n Activation of auxiliary units if

required only (reduction of the basic

energy consumption)

n Optimisation of the cooling lubricant

supply by means of adapted line

cross-sections, speed- and/or con -

sumption-controlled cooling lubricant

pumps and cooling lubricant nozzles

that can be activated individually

n Process simulations for the confi gu-

ration of a machine, programmes for

technology support and for technolo-

gy and process integrations

n Advanced training content based on

energy-effi cient and resource-conser-

ving manufacturing, as well as

information regarding the ideal

confi guration in the documentation

and/or instructions for use

n Energy recovery when decelerating

axes and grinding spindles

MORE EFFICIENCY

All SCHLEIFRING companies qualify

for the label of Blue Competence®

MOTION 01/12

(for example WALTER ToolStudio, StuderGrind, StuderWIN, or JUNG GRIPS) in

turn avoids downtime and the production of scrap and reduces the need for en-

ergy and resources.

Less is more

Furthermore, resources can be saved during the grinding process itself. Organisa-

tions such as the Institute of Machine Tools and Manufacturing (Institut für

Werkzeugmaschinen und Fertigung – IWF) of the ETH Zurich carries out research

in this fi eld. “Due to the basically unfavourable machining kinematics on the

individual grain intervention, the grinding process is an exception,” says Prof.

Dr. Konrad Wegener, head of the IWF (see interview on

page 14). Reducing the amount of friction – for exam-

ple, by creating enhanced cutting conditions, sharp-

ening and structuring the grinding wheels –

helps in two respects: less energy is

consumed and there are less heat-related

issues, for example overheating due

to grinding or workpiece and ma-

chine warpage.

Fritz Studer AG closely cooperates

with the IWF in order to further

optimise their machine portfolio

regarding resource and energy

effi ciency. An integral part of the

development process with

STUDER is called Ecodesign,

which results in the most energy-

effi cient and economic solution

depending on the grinding assign-

ment. “For us, the aspect of energy

ening

helps in

consumed an

issues, for exam

to grinding or

chine warp

Fritz Stud

with th

optim

reg

e

pl

Software for many applications: version1.9 of WALTER HELITRONIC TOOL STUDIO

Environmental technology solar

panels: development of energy-

and resource-effi cient solutions


12

conservation is an integral part of the

requirements specifi cation,” says Fred

W. Gaegauf, managing director of

Fritz Studer AG. “The product and the

individual components must be in-

volved even when developing a ma-

chine. In addition, less is more. In order

to guarantee maximum resource effi -

ciency, we think about what is really

necessary, about which materials we

will use, and about which materials we

can reduce even before the develop-

ment phase.” One example is the use

of copper.” We discuss what will happen if this resource can no longer be used

in the long term. After all, copper resources will presumably be exhausted in 40

years“, adds Wolfgang Labus, manager of Product Engineering with Fritz Studer

AG. Therefore, STUDER engineers are working to fi nd out how to avoid using rare

resources. The energy input required for producing the materials is also taken

into consideration.

Sustainable developments

The GRANITAN® developed by STUDER is one example of material effi ciency, a

polymer concrete casting for machine beds. “For production, we only need ap-

proximately one third of the energy when compared to the production of grey

cast iron,” said Labus. Machine manufacturers and researchers also focus their

attention on the issues of cold and dry machining (see below). Both the process

of heating and the process of cooling are real energy guzzlers. “When operating

grinding machines, 50 percent of the energy is required for cooling alone“,

explains Labus. “Therefore, the idea of cold and dry machining is the

right approach for the future.” Furthermore, dry machining will

result in less waste, such as consumed cooling lubricants,

oil-containing grinding slurries, or oil binding agents.

Within the service life of a machine – from pro-

duction to utilisation to disposal – the operating

time of a machine makes up 95 percent of its

energy consumption. And this is the decisive

point, emphasises STUDER managing direc-

tor Gaegauf. “This is where we begin. The

idea is for the customer to operate the

machine in an energy-saving manner; the

process chain issue is also important. It is

C OV E R S T O RY

MOTION 01/12

GRANITAN® machine bed: two thirds

less energy during production

StuderTechnology: the software instantly delivers ideal results during

cylindrical grinding at reduced machining times

Grinding, turning, milling: combined machining as shown here on a MÄGERLE

MGC L increases effi ciency of production


Performance by quality..de

important to talk to the customer about

how the workpiece is to be machined,

what will be ground or turned, and many

other aspects.” STUDER calls this proc-

ess “Simultaneous Engineering” and

has been offering it for a couple of years

now. “We cooperate closely with our

customers. It is about fi nding individual

solutions.”

Doing the right thing

Investment in environmentally-friendly

technology has long-term effects. In

close collaboration with the customers,

all SCHLEIFRING companies try to joint-

ly plan the use of the machines in an

energy-specifi c manner and to individu-

ally optimise it on the basis of reliable

operating data. Not every measure is the

best solution for every machine in order

to achieve the highest resource effi cien-

cy. It is more important to do the right

thing at the right point. This involves

development and design, production,

operation, and preparation. That is not all; the aspects of training and service also

play an important role according to Gaegauf. “Advanced training content based

on energy-effi cient and resource-conserving manufacturing, as well as informa-

tion regarding the ideal confi guration of the ma-

chine in the documentation and instructions for

use will result in sustainable improvements in the

interests of our environment.”

[email protected],[email protected]

FURTHER INFORMATION

STUDER experts in energy-effi cient grinding technology: Wolfgang Labus (head of Product Engineering, left

side) and managing director Fred W. Gaegauf


T O O L S & T E C H N O LO GY

Prof. Dr. Konrad Wegener:

Resource effi ciency is the

appropriate target value

14 MOTION 01/12

INTERVIEW

The key lies in EcodesignProf. Dr. Konrad Wegener, head of the Institute of Ma-chine Tools and Manufacturing (Institut für Werkzeugmaschi-nen und Fertigung – IWF) at the ETH Zurich, about the effi cient use of energy and re-sources in modern production.

MOTION: Prof. Wegener, the topic of

conserving energy in production is

becoming increasingly important.

Some estimate the potential to be up

to 50 percent. What do you think about

these numbers?

WEGENER: The potential is considerable.

According to studies, the conservation

potential for operation of production ma-

chines alone is estimated by manufactur-

ers to be approx. 25 percent. The potential

of these machines can be harnessed fi rst

and foremost by purposefully switching

off loads, avoiding the wasteful use of

media, compensating instead of cooling,

improving processes, avoiding scrap and

reducing friction. The potential is even

higher when considering how a machine

is embedded into the operating context.

For example, if an electrical control cabi-

net emits waste heat into the ambient air

within an air-conditioned room, this will

result in an ineffi ciency cascade. This cas-

cade will no longer result if the heat is

dissipated purposefully at the source. At

this point, shorter process chains, the

avoidance of intermediate cooling and

heating fi rst and foremost within the fi rst

process stage, the utilisation of waste

heat, more effi cient transport and mate-

L_S.14-17_Meinung_ENG.indd 14 20.06.12 16:58

fi cient components on a case-by-case basis on the basis of a measurement. There

are measures that can be implemented without any problems. Other measures are

very complex or still need to be explored. Such being the case, the entire fi eld of

production research is currently devoted to the commonplace issue of energy effi -

ciency. However, it must be taken into consideration that exclusively considering

energy consumption is too short-sighted. There are cases in which energy consump-

tion is simply reduced to the detriment of material consumption. Therefore, resource

effi ciency is the more correct objective function.

MOTION: How can production processes be optimised?

WEGENER: In this regard, energy consumers are mostly peripheral devices, with

cooling lubricant supply and temperature stabilisation leading the way. The actual

manufacturing process does not allow much leeway; the grinding process is an excep-

tion on the basis of the principle-related unfavourable machining kinematics on the

individual grain intervention. Intensive research work is being conducted in this area.

MOTION: Is the fi eld of simulation able to contribute to the optimisation of the

peripheral devices?

WEGENER: Yes. Let us look at the cooling lubricant supply. Initially, we must convince

the cooling lubricant to enter the grinding gap at the grinding wheel. This is done with

pure force as you can see when looking at the size of the cooling lubricant units.

Furthermore, the supply of the cooling lubricant must be robust. Thus, it must be

resistant to misalignment. If you start producing missing parts, the effi ciency require-

ment – not only regarding energy – will certainly no longer be complied with. At this

point, it is worthwhile to fi nd the optimum by means of simulation. Simulation is a

good method in order to fi nd the lowest-wear method of operation, and thermal

machine simulation can be used to predict and compensate the deformation behav-

iour of the machine. In order to achieve process optimisation, the simulation must

ask the proper question and use the proper model. Admittedly, the implementation

of the solution will initially cost time and money in most cases. However, the simula-

tion can at least predict the effect that can be achieved.

MOTION: Which trends have you observed in the machine tool industry regarding

energy effi ciency?

WEGENER: The topic has been addressed amongst the machine manufacturers.

There is still potential for development regarding the operators. We observe that

shortcomings in effi ciency are fi rst and foremost caused by an incorrect adapta-

15MOTION 01/12

rial fl ow and, fi nally, building insulation

must be mentioned. Added up, the sav-

ings potential is very high, without mak-

ing any claims of being complete. Here,

the information mentioned contains very

high cluster potentials or marginal im-

provements and everything in between.

MOTION: What is the best way to tap

this potential?

WEGENER: Improved material utilisation

and indirect savings resulting from the

qualitative improvement of the produced

products are important if the products

consume energy during their service life.

The leverage which results from the re-

duction of fuel consumption by means

of manufacturing fuel supply systems and

motors more precisely is so huge that

savings in production completely pale in

comparison, even if the actual production

is a noteworthy energy consumer on the

basis of the absolute numbers. However,

energy savings in production which di-

minish product quality are a total failure.

MOTION: It is nevertheless possible to

save large amounts of energy in the fi eld

of production.

WEGENER: Yes. However, tapping this

potential is not always easy. We have

measured the power consumption of doz-

ens of machine tools, including the pe-

ripheral devices, down to the last detail.

Here, each machine showed a potential

for improvement in the magnitude men-

tioned above – but every time at a differ-

ent point. Therefore, instead of a standard

list containing the “usual suspects” such

as pumps and compressed air consum-

ers, we have developed a method estab-

lishing a position table of the most inef-

Tapping savings

potentials: within

the research laboratory

of the IWF, machine

components

are measured in

every detail


16 MOTION 01/12


tion of the peripheral devices or in the

operational environment. This can only

be improved if the operators start opti-

mising their systems in a systematic

manner. This will also result in a series

of new requirements for the machine

manufacturers.

MOTION: What can a mechanical engi-

neer do in order to be prepared in terms

of resource and energy effi ciency?

WEGENER: For one thing, mechanical

engineers must know and be able to pro-

vide information about the energy profi le

of their products. For another thing,

Ecodesign must be implemented into the

product development process as one of

several requirements. Thirdly, mechanical

engineers must be able to equip the ma-

chines in accordance with the energy-

specifi c customer requirements.

MOTION: How can a machine tool be

optimised from a structural point of

view?

WEGENER: The key lies in the Ecodesign

process implementing the best solution,

i.e. an energy-effi cient, economic, reli-

able, and safe solution, under the given

circumstances. The ability to calculate is

essential. The diffi cult thing about this

matter is that robustness decreases as

perfection increases. You improve and

improve with increasingly fewer effects

until you fi nally go too far and reach a

very poor condition.

MOTION: What are the concrete ap-

proaches for grinding machines, in your

opinion?

WEGENER: There is the potential for op-

timisation in the fi elds of media supply

and preparation and thermal stabilisation,

as well as quick and effi cient shut-off and

start-up procedures of individual loads.

There is also the grinding wheel, the proc-

ess, and the ideal dressing cycles. After

all, the majority of the volume of the grind-

ing wheel is lost during the dressing proc-

ess on average. There is also potential in

the fi eld of compressed air. The drives are

only addressed rather late. It is not only

possible to achieve effi ciency at a nominal load, but in all partial and overload condi-

tions. This is frequently the challenge.

MOTION: How can energy consumption be recorded and optimised?

WEGENER: Quite simply by using a measuring device. This will probably be part of

the standard equipment of systems in the future – i.e. a machine, including its periph-

eral devices, measuring the consumption of power and compressed air as a minimum

and providing input to the operating data records. This will form an awareness,

measures will be developed, implemented and can be checked regarding their effi -

ciency. And there will be competition. Consumption displays in vehicles will result

in vehicles being driven more economically simply because it is challenging. Likewise,

the intervention options of the machine operator on the facility are limited. For the

operator, the huge fi eld of machine embedding is the fi rst assignment.

MOTION: What should you pay attention to when purchasing a machine tool? Does

a higher investment into an effi cient and process-optimised machine pay off?

WEGENER: Energy effi ciency is one of many requirements; the expected machining

option and the quality must certainly be weighted much higher. Regarding the work-

piece, considering the entire process chain, and regarding the machine, the ideal

adjustment to the operational circumstances is important. Since it is fi rst and foremost

a question of ideal system design, a better system does not necessarily cost more.

Better preparation, more mental work, and competence are required during the pre-

liminary stages. The trick is to de-

sign the machine in a way that it

still meets the quality requirements

even in rooms without any air con-

ditioning. In the future, clever pur-

chasers will also make their pur-

chase decisions dependent on the

competence of the manufacturer

in terms of resource effi ciency.

BIOGRAPHY

Prof. Dr. Konrad Wegener is the head of the Institute of Machine Tools and Manufacturing (Institut für Werk-zeugmaschinen und Fertigung – IWF) at the ETH Zurich. The IWF specialises in machine tools, production pro-cedures, and process chains, as well as methods for developing, assessing, and optimising production fa-cilities. www.iwf.mavt.ethz.ch/

Expert in demand: Prof. Dr.

Konrad Wegener discussing

with students


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DM200 + DP200


Extreme conditions:

completion of a

low-pressure turbine

with MTU Aero Engines

in Munich

Full thrust: the

A380 with four

GP7000 turbines

18 MOTION 01/12

as in other industry sectors, people are discussing how emissions can be reduced

in a sustainable manner. There are many ideas and approaches (see box page 20).

From the fi rst fi eld experiments comprising the admixture of biofuels to the use of

auxiliary units for the internal energy supply of planes up to the design using new

and lighter materials such as for the Dreamliner from Boeing. However, at the same

The objective is ambitious: by 2050,

reduce the CO2 emissions of the

aviation industry by 50 percent. This is

the requirement of the IATA, the Inter-

national Air Transport Association. Just

TURBINE ENGINEERING

Flying more economically

BLOHM and MÄGERLE are successful brands in the aviation turbine industry. New manufacturing technology reduces the energy consumption of turbines – even during production.


L_S.18-21_Antriebe_ENG.indd 18 20.06.12 11:44

19MOTION 01/12

Quality determines

effi ciency: cross-section of a

GP7000 turbine

the brands BLOHM and MÄGERLE have made a name for themselves. Using the

solutions of the companies, turbine manufacturers can produce in a more energy-

effi cient manner and machine high-strength materials. For example, Blohm Jung

GmbH has been cooperating successfully with leading turbine manufacturers for

decades and has developed industry-specifi c innovations such as speed stroke

grinding and BLOHM PROKOS. The BLOHM brand is the technological leader in

this segment. The Mägerle AG Maschinenfabrik also knows how to produce high-

quality turbine components using innovative procedures. These are all good

reasons why the leading manufacturers rely on technology of the profi le grinders

and readily ask the experts for advice in the event of complex issues.

New manufacturing line with MTU

The new development of a manufacturing line for MTU Aero Engines in Munich

is a current example of the solution competence of Blohm Jung GmbH. The task

was to develop a machining solution for connecting components between high-

pressure and low-pressure turbines with which all individual components could

be machined completely and precisely on one machine. The so-called FPH parts

time it is obvious that planes will also

use kerosene for fl ying in the future. On

the one hand, the planes are too heavy

for the use of electrical drives; on the

other hand, the volume of biofuels with

a positive effect on the climate is cur-

rently still very cost-intensive and lim-

ited. By contrast, the further develop-

ment of effi cient turbines is more

promising in terms of energy and re-

source effi ciency. In this regard, manu-

facturers are constantly working to de-

velop the existing turbine types. In doing

so, even the smallest progress may have

considerable effects – always relating to

the number of planes and/or the con-

sumed volumes of kerosene. The reduc-

tion of the SFB Rate (Specifi c Fuel Burn)

is crucial in this respect. The require-

ments for the drive systems are

correspondingly high; these

requirements include in-

creasing the maximum

temperature in the com-

bustion chamber, better

fl ow conditions at the

blades and more narrow

form tolerances in order

to reduce gap losses.

The fi rst choice

This is a matter for experts.

Within the turbine industry,

Innovative concept: the new MTU manufacturing line for

FPH parts with seven BLOHM PROFIMAT MC 610



20 MOTION 01/12

(Flow Path Hardware) are used in dif-

ferent turbine programmes, for exam-

ple, GP7000 for the Airbus A380 or GEnx

for the models Dreamliner and 747-800

from Boeing. “They are exposed to ex-

treme conditions due to hot gases.

Therefore, the quality of the FPH parts

which allow an ideal distribution of the

forces within the turbine is crucial for

the effi ciency of a turbine. This in turn

results in an ideal alignment of the de-

fl ection curve allowing very small clear-

ances between the rotating and the

stationary components of the turbine.

The lower the clearances, the less leak-

age air will be present. The effi ciency

of the turbine will increase,” says Peter

Dirr, head of Airfoils and Flowpath Hard-

ware with MTU Aero Engines.

An innovative concept for automati-

cally equipping machines with tools and

components, as well as for measuring

the workpieces was developed. “The

new manufacturing line consists of

seven modifi ed versions of the BLOHM

PROFIMAT MC 610. Within the frame-

work of the design phase, we combined

two machine concepts,” says Ralf

Bleich, chief marketing offi cer with Blo-

hm Jung GmbH. The engineers extend-

ed the original PROFIMAT MC 610 with

its three linear axes by a double NC ro-

tary table (B-C combination). From an-

other machine type, they took over the

tilting spindle. “Thus, the machine con-

cept comprises six axes: three linear

axes, two axes from the rotary table,

and one axis in the grinding spindle.

Combination of processes

A customer-developed measuring pro-

gramme is also new. It measures the

raw part even while it is in the machine.

This so-called “best-fi t” allows for an

ideal distribution of the stock amount.

The programme uses the distribution

to project the contour of the fi nished

part in perfect alignment into the raw

part and calculates the best component

machining. Milling and drilling work

also takes place within the combined

manufacturing process. The very frag-

SAVING ENERGY IN AIR TRAFFIC

Other ways in which the aviation industry tries to reduce the consumption of energy

and resources. Four examples:

Similar to road traffi c, there are also experiments regarding the admixture of biokero-

sene to the traditional fossil fuels in the aviation industry. A fi eld experiment of Lufthan-

sa with approx. 1190 test fl ights was completed in March. Result: biokerosene could

be used for airline operations without any problems and did not generate any higher

exhaust emissions when compared to traditional fuel. However, according to the airline,

there is not enough biofuel for any larger scale use; furthermore, the current biokerosene

is signifi cantly more expensive than the traditional kerosene.

There are also considerations of setting auxiliary units for the plane-internal energy

requirements on a new basis, with fuel cells leading the way. If and when this will be

established cannot be assessed at the current point in time.

It is also planned to reduce the energy requirements for ground-based operations. At

this point, the energy being supplied from the ground promises more effi ciency and

economic effi ciency when compared to the supply using traditional in-plane units.

Plane engineers also set their hopes for improving the energy effi ciency in the use

of lighter design materials such as carbon fi bre for the Dreamliner (Boeing 787).

Less leakage air, more

effect: a GEnx turbine

drives the Boeing 787


foremost compressor blades with radial, i.e. curved, roots are used. “These allow

easier installation when compared to the straight roots, which has advantages

in production and maintenance of the turbines. However, the manufacturing

process is somewhat more complex,” says Rainer Hungerbühler, chief sales and

marketing offi cer with Mägerle AG Maschinenfabrik. The compressor blades are

made of materials that are diffi cult to machine such as Inconel, titanium, and

other high-alloyed materials. To date, the parts were broached or milled in sev-

eral clamping operations. One manufacturing process used is the process of

grinding on a fi ve-axis grinding machine. However, due to geometry-related

reasons, these machines are not able to manufacture the radial root profi les

without deformation. As a result, the form tolerances are partially or completely

used up.

For this reason, MÄGERLE extended the proven fi ve-axis grinding machine

equipped with tool changer MFP-050.65.65 by a sixth axis. The three rotary axes

are equipped with state-of-the-art, completely wear-free torque drives. Using

this solution, all root geometries can now be machined completely without any

deformations in one clamping operation. Furthermore, using the integrated over-

head dressing unit, it is possible to continuously dress the grinding wheel while

grinding the blade depending on the machining assignment. Furthermore, the

six-axis principle allows optimised profi le depths, shorter manufacturing times,

and reduced wheel wear. Thanks to the integrated tool changer, this machine can

also be used to execute additional milling or deburring operations in the same

clamping, if required.

Getting more complex

The innovation pressure on the turbine manufacturers is high. “In the future it

must be anticipated that the components used in manufacturing will be charac-

terised by more complex shapes with increasingly narrow tolerances. Probably

a signifi cantly greater number of components will consist of exotic materials that

can only be machined with greater diffi culty,”

forecasts Hungerbühler. “With our six-axis ma-

chine, we already have the answer to complex

shapes. Narrow tolerances are our thing.”

ile workpieces are fi xed to a so-called

shuttle by means of a clamping concept

that is also new. The workpiece supply

and the tool change are executed in a

fully automatic manner by means of a

robot. The combination of these proc-

esses with MTU has not only resulted

in a quality enhancement regarding the

FPH parts, the company itself benefi ts

from sustainable reduction as well.

Some of these benefi ts include:

Power consumption: lower energy

consumption due to reduced number

of machines

Time: complete machining without

any additional non-productive time

for re-clamping the workpieces

Cleaning: use of a central system for

all machines

Space: fewer machines result in a

reduction of the overheads

Reduced gap losses

MÄGERLE once more repeatedly rises

to the changing challenges in the tur-

bine industry and offers effi cient and

economic solutions to problems, such

as in aviation turbines where fi rst and [email protected]@maegerle.com

FURTHER INFORMATION

Working space:

deformation-free

manufacturing of radial

roots

MÄGERLE MFP-050: extended

by a sixth axis

Simulation:

exact geometry

machining of the

blade

21MOTION 01/12


of silicon, the electrically-powered Tesla Roadster is at home – a real competitor for

gas guzzlers. It is the fi rst electrically-powered roadster with strong performance,

zero emissions, and a fancy design. Together with a large number of other high-tech

companies in the US Golden State, Tesla dreams about changing the world. The

internet giant Google has already provided a contribution. For example, the corpora-

tion provides its employees with an in-house CarSharing offer comprising electri-

cally powered and hybrid vehicles and operates more than 200 charging stations for

electrically powered vehicles. Google therefore has the largest network of a compa-

ny-owned charging infrastructure in the USA, according to their own statements.

USA invests into renewable energy

Admittedly, the annual savings of CO2 of 5,400 tons mentioned by the internet

giant are not exactly an insignifi cant amount. However, since the United States

Noiselessly it swooshes through the

valley of computer kings and only

needs 4.3 seconds to reach a speed of

100km/h (62mph). Here in Silicon

Valley, California, where

dreams are made

COUNTRY SPECIAL

Green, greener, California

California plans to obtain at least 33 percent of its energy consumption from renewable energy sources by 2020 – and thus stands out in the USA with particularly ambitious environmental guidelines.

Golden state: the Golden

Gate Bridge in the San

Francisco Bay is one of the

landmarks of California


Valley, California, where

dreams are made

Ground-

breaking:

environmen-

tally friendly

technology

from Silicon

Valley

L_S.22-25_Kalifornien_ENG.indd 22 13.06.12 10:58

23MOTION 01/12

taken as a whole do not necessarily be-

long to the pioneers in terms of climate

protection and resource effi ciency, crit-

ics only regard these fi gures as a drop

in the bucket. But there is something

happening. Interestingly, the USA came

to be the worldwide pioneer in terms of

investments in renewable energies in

the past year, according to Bloomberg

New Energy Finance. In 2011, the coun-

try invested approx. 55.9 billion US dol-

lars to this end.

The sums are likely to increase. For ex-

ample, the fl agship state of California

initiated its own emission trading sys-

tem with the “cap-and-trade program”.

At the beginning of January 2012, Gov-

ernor Jerry Brown expressed his confi -

dence during the presentation of the

Californian household budget in Sacra-

mento: “This is a strong, confi dent in-

vestment into the future of California.

We are an innovative state.”

The Californians have always been a

little bit greener than the others. For

example, the state required the compli-

ance with stringent emission limits for

vehicles even at a time when this was

not yet a topic in Europe. Now, Brown

plans on investing approximately one

billion US dollars from the profi t of the

new “cap-and-trade program” into the

reduction of greenhouse gases. The

money is to be invested into research

in the fi eld of clean energy sources, into

the protection of natural resources, and

Tesla Roadster: the electrically-powered vehicle made in California needs only 4.3

seconds to reach a speed of 100km/h (62mph)

Committed to the environment: Governor Jerry Brown is proud of the

commitment of the Californians in terms of new forms of energy

CALIFORNIA AT A GLANCE

Inhabitants: 37,253,956 (census 2010)

Capital: Sacramento

Largest cities: Los Angeles, San Francisco, San Diego

Nickname: The Golden State

Currency: US dollar

GDP: 1.9 billion US dollars (2010)

Languages: English (60.5 %), Spanish (25.8 %), Others

(13.7 %), additionally, more than 100 Indian languages

Surface area: 423,970 km², third-largest state in the USA

Governor: Edmund Brown Jr. , a.k.a. Jerry Brown

Sacramento

Los Angeles

San Francisco

into infrastructure projects in the context of alternative energies. “We Californians

can be proud of the fact that our state leads the rest of the country regarding our

commitment for new forms of energy and energy effi ciency,” said Brown during

his inaugural speech last year. By 2020, it is planned that at least 33 percent of

the energy consumption will be generated from renewable energy sources, cor-

responding to a total output of 12 gigawatts and/or the annual consumption of

approximately three million households.

Leading in the fi eld of solar energy

The Golden State is particularly developing the generation of energy using pho-

tovoltaics. According to the latest study of IHS iSuppli (El Segundo, California),



24 MOTION 01/12

Water power: tidal and wave power plants could generate more than 140 terrawatt hours of electricity

the generation of energy using photo-

voltaics (PV) is planned to increase by

7.5 gigawatts between 2010 and 2015.

In this way, the west-coast state further-

more asserts its leading role in terms

of solar energy in the United States.

For 2011, IHS iSuppli forecasted the en-

ergy production of the Californian PV

facilities with 967 megawatts; in 2012,

the production was likely to increase to

1.2 gigawatts. Until 2015, 7.5 gigawatts

can go on line to the local energy net-

work on the basis of planned photo-

voltaics projects, more than half of the

aimed at goal of 12 gigawatts for all re-

newable energies taken together.

Currently, First Solar is building the larg-

est PV facility in California: the Topaz

Solar Farm to the north-west of Los An-

geles will deliver 550 megawatts. Over

the course of the next fi ve years, Pacifi c

Gas and Electric plans on building PV

facilities in California that, taken as a

whole, will deliver approximately 500

megawatts. However, there are also

shadows in the Golden State; whilst in-

vestors had been enthusiastic regarding

the clean-tech wave in the USA for years – similar

to the internet and real estate booms – the Cali-

fornian solar panel manufacturer Solyndra has

been looking for suitable investors on an inter-

national scale since its insolvency application in

September 2011. The company ranges amongst

the fl agship start-ups of Silicon Valley in the so-

called clean-tech cluster. In less than two years,

at least eight PV manufacturing sites either closed

down or have at least been reduced in size. Chi-

na has taken over this market as well and PV

modules “made in China” are up to 20 percent

cheaper when compared to American modules.

Harnessing tidal resources

A new report issued by the US Department of

Energy furthermore purports that the 1,800

kilometre-long coast of California could gener-

ate more than 140 terrawatt hours of electric-

ity with tidal and wave power stations – enough

to provide approx. 14 million households with

energy. An initial project at the coast of San

Onofre has already been approved. Things are

on the move in Silicon Valley as well. Quite

recently, the implementation of the “Green

Button” was celebrated on the internet. Consumers can use this function in order

to download clearly understandable energy consumption data from the internet.

The examples demonstrate: Californians have become more environmentally

aware. On the basis of governmental programmes, with new technology and the

commitment of far-sighted companies, the

Golden State has taken a pioneering role in

terms of climate protection in the USA.

t

t

f

Construction of the

Topaz Solar Farm: the

largest photovoltaics

facility is built to the

north of Los Angeles

http://energycenter.org/http://www.energy.ca.gov/

FURTHER INFORMATION


sharp by nature

www.meister-abrasives.com


“Together to the top!”: The logo of

the “Strategie 2015” symbolises

the future path of the brands

WALTER and EWAG

Achieving more

together: WALTER

and EWAG

co-operate even

more closely

26 MOTION 01/12

Last November, WALTER and EWAG

opened a new sales offi ce in Wuxi,

China. From there, the two brands or-

ganise the sales and service activities

for the most important market in East

Asia. Their joint offi ce is only one exam-

ple for the close collaboration of the two

leading manufacturers of tool grinding

and measuring machines. With the

“Strategie 2015”, Walter Maschinenbau

GmbH and Ewag AG intensify their co-

operation. Their objective is to create

innovative solutions for tool machining

and sustainable all-round customer sup-

STRONG PARTNERS

Systematic solutions

The brands WALTER and EWAG concentrate synergies and are becoming a system and solution provider. Customers benefi t from the know-how transfer and the service of the tool grinders.

Ceremonial opening: from the sales offi ce in Wuxi,

WALTER and EWAG are organising sales and service

activities for the Chinese market


port. “We do not only deliver machines.

We see ourselves as system and solution

suppliers,” says Knüpfer.

Partners working well together

The underlying circumstances for this

are right: together, WALTER and EWAG

are the only brands worldwide which

offer a comprehensive machine port-

folio for grinding, eroding, lasering, and

measuring tools – including their pro-

prietary software and services. The

partners complement each other per-

fectly: for example, in the fi eld of grind-

L_S.26-27_Systemanbieter_ENG.indd 26 18.06.12 11:59

27MOTION 01/12

EWAG LASERLINE: Ewag AG had a successful start in the realm of

laser machining technology — of great relevance for the futureSpecial solution from WALTER: a chain loader for loading tools in the woodworking fi eld

tools by grinding, eroding or lasering, and we furthermore give advice regarding

the purchase of measuring machines for controlling the quality of the produced

tools,” says Knüpfer. “We are also the right contact person for any queries and

problems in terms of software. This way, our customers can be sure that their

customers will also receive the quality they expect.”

Everything from one source

Moreover, the joint development and research work is intensifying. At reasonable

points of contact, Walter Maschinenbau GmbH and Ewag AG provide for compre-

hensive knowledge transfer and completely tap the synergies. Apart from that,

both brands continue to drive their own product innovations and secure their

technology leadership in this way.

This strategic focus also comprises a joint sales and service organisation. In the

future, the eleven international sales and service offi ces of WALTER will also man-

age all customer services and consultations for EWAG machines. Here, the engi-

neering experts of both companies will continue to implement the detailed project

planning with the customers. This will pro-

vide the customers with a real advantage:

WALTER and EWAG will provide them with

systematic solutions from one source.

ing, WALTER primarily offers solutions

for the production of rotationally sym-

metric tools. By contrast, EWAG is an

expert for machines for the production

of replaceable cutting inserts. Quite

recently, WALTER launched several in-

novations in the fi eld of software and

measurement engineering (see page

6), as well as a loader for the use of

tools in the woodworking market. In

turn, EWAG successfully entered the

realm of laser technology, of great rel-

evance for the future, by developing

their LASERLINE.

One provider, two brands

This concentration of skills carries with

it signifi cant advantages: “People com-

ing to us will receive an individually

appropriate overall package from one

provider”, says Knüpfer. This means:

tool producers no longer need to con-

tact several persons of different ma-

chine manufacturers. WALTER and

EWAG act as one provider for all con-

cerns in the fi eld of tool production.

“We support our customers both re-

garding fi nancing and regarding the

selection of the machines they want to

use in order to produce the required [email protected],www.walter-machines.com, www.ewag.com

FURTHER INFORMATION

“We provide our customers with an individually-appropriate overall package from one source.”Siegfried Knüpfer, Managing Director of marketing,

service and sales with Walter Maschinenbau GmbH

L_S.26-27_Systemanbieter_ENG.indd 27 18.06.12 11:59

Development team: Heinz Häckh, head of control

technology and documentation (left) discussing test results

with Thomas Engelfried, head of the testing department

28 MOTION 01/12

source-conserving manufacturing.” For the HELITRONIC POWER machines, the

following measures are used to optimise the energy and resource effi ciency, amongst

others (see also page 31):

n Optimised drives: synchronous motors achieve high effi ciencies in the axes and

in the grinding spindle

n Coolant: reduced use of coolant with up to six individually on-demand

coolant valves

n Mechanics: bellows instead of sliding plates means less friction

n Central lubrication: the lubricating oil pump is activated for a few seconds only

until the lubrication pressure is established and is then switched off until the next

cycle

n Home-time circuit: the machine continues to produce even after the end of the

shift, then switches off automatically, and switches to the standby mode

n Simulation of the machining process

Up to 44 percent less energy consumption

for one component family

The exact savings always are very different from customer to customer and not

least also depend on the range of application and the conditions on site with the

customer. However, the fact that WALTER provides a signifi cant contribution to

energy-saving manufacturing by means of the structural measures for the HELITRONIC

POWER machines is demonstrated by an independent expert opinion. A customer

The energy consumption in the fi eld

of manufacturing is currently a

much-discussed topic given the increas-

ing costs, statutory changes, and the

changed awareness of the consumers.

Machine tools can provide an important

contribution to harnessing the energy

used for manufacturing purposes more

effi ciently. For the energy consumption

of machine tools is a signifi cant infl uenc-

ing variable for the productivity.

By taking numerous measures, the

engineers of Walter Maschinenbau

GmbH managed to sustainably minimise

the energy consumption of the

HELITRONIC POWER machines. Along

with the energy-optimised operational

management of the machines, the en-

ergy and power consumptions are re-

duced fi rst and foremost by structural

measures, while simultaneously increas-

ing the productivity.

Structural features

“In former times, the energy consumed

by our machines was signifi cantly high-

er,” says Heinz Häckh, head of control

technology and documentation with Wal-

ter Maschinenbau GmbH in Tübingen,

Germany. “Today, we develop much

more intelligent software solutions, use

better materials and technologies, and,

thus, are able to provide for more re-

TOOL GRINDING

Small measures, huge effectWALTER engineers use the most different solutions inorder to signifi cantly reduce the energy consumption ofthe HELITRONIC POWERmachines.


L_S.28-31_Loesungen_ENG.indd 28 13.06.12 11:00

29MOTION 01/12

Targeted application:

fi ne-adjusted

individually controlled

nozzles reduce the con-

sumption of coolant

Shank cutters for the timber industry: consume signifi -

cantly less material and energy while manufacturing

from the timber processing industry planned to substitute a

HELITRONIC POWER HMC 500 by an eroding machine HELI-

TRONIC POWER DIAMOND with Fanuc control. For the cus-

tomer, the question of whether the investment will pay off was

decisive. The objective: when compared to the old machine,

the new machine was supposed to provide energy savings of

at least 20 percent, measured against the average consumption

of the past three years. Therefore, the independent BayTech

Institut für Holztechnik (Institute for Wood Technology) in Rosen-

heim examined whether the investment in the machine park

and the related interdisciplinary technology re-

sults in the desired savings. In doing so, the elec-

trical drives, compressed air, vacuum and

pumps, the process cold and heat, heat recovery

and utilisation of waste heat, as well as meas-

urement and control technology and commu-

nications technology were taken into consid-

eration. In order to ensure comparability, three

PKD tools (one jointing cutter, radius edge cut-

When clamping becomes critical …Extraordinary applications demand

extraordinary solutions. Many work-

pieces cannot be properly clamped

by virtue of their unique characte-

ristics. We develop targeted custo-

mized chucking systems.

FORKARDT SCHWEIZ GMBHIndustriestrasse 3, CH-8307 EffretikonTel. +41 52 355 31 31, [email protected] ITW Workholding Company

WWW.FORKARDT.CH Highest quality and precision within the m range



30 MOTION 01/12

DESIGN

Perfect interactionDrives, hydraulics, mechanics – by means of numerous individual measures, engineers of

Walter Maschinenbau GmbH reduce the energy consumption of HELITRONIC POWER machines.

DRIVESIdeally designed drives and energy feed-back into the mains when decelerating the axes and the grinding spindle. Furthermore, synchronous motors with high effi ciencies of 0.9 are used in both components.

SIMULATION The work -pieces and the machining process on the machine are simulated virtually in advance using the WALTER software solutions HELITRONIC ToolStudio or Cybergrind-ing. This way, the period required for test operation of the machines is reduced signifi cantly, as well as the consumption of test workpieces.

CENTRAL LUBRICATIONDesign as impulse lubrication: in this, the

lubricating oil pump will run for a few seconds only until the lubrication pressure is established.

Then, the pump is switched off automatically until the next lubrication cycle.

MECHANICSA smooth-running recirculating ball screw, as well as linear guidances with high-rigidity ball races reduce the friction and provide for smoother

operation. Furthermore, by using bellows

instead of a sliding plate the friction is reduced and more uniform.

COOLANT VALVES Precisely accurate coolant supply using up to six individu-al on-demand coolant valves.

COOLANT PUMPUse of frequency-controlled coolant pumps and of motors with high effi ciencies (EFF1 class 0.92). Pump activation is controlled by the CNC pro-gramme.

HYDRAULICSA hydraulic aggregate with pressure reservoir. The impulse valves are blocked in the centre position. Result: the pump is inactive during the breaks and is only active in order to fi ll the pressure reservoir.

Optimised: A

HELITRONIC POWER DIAMOND


times) up to better and bet-

ter PC simulations of vir-

tual instead of real grinding

processes – there were

many approaches, accord-

ing to Engelfried. “For ex-

ample, we are dealing very

intensely with the group of

themes energy recovery,

particularly with regard to

the central coolant sys-

tem.” The work is conduct-

ed in close collaboration

with the customers. These

describe the problem and/or the assignment. As a system and solution provider

(see also page 26), WALTER then discusses ways of implementing the energy re-

covery adapted to the manufacturing system of the customer. In this, it is mostly

about interface solutions. “For example, for one customer we were able to use the

heat from the motors and the coolant system in order to heat the entire factory

building,” says Häckh. Another trend towards energy indication on the machines

and/or energy recording within the framework of the overall energy management

of a company can be observed. Walter Maschinen-

bau GmbH conducts intensive research activities

in this fi eld as well.

ter, and shank cutter in each case)

representative for the timber in-

dustry were machined on both

machines for the purposes of the

expert opinion. With energy

savings of nearly 44 percent, the

use of the HELITRONIC POWER

DIAMOND by far exceeded the

expectations.

What the future

will bring

“This is a great success demon-

strating that our work bears

fruit,” Thomas Engelfried, head of the

testing department with WALTER says

happily. For him, such design solutions

are subject to a continuous development

process. With new procedures and spe-

cial energy gauges, the WALTER engi-

neers are looking for further potentials

for savings. From software standby

modes via procedures for saving energy

(particularly for set-up times and down- [email protected]

FURTHER INFORMATION

WALTER energy gauge:

looking for and

developing potentials

for savings


32 MOTION 01/12

M O T I O N S & M O R E

With a self-produced article, Fritz Studer laid the foundation for a unique success story in 1912. Today, the company Fritz Studer AG is the world’s number one in the fi eld of cylindrical grinding technology.

Corporate headquarters:

the STUDER premises

viewed from above in 1937

10 0 YEARS OF STUDER

From pioneer to market leader

The Fritz Studer AG celebrates its birthday: in February,

STUDER sales representatives and employees of the

brand came to the Swiss town of Thun in order to celebrate

the 100th anniversary of the company within the framework

of the Motion meeting (sales training for representatives).

One of them was Kunio Kitamura from Japan (see portrait

on page 34). The service technician has been part of the

STUDER history for 50 years now and provided a huge con-

tribution to the success of the brand in his home country.

High renown all over the world

100 years of STUDER – this is built upon high levels of dili-

gence, high professional capabilities, and a strong spirit

and innovative energy. Up to the present day, these char-

acteristics of the founder and mechanical engineering pio-

Production extended: up to this date, the capacitieswith STUDER were extended continuously

The pioneer: 100 years ago,

Fritz Studer started the

STUDER success story with

a self-produced article

L_S.32-35_100. Jahre Studer_ENG.indd 32 13.06.12 11:04

33MOTION 01/12

ing machines up to CNC cylindrical grinding machines for small to medium-sized

workpieces. For large batch production purposes, the range was extended by single-

purpose machines with optimised grinding cycles and highest levels of availability,

as well as by a combination machining unit for process optimisation for rational hard

fi ne machining. With the integration of Combitec AG in Biel as technology centre

Internal grinding in 2008, Fritz Studer AG again extended the solution competence.

Up to 2012, more than 21,000 cylindrical grinding machines were delivered worldwide.

With innovation into the future

In order to develop new machines, clever minds and the use of leading-edge technol-

ogy within the framework of proprietary manufacturing are necessary. In the com-

pany headquarters in Thun alone, we employ 800 committed employees. Addition-

ally, STUDER is represented in the market by sales representatives in 40 countries.

Fritz Studer AG disposes of proprietary software and hardware development and

cooperates with leading research institutes. 400 grinding tests are implemented

each year in the customer and technology centres and emphasise the technology

know-how. In a couple of years, the machines will be designed lighter and in a more

dynamic manner and will be characterised by additional intelligence and more eco-

nomical energy consumption. By means of the label Blue Competence (see title

story on page 8), STUDER reduces the CO2 emissions during design and operation

of the machines. Within the proprietary state-of-the-art application centre, more

than 80 engineers and designers are working on

the aforementioned. So we must not be afraid of

the next 100 years.

neer Fritz Studer have been a primary

element for the success of the company.

It all started in February 1912. Back then,

Fritz Studer founded a mechanical work-

shop in Steffi sburg. However, in order to

machine precise components, he lacked

a grinding machine. Therefore, he de-

cided to self-dependently build a cylindri-

cal grinding machine without hesitation.

In doing so, the back then 33-year old laid

the foundation for making Fritz Studer

AG the world’s market leader for preci-

sion cylindrical grinding machines 100

years later.

Today, the machine concepts and grind-

ing solutions of the brand are held in high

esteem amongst experts. If nothing else,

this can be attributed to the fact that the

Swiss made a name for themselves as

competent solution provider right from

the start. The range of most different ma-

chine types was extended consistently:

From the conventional cylindrical grind-

Changing production: view into the STUDER factory building in the 30ies (left) and today, the factory buildings were consistently upgraded and extended

Internal grinding process: extension of the range of know-

how by means of the integration of Combitec AG in 2008 [email protected]

FURTHER INFORMATION

STUDER – THE DEVELOPMENT IN A NUTSHELL

1912: First patent for the silent

reversal of the table

1931: Export of the fi rst STUDER

machine to Russia

1936: RHU 450 – the world’s fi rst

hydraulically controlled cylindrical

grinding machine is launched

1962: 10,000m2 factory area. The

technological progress and the

increasing demand result in many

more capacity extensions

1977: Fritz Studer AG presents the

world’s fi rst CNC-controlled cylindri-

cal grinding machine

1994: STUDER joins the SCHLEIFRING

Group of the Körber corporation

2008: Integration of Combitec AG as

technology centre Internal grinding

2012: More than 21,000 sold cylindri-

cal grinding machines in 100 years


34 MOTION 01/12


PORTR AIT

„I am proud to be a part of this company“50 years working at STUDER Machines – Kunio Kitamura has led the STUDER brand to success in Japan.

Kunio Kitamura is a modest and re-

served man. You’re only likely to learn

of his decisive contribution to the success

of STUDER in Japan incidentally. On the

periphery of the Studer Motion Meeting,

MOTION gained interesting insights into

50 years of work for STUDER. Mr. Kita-

mura, who hails from Japan, fi rst became

enthusiastic for machinery at the end of

his school days. He couldn’t afford to go

to university, however, so he looked for

opportunities abroad. A teacher put him

in contact with a company that imported

European machinery into Japan.“ I

worked as an Assistant to the Service

Technicians in Japan,” explains Kitamura-

san. “In 1962 I then came into contact with

STUDER, and two years later, I was of-

fered an apprenticeship with them in

Switzerland.” In 1964, Kitamura-san

spent 20 months in Thun, where he was

trained to be a Service Technician. “It was

a great time. My colleagues were nice

and I made some great friends. I learned

how to drive and ski and I also became

fond of the food, such as the Berner

Rösti.” He was also impressed with the

Swiss working culture. “The people start

earlier and go home on time. In Japan,

people tend to work a lot longer and only

get home late in the evening.”

Meticulous attention to detail

His apprenticeship was formative in terms of quality, precision and organising his

work – and important for his subsequent work in Japan. When he returned home,

Kunio Kitamura worked as an Expert for STUDER Machines for several different

agencies. His biggest task was that of transferring the technology into Japanese as

no information material was available in his language. In this context, Kitamura-san

compiled technical data and solutions with meticulous attention to detail, putting

the key information together in a textbook. It was in this way that he was able to

familiarise his customers with the technology and explain solutions to their problems.

The machines became increasingly sophisticated and in need of explanation. To be

able to offer his Japanese customers an even better service, in 1999 STUDER opened

its own branch in Tokyo, Studer TEC K.K. Kunio Kitamura became its Director, and

together with his team, developed the success of the brand in Japan: “I am very

proud of having been able to work for STUDER for such a long time.” And colleagues

and customers will also be able to use his know-how in the future. In the Japanese

tradition, the Service Technician has continued to stay true to his company even

though he is now semi-retired, and continues to manage the Overhauls division. It

is the passion and dedication of employees like Kunio Kitamura who have helped

make the STUDER brand the number one in the world.

Half a century with STUDER: Kunio Kitamura at STUDER

Machines in the 1960s and in 2012.

The guest of honour at the Motion meeting: Kunio

Kitamura has over 50 years of STUDER know-how.

Looking back: with Adrian Stalder, Head of Service

at Fritz Studer AG, Kunio Kitamura leafs through one

of his hand made ‘textbooks’


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36 MOTION 01/12

The fi eld of machinery and plant en-

gineering is an industry sector with

worldwide importance. The industry of-

fers interesting professional fi elds and

good future prospects, particularly for

young people starting out in their pro-

fessional lives. However, many compa-

nies have been complaining about a lack

of skilled personnel for some time. This

is supported by international surveys,

according to which 50 percent of all

INDUSTRY WITH PROSPECTS

Skilled personnel do not appear out of the blueThe creativity and the commitment of the employees are also crucial for the success of the SCHLEIFRING companies. As a result, the companies invest huge sums into the individual education and training of their skilled personnel.

companies have experienced diffi culties in fi nding suitable personnel for open

positions in the past year. At the same time, the companies must also position

themselves as attractive employers and offer career opportunities and individual

education and training to their employees as well as future colleagues.

The companies of the SCHLEIFRING Group know that employee knowledge, crea-

tivity, and commitment are important foundations for the success of a company.

As a result, they consistently invest in company-specifi c training programmes,

such as dual vocational education and training. In cooperation with the Baden-

Wurttemberg Cooperative State University, Walter Maschinenbau GmbH offers

a combined vocational education consisting of university studies and apprentice-

ship for Bachelor of Engineering in the fi elds of mechanical engineering and applied

Many job descriptions:

the SCHLEIFRING

companies train

employees such

as multi-skilled

mechanics [1],

industrial mechanics

[2], logistics experts

[3], computer

scientists [4],

and automation

engineers [5]

[5][4]

[2]

[3]

[1]

L_S.36-39_Ausbildung_ENG.indd 36 13.06.12 11:08

37MOTION 01/12

computer sciences. On the other hand,

Blohm Jung GmbH cooperates with the

Hamburg University of Applied Sci-

ences within the framework of a dual

bachelor degree course in the fi elds of

mechanical engineering and electrical

engineering. The strength of such offers

lies in the combination of postsecondary

education and professional practice.

They have been an important source of

new skilled personnel for many years

and guarantee fi rst-rate qualifi cation.

Appreciated and nurtured

In general, the companies of the

SCHLEIFRING Group offer many open

spaces for individual development —

just as they have for Andreas Werz. The

industrial sales representative-to-be

with Walter Maschinenbau GmbH will

graduate soon and recently signed a

permanent employment agreement as

a service employee in the fi eld of spare

parts sales — a stroke of good fortune

for both sides. Werz demonstrated in-

dustriousness and initiative far beyond

the classroom curriculum. He became

involved as a youth and educational rep-

resentative and developed a very useful

database in his fi eld of service. Such a

commitment is appreciated and nurtured

by instructors and human resources of-

fi cers. The future skilled personnel must

act self-dependently and get their bear-

ings quickly. “We appreciate when

somebody demonstrates willingness

and assumes responsibility. That is what

advances a company,” says Bettina Üh-

lken, human resources manager with

Walter Maschinenbau GmbH. Open-

mindedness and a distinct ability to com-

municate were expected, as well as a

certain level of fl exibility: “In return, we

provide our employees with the greatest

possible opportunities for develop-

ment.” For example, the SCHLEIFRING

companies offer a wide range of promo-

tion offers. This way, along with trainee

positions, positions for graduands and

student employees of the computer sci-

ences and mechanical engineering de-

partments are also granted. Within the

framework of internships, school and university students can familiarise themselves

with everyday professional life in the companies. The comprehensive offer also

comprises technical training measures and foreign language seminars, as well as

scholarships for extension courses of studies or continued education with qualifi ed

degrees. “Skilled personnel do not appear out of the blue. As a company, we are

responsible in this area,” says Roger Leuenberger, head of the training workshop

with Fritz Studer AG.

Doors and gates are open

“As with all companies of the SCHLEIFRING Group, we have a global presence, we

are represented in all important markets, and we cooperate in international teams,”

says Ulrike Ettel, human resources offi cer with Blohm Jung GmbH. This also includes

opportunities for a trans-national career. “Our engineers and other skilled person-

nel are deployed on a global scale. Of course, they need a good knowledge of

languages and an intercultural competence for that. We promote both.” Whoever

takes these opportunities will basically fi nd all doors and gates open, according to

Ettel. Whoever decides on an engineering career today, according to her colleague

Ühlken, will basically select a line of occupation with secured future prospects. This

is also confi rmed by the Association of German Engineers (Verband Deutscher

Ingenieure – VDI): “The market is very robust,” says VDI director Dr. Willi Fuchs.

The “lack of engineers” in Germany has even grown to approx. 80,000 people. For

example, in December 2011, approx. 18,300 engineers were looking for a job, but

Learning from real life

for real life: as here with

WALTER, trainees are

trained directly on

the machines



38 MOTION 01/12

“We” wins: at the joint lunch with WALTER, junior employees exchange experiences. Afterwards, an experienced

employee makes a speech about his or her area of responsibility

Creative minds:

once a year,

there is a

meeting of the trainees in their

fi rst year of apprenticeship

of all companies

of the Körber

Group in the

corporate headquarters in

Hamburg

simultaneously there were 98,300 open

positions according to the VDI. Produc-

tion and mechanical engineers are espe-

cially needed, as well as electrical engi-

neers. “This can also be attributed to the

large number of future topics where en-

gineering services are currently in de-

mand, for example regarding energy

turnaround, electrical mobility, or medi-

cal engineering,” says Dr. Fuchs.

Tolerant cooperation

A harmonic environment and soft skills

are as important for a consistently high

performance level as the technical qual-

ifi cation. That is why STUDER, SCHAUDT,

MIKROSA, MÄGERLE, BLOHM, JUNG,

EWAG, and WALTER do not only teach

the trainees expert knowledge. “Further-

more, it is the objective of the training to

convey a proper appearance and the abil-

ity to work in a team. Cross-departmen-

tal events such as the trainee camp with STUDER, joint sports activities, and meet-

ings promote solidarity. Social competence and tolerant cooperation are very

important,” says Leuenberger. For example, with WALTER, trainees organise a joint

lunch in each quarter at which experts of the company are invited to make speech-

es after lunch. The stays in the Czech factory in Kurim are a special highlight. There,

the trainees collect practical experience. They fi rst and foremost get to know the

production, as well as further departments such as order centre, warehouse, ship-

ping, etc. The SCHLEIFRING companies also think outside the box: in order to

provide the trainees with insight into the procedures of other companies, STUDER

has been running a trainee exchange programme in Hamburg for years together

with Hauni Maschinenbau AG, part of Körber AG. Two trainees in their third year of

apprenticeship work for the partner company for six to eight weeks. Blohm Jung

GmbH also cooperates with Hauni Maschinenbau AG. Trainees can also use training

courses and seminars, as well as job-related postgraduate training of the company

at this point. Furthermore, all trainees of the Körber AG in their fi rst year of appren-

ticeship meet once a year in Hamburg. At this event,

the focus is on getting to know the company better

and exchanging information with other employees

regarding different companies, fi elds of technol-

ogy, and qualifi ed jobs.

Gigathlon as a team: with STUDER, cross-depart-

mental events are part of the training programme

such as conveying technical knowledge

[email protected]@walter-machines.deroger.leuenberger@studer.comwww.schleifring.net/de/karriere

The most common skilled trades in the

companies of the SCHLEIFRING Group:

mechatronics engineer and automation

engineer

industrial mechanic, cutting machine

operator, and multi-skilled mechanic

electrical and mechanical professional

design engineer

energy electronics technician and indus-

trial electronics technician

logistics expert

management assistant and industrial

sales representative

computer scientist

JOB DESCRIPTIONS

FURTHER INFORMATION

ith STUDER cross-depart-

ˇ


Gauging and control for grinding machines

Absolute measuringsystem for parts with a large measuring range

Leading...

Please visit our website where you will find more detailed information and your nearest Marposs office.

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...results from the perfect combination

of many factors

Acoustic sensors for grinders

Grinding wheel balancing systems


40 MOTION 01/12


Waymark: colourful

buoys provide

orientation along

the path

Despite low tide through

the Pacifi c Ocean: at

some points the water

fl ows up to the interior of

the island

OUTDOOR-ADVENTURE

Hiking on the Edge

Dusk is already falling as the fl oat

plane takes off from Gold River on

the west coast of Vancouver Island. The

destination is the Louie Lagoon in the

wilderness of Nootka Island. Also

aboard: MÄGERLE area sales manager

Hans Seifert, as well as his life partner

Astrid Rüttimann. Expectantly, they

Backpacking through solitude: MÄGERLE

manager Hans Seifert is attracted by the

free wilderness. His thirst for adventure

led him to Canada in 2011.

start their adventure through the Canadian solitude. They had actually planned

to get going much earlier today. Since the early morning hours, the two of them

have been waiting for their plane to take off to the island off the west coast of

Canada located at a distance of only 35 minutes by air and with a size of approx.

500km2. However, heavy fog over the Pacifi c Ocean delayed the departure. Thus,

the fi rst unplanned obstacle of their trip came directly after touching down. “We

had to hike the two kilometres to the fi rst camp through thick rain forest as night

was falling,” says Seifert. “That was not exactly safe.”

L_S.40-44_Hobby_Adressen_ENG.indd 40 20.06.12 11:43

41MOTION 01/12

Solitude on Nootka

Island: the island with

a size of approx.

500km2 is scarcely

inhabited

Over the sea: Hans Seifert

and his partner start the

trip in a fl oat plane

Rugged coastline: in

1778, captain James

Cook was the fi rst

European on

Nootka Island

Travelling the world with

20 kilos of luggage

On their seven-day tour, Seifert and his

partner covered a total distance of 35

kilometres. “This was not a long dis-

tance, but a diffi cult and pathless route.

When the tide was out we were able to

walk along the ocean, to be sure. How-


42 MOTION 01/12

A Swiss native in Canada: instead of mountains and alpine glow, Hans Seifert will have rough wilderness and

wild animals. He always has a radio and anti-bear spray at hand for cases of emergency

ever, there were also occasions where we had to take off our backpacks and crawl,

because fallen trees blocked the way. Things like that cost time and energy,” says

Seifert. The adventurers carried 20 kilograms of luggage on their backs: the

equipment comprised freeze-dried meals, fuel for the stove, tent, sleeping bag,

clothes, and emergency radio. “The fascinating thing about backpacking trips is

that you are on your own and that you carry the entire equipment and food for

the entire time,” says Seifert. When it comes to organising, no one can show him

anything new: the Swiss native has been attracted by nature since he was a young

boy. The 53-year old regularly starts off on backpacking trips. At the weekends

he often does mountain hiking, climbing, and skiing trips in the Alps. “The most

beautiful trips led me into the mountains of California, as well as to British Co-

lumbia in the western part of Canada. For example, on Vancouver Island I spent

ten days exploring the legendary West Coast Trail, an originally developed rescue

trail for shipwreck survivors,” says Seifert.

No chance for pickpockets

“In the wilderness, you don’t deal with technology and machines,” says the

area sales manager. “It is about more essential things: where do I fi nd fresh

drinking water? Where can I fi nd a good spot for my tent for the night?” When

choosing their sleeping place on Nootka Island, high trees standing close by

were important. The reason for that is that Seifert and his partner had to suspend

their supplies every evening in bags from a branch with a height of at least 4

metres using a wire rope hoist. This way, hungry wolves and brown bears

widely spread in this region did not have a chance for a meal and stayed away

from the adventurers. Along their route, the hikers observed many other wild

animals such as sea otters, whales, and bald eagles. The fi rst time they met

other tourists was at the fi nal point of the trip, the small Indian village of Yuquot.

Then, they took a ship back to the mainland. There, the couple was looking

forward to some days of relaxation. After this

trip to Nootka Island, Hans Seifert still is fasci-

nated by Canada: the next adventure on Vancou-

ver Island is already lined up. [email protected]; www.vancouverisland.com

FURTHER INFORMATION


Improvised: in the wilderness, shaving is one of the

daily challenges

Enjoy your meal: special high-caloric food provides

power for the strenuous way to Yuquot

Good-humoured: even with 20 kilos of luggage on the

back, the hikers are still smiling

Unspoiled countryside: colourful starfi sh bring colour

to the beach of Nootka Island

Campsite with ocean view: the

two make themselves at

home in the tent during the night


43MOTION 01/12

During web and straight dress-

ing with form feed, the feed is

traditionally entered in mm/min.

However, doing so does not take

the fact into consideration that the

degree of dressing overlap chang-

es when the grinding wheel is re-

duced in size. The updated VDI

directive 3392 gives good insight

into this matter; in it, the user de-

tects that a constant degree of

dressing overlap is important for

constant dressing conditions over

the entire grinding wheel diameter. In order to take this issue into account,

the Blohm Jung user interface is now equipped with a variable input option.

This means that the operator can enter the form feed during dressing either

in mm/min or in mm/rotation. Now and in the future, this will be standard for

all BLOHM JUNG dressing cycles.

With the new plug-in tools

Feedrate Optimizer and Tool

Balancer, WALTER now offers new

performance-enhancing software

solutions. The Feedrate Optimizer

determines the occurring loads on

the grinding wheel for every grind-

ing movement and controls the

ideal feed. In this way, grinding

movements with low grinding

wheel load are accelerated and

loads on the grinding wheel that

are too high are avoided by reduc-

ing the feed speed. This optimised

process sequence reduces the

grinding time by up to 40 percent.

The Tool Balancer is used to ana-

lyse the imbalance of a tool and to

automatically take the correspond-

ing corrective actions. Result: a

perfectly balanced tool. This re-

sults in longer service lives and an

improved surface quality of the

produced tools.

BLOHM JUNG

Dressing with form feed

HELITRONIC TOOL STUDIO

Plug-ins increase the performance

STUDERMESSENGER

Error message via SMS

NEWS TO USE

Practical production tipsUseful developments of the SCHLEIFRING companies help making your manufacturing easier and more effi cient. For example, new plug-ins for the HELITRONIC Tool Studio from WALTER, the StuderMessenger service, and new input options for BLOHM and JUNG machines.

The StuderMessenger service provides infor-

mation automatically about current error

messages of machines via email or SMS – at any

time and independent of the current location of

the user. StuderMessenger is part of the StuderWIN

operating system and works with all machines

equipped correspondingly that are connected to the

internet during operation. Operators can select the

errors they want to be informed about specifi cally

from a list of possible errors. The StuderMessenger

will then provide reliable information in the case of

an incident. All messages are furthermore docu-

mented in a logbook. Advantages: downtimes can

be avoided by means of the alarm and the per-

sonnel can be deployed more effi ciently.

[email protected]

[email protected]

Dressing feed: optional input of mm/min or mm/

rotation

christoph.ehrler@

walter-machines.com

Sor-

or

ny

of

WIN

hine

o th

ct th

fical

enge

se o

ocu

an

r-

N

es

he

he

ly

er

of

u-

Informed: the

StuderMessenger

monitors your

production

Effi cient solutions: using new plug-ins,

WALTER reduces the grinding times by up

to 40 percent


Körber Schleifring AG

Nagelsweg 33–35

20097 Hamburg

Germany

Phone +49-40-21107-03

Fax +49-40-21107-13

[email protected]

www.schleifring.net

Körber Schleifring Machinery

(Shanghai) Co. Ltd.

1128, Tai Shun RoadAnting TownShanghai Jiading District 201814, ChinaPhone +86-21-395873-33Fax [email protected]


(Shanghai) Co. Ltd.

Beijing Branch Offi ce

Room 202, Building 18, Tower B, Universal Business Park,No.10 Jiuxianqiao Road, Chaoyang DistrictBeijing 100015, ChinaPhone +86-10-659318-31Fax [email protected]


(Shanghai) Co. Ltd.

Wuxi Branch Offi ce

A-096 YangmingHi-Tech Industrial ParkWuxi Jiangsu 214024, ChinaPhone +86-510-854206-66Fax [email protected]


(Shanghai) Co. Ltd.

Chongqing Branch Offi ce

Room 17-03 AMetropolitan Tower 68Zou Rong Lu, Central DistrictChongqing 400010, ChinaPhone +86-23-63 70-36 00Fax +86 23 637 4-10 [email protected]


(Shanghai) Co. Ltd.

Guangzhou Branch Offi ce

Room 2003, 20/FCenter Plaza Tower B161 Linhexi Rd.Tianhe District GuangzhouGuangdong Province 510620, ChinaPhone +86-20-38 62-12 41Fax +86-20-38 62-12 [email protected]

United Grinding

Technologies Inc.

510 Earl Blvd.MiamisburgOH 45342, USAPhone +1-937-859-1975Fax [email protected]

United Grinding

Technologies Inc.

5160 Lad Land DriveFrederiksburgVA 22407, USAPhone +1-540-898-3700Fax [email protected]

Körber Schleifring GmbH

India Branch Offi ce

99 Spencer Road, 1st FloorFrazer TownBangalore 560 005, IndiaPhone +91-80-41554-601/602Fax [email protected]

Mägerle AG Maschinenfabrik

Allmendstrasse 508320 Fehraltorf, SwitzerlandPhone +41-433-5566-00Fax [email protected]

Blohm Jung GmbH

Kurt-A.-Körber-Chaussee 63–7121033 Hamburg, GermanyPhone +49-40-7250-02Fax [email protected]

Blohm Jung GmbH

Jahnstraße 80–8273037 Göppingen, GermanyPhone +49-716-1612-0Fax [email protected]

Fritz Studer AG

3602 Thun,SwitzerlandPhone +41-33-43911-11Fax [email protected]

Schaudt Mikrosa GmbH

Saarländer Straße 2504179 Leipzig, GermanyPhone +49-341-4971-0Fax [email protected]

StuderTEC K.K.

Matsumoto Bldg. 2F4-10-8, Omorikita Ota-ku,Tokyo 143-0016 JapanPhone +81-36-80161-40Fax [email protected]

Walter Maschinenbau GmbH

Jopestraße 572072 Tübingen, GermanyPhone +49-7071-9393-0Fax [email protected]

Walter Machines

Asia Pacifi c Pte. Ltd.

25 International Business Park#01-53/56 German Centre,609916 SingaporePhone +65-65-6281-01Fax [email protected]

Ewag AG

Industriestrasse 44554 Etziken, SwitzerlandPhone +41-32-6133-1-31Fax [email protected]

Walter Machines UK Ltd.

B 13 Holly Farm Business Park,Honiley, Kenilworth, Warwickshire,CV8 1NP, Great BritainPhone +44-19-26-4850-47Fax [email protected]

Walter Kurim s.r.o.

Blanenská 128966434 Kurim, Czech RepublicPhone +420-541-4266-11Fax [email protected]

Walter Machines Italia Srl

Via G. Garibaldi, 4222070 Bregnano (CO),ItalyPhone +39-031-7708-98Fax [email protected]

Walter Japan K.K.

1st fl oor MA Park BuildingMikawaanjo-cho 1-10-14Anjo City 446-0056, JapanPhone +81-556-71-1666Fax [email protected]

Walter Máquinas Ltda.

Avenida XV de Agosto, 5.060Sorocaba, BrazilCEP: 18 085 290Phone +55-15-3228-6910Fax [email protected]

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