SLOTTING MACHINE S8
Transcript of SLOTTING MACHINE S8
Cold forming machinesSlotting machines
SLOTTING MACHINE S8
ERNST GROB AG
ERNST GROB AGCold forming machinesSlotting machinesRohrgasse 9, P.O. Box 830CH-8708 MännedorfSwitzerland
Phone +41 44 922 77 00Fax +41 44 922 77 88
Products and ServicesCold forming machines
ERNST GROB AG develops, designs and builds cold forming machines; from basic,
manually loaded units to fully automated production lines. The primary fields of
application for the sheet metal and solid components produced by cold forming
are to be found in the automotive industry. Our machines, however, are also opera-
tional wherever efficiency and quality are key considerations.
Slotting machines
Sheet metal parts that have been splined on GROB cold forming machines can be
transferred to our slotting machines for secondary operations, thereby ideally com-
plementing the cold forming process. Non-splined workpieces can also be slotted.
The design concept of our equipment is modular and can be optimally tailored to
suit the specific requirements of the application involved.
Tools
All tools used on GROB machines are developed and manufactured in GROB‘s in-house tool
shop in accordance with the specific requirements of the materials and applications involved.
An in-depth expertise, plus state-of-the-art toolmaking equipment combined with
continuous research and development allows ERNST GROB AG to provide optimal
tooling delivered in the shortest possible delivery times.
Subcontracting
At our subcontract facility we use our own cold forming and slotting machines to
produce components to customer order. We can take on your production needs
for individual components or small pilot runs. To overcome production bottlenecks,
we also process full-scale mass volumes. Our Quality Management System is certified
to ISO/TS 16949.
Engineering
A cornerstone of our success is the relentless search for optimal solutions to specific
engineering challenges. Our development department is key in this objective, as this is
where years of in-depth experience and the latest technological expertise are merged.
Close collaboration with our business partners invariably succeeds in generating innovative
results that our test department rapidly converts into prototype components, which
are already close to mass-production maturity.
ContentsPage
Company profile .................................................................................................. 2
Products and applications for the S8 ................................................. 4
Machine description ........................................................................................ 6
Layout, technical specifications ............................................................ 10
Installation, operation, service ................................................................ 12
Company profi le
CompetenciesERNST GROB AG develops, designs and
builds precision machines dedicated to
the cold forming of splined and non-
splined workpieces. The manufacture
of slotting machines for secondary
and finishing operations on cold
formed workpieces is yet another core
competence of the company.
From the initial idea through to its de-
velopment, and right up to the industrial
application – the entire concept is available
from a single partner: ERNST GROB AG
provides customer specific solutions,
from manually loaded single machines
to fully automated production lines.
GROB slotting machinesGROB slotting machines are employed to
finish cold formed splined or non-splined
hollow components.
Diverse slotting and coining
operations are undertaken at various
stations.
Separate stations for dedicated applica-
tions can also be integrated.
GROB cold forming machinesGROB cold forming machines are based
on the principle of the cold roll forming
in planetary type movement process.
The technology provides a solution for
the cost-effective production of splined
or reduction type cylindrical workpieces.
The founder of our company, Ernst Grob,
further developed and refined the
principle (see infobox «The GROB story»).
Diversity of finished productsApplications for GROB-Machines are
highly flexible, for example, when
producing:
Clutch disc carriers
Splined shafts
Gearbox shafts
Drive shafts
Steering system parts
Pump shafts
Extruder shafts
Splined shafts for:
– Printers
– Medical instruments
– Communal vehicles
– Helicopters
– Food processing equipment
– Torsion bars and progressive coil springs
Gearbox shafts
Thin-walled tubular components, cold rolled without support mandrels
Components for a wide range of vehicles
Machines for the automotive industryGROB machines are primarily used in
the automotive industry. Typical compo-
nents are clutch disc carriers in auto-
matic transmissions and other splined
components within the power train.
Slotted workpieces
GROB cold forming technology
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ERNST GROB AG • Rohrgasse 9 • CH-8708 Männedorf • Phone +41 44 922 77 00 • Fax +41 44 922 77 88 • [email protected] • www.ernst-grob.com
Dedicated partnershipsAt ERNST GROB AG the development
department is intensely focused on the
refinement of existing technologies,
plus the development of new processes
and applications. In close cooperation
with customers and other interested
parties, solutions are generated that
permit economic production of accurate
finished parts. When required, ERNST
GROB AG offers customer support
throughout the entire service life of
machines installed by our company.
Success factor employeesThe key success factor of ERNST GROB AG
is the professional competence and
dedication of its employees. A team of
highly qualified and experienced
specialists is the best guarantee for
meeting the most demanding challenges.
An innovative spirit coupled with an
inherent flair for technical solutions
are the foundation on which innumer-
able and unique developments are
based.
Headquarters in Maennedorf
LocationsERNST GROB AG plants are located in
Switzerland’s greater Zurich conurbation
where the company is able to benefit
from an outstanding infrastructure
with excellent transport facilities.
Headquarters (administration, research,
development, assembly) are located
in Maennedorf, while the subsidiary
(production, subcontracting) is to be
found in Oetwil am See.
Subsidiary in Oetwil am See
The GROB story
up to 1961 Dr. h.c. Ernst Grob develops cold forming machines at the machine tool works he founded in Munich in 1926.
1962 1962 Dr. h.c. Ernst Grob founds a company making cold rolling machines in Maennedorf and delivers the first one to Sulzer, Zuchwil, Switzerland.
1963 Further machine deliveries to Germany, Italy and Japan. Subsequent set-up of global sales and marketing network.
1979 Introduction of PLC technology and establishment of in-house electrical department.
1984 Introduction of multiple axis CNC technology.
1985 Following death of Dr. h.c. Ernst Grob: establishment of ERNST GROB AG. Business continued and expanded by his grandson and current owner, Mr. Daniel Dériaz.
1991 Acquisition and expansion of a subsidiary plant of ERNST GROB AG in Oetwil am See, Switzerland.
1999 Quality Management Certification to ISO 9001.
2001 Expansion of product portfolio with type S8 slotting machine for hollow parts and delivery of first slotting machine to General Motors Strasbourg.
2005 Start-up of production at the newly constructed workshop in Oetwil am See.
2006 Certification of subcontracting facility in Oetwil am See to ISO/TS 16949.
2007 Introduction of torque drive technology (NCT).
2008 Modern centralised office building in Maennedorf is occupied.
2009 Market roll-out of newly developed stroke-stamping process.
2012 Opening of our own Beijing representative office.50 years jubilee of ERNST GROB AG.Quality inspection using state-of-the-art methodology
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Products and applications for the S8
Industries Machines from ERNST GROB AG are
used primarily in the automotive and
vehicles industries. Virtually all the well
known makers and their top suppliers
are using these installations to produce
gearbox components, steering systems
and numerous other parts.
Splined and slotted workpieces are also
used in a diversity of other applications,
for example in the plastics and paper-
making industries.
High and low production volumesWhereas ERNST GROB AG machine
customers tend to produce high
volume runs, the situation is different
when smaller production batches are
involved: components for a wide range
of applications are often subcontracted
direct and then produced by
ERNST GROB AG.
Finished productsExample clutch disc carrierThis double-clutch disc carrier for a
DSG (direct shift gearbox) was initially
processed on a GROB cold forming
unit and subsequently finished on a
GROB S8/4 slotting machine. It was
trimmed to length, its holes slotted and
the snap ring groove formed. Based
on customer specific requirements,
ERNST GROB AG designs, develops and
realises appropriate production pro-
cesses. Key considerations in these
solutions are economical output and
consistently high component accuracy.
Double-clutch for a direct shift gearbox (DSG) Slotted, smooth workpiece
Double-clutch disc carrier
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Slotted round and elongated holes, semi-sheared retention dogs and snap ring grooves generated by a combination of slotting and coining
Snap ring groove generated by a combination of slotting and coining (insertion chamfer cold rolled)
Selection of workpieces slotted on a S8 slotting machine Workpiece with castellations, elongated holes and snap ring groove
Examples of slotting direction: stop has been formed outside-in and the snap ring groove inside-out
Oil pockets semi-sheared without reducing spline length
ERNST GROB AG • Rohrgasse 9 • CH-8708 Männedorf • Phone +41 44 922 77 00 • Fax +41 44 922 77 88 • [email protected] • www.ernst-grob.com 5
Machine description
One or more workstationsThe single-station S8/1 slotting machine
is a 1 station configuration that is
ideally suited to individual processing
operations.
In the standard versions S8/2, S8/3 and
S8/4, additional dedicated worksta-
tions can be incorporated to handle
a diversity of combined processing
steps. These machines are generally
automated to assist loading and unloa-
ding. When required, however, they
can be operated manually. For reasons
of safety and noise attenuation, the
machines are normally installed in
sound damping cabins, into which the
electrical controls and the control pa-
nel are also integrated.
Modular, compact and flexibleThanks to their modular design and
ease of operation, the machines are
highly flexible and can be used univer-
sally for the slotting, coining, trim-
ming to length or cold forming of cup
shaped and ring shaped sheet metal
workpieces.
The machine design concept allows
them to be transported as completely
assembled units that can be installed
on anti-vibration pads, without any
need for foundations.
Slotting machine S8/4
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ERNST GROB AG • Rohrgasse 9 • CH-8708 Männedorf • Phone +41 44 922 77 00 • Fax +41 44 922 77 88 • [email protected] • www.ernst-grob.com
1 Station slotting machine S8/1, vertical layout
Slotting machines S8/2, S8/3 and S8/4With this machine concept, the design
of the individual workstations is ex-
tremely compact. This allows them to
be linked and automated in a minimal
space requirement to achieve a diversity
of slotting and coining operations.
All stations are linked by a machine-
internal automatic gripper system. If
required, special purpose workstations
can be integrated into the machine
layout.
1 Station slotting machine S8/1The slotting unit of the S8/1 is based
on the same concept as the standard
machines, but is designed as a single-
station model. According to the specifi-
cations, the S8/1 can be executed
either as a vertical stand-alone version,
or as a horizontal, integrated configu-
ration, for example in a 12-NCT cold
forming machine.
S8/1: Features and benefits
• Compact and rugged design concept
• Very short cycle times
• Very high process stability
• High tool life
• Affordable tool costs
• Universal application potential, minimal changeover times
• Extremely high slotting capacity
• Slotting direction inside-out or outside-in
• Mechanically defined stroke end position
• No lubricant or coolant needed
• Ease of service and maintenance (e.g. remote diagnosis)
S8/2, S8/3, S8/4: Features and benefits
• Very short cycle times
• Minimal downtimes
• Very high process stability
• High tool life
• Affordable tool costs
• Universal application potential, minimal changeover times
• Compact and rugged build quality
• Flexible machine concept: 1-4 worksta-tions, plus special purpose stations
• Extremely high slotting capacity
• Slotting direction inside-out or outside-in
• Mechanically defined stroke end position
• No lubricant or coolant needed
• Ease of service and maintenance (e.g. remote diagnosis)
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Combined operationsAs this machine concept has a mecha-
nically defined stroke end position,
combined slotting and coining opera-
tions are possible. Typical applications
are the generation of snap ring groo-
ves in clutch disc carrier housings.
Application examples:
• Slotting of holes and forming
grooves
• Coining operations (e.g. for oil dams
and assembly location holes on
clutch disc carriers
• Combined slotting and coining ope-
rations (e.g. for snap ring grooves)
• Bending (e.g. of tabs)
Operator panel with colour screen and control elements
Horizontally configured 1 Station slotting machine S8/1, integrated into a 12-NCT cold forming machine
Control panelAll functions can be entered and
accessed via the control panel.
Tooling for elongated holes
Slotting stations of a model S8/31 Station slotting machine S8/1, integrated into a 12-NCT cold forming machine, horizontal configuration
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ERNST GROB AG • Rohrgasse 9 • CH-8708 Männedorf • Phone +41 44 922 77 00 • Fax +41 44 922 77 88 • [email protected] • www.ernst-grob.com
Slotting zone of 1 Station slotting machine S8/1
Oblique hole slotting station
Functions
Counterholder Workpiece Workpiece mandrel Tooling B axis C axis X axis Z axis
1234BCXZ
1
2
3
4
B
C
X
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Technical Specifications S8/2, S8/3, S8/4 *
Machine model S8/2 S8/3 S8/4
Total installed rating (kW) 28 40 52
Power consumption (kW/h) 12 14 18
Weight (t) 11.0 12.5 14.0
Machine width W, range (mm) 1 900 1 900 2 200
Workpiece diameter (mm) 80–240 **
Max. Workpiece length (mm) 170 **
Stroke rates (strokes/min) 200 **
CNC controls Fanuc / Siemens
Slotting force (N) 90 000
* As GROB machine concepts undergo continuous development refinement, all technical specifications are subject to change without notice!
** Limits of range
Layout, technical specif ications
Layout S8/2, S8/3, S8/4
BX
C
Z
1050
2650
4650
4900
W
1320
2140
2000
1150
BX
C
Z
1050
2650
4650
4900
W
1320
2140
2000
1150
BX
C
Z
1050
2650
4650
4900
W
1320
2140
2000
1150
10 © ERNST GROB AG • S8
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ERNST GROB AG • Rohrgasse 9 • CH-8708 Männedorf • Phone +41 44 922 77 00 • Fax +41 44 922 77 88 • [email protected] • www.ernst-grob.com
Technical Specifications S8/1 *
Machine model S8/1 (stand-alone) S8/1 (horizontal)
Total installed rating (kW) 18 15
Power consumption (kW/h) 4–6 3–4
Weight (t) 5 2.5
Dimensions HxWxD (mm) 2 650 x 1 800 x 2 400 1 900 x 900 x 1 900
Workpiece diameter ranges (mm)
80–240 / 120–280 / 160–320 mm **
Max. Workpiece length (mm) 170 mm **
Stroke rates (strokes/min) 200 **
CNC controls Fanuc / Siemens
Slotting force (N) 175 000 90 000
* As GROB machine concepts undergo continuous development refinement, all technical specifications are subject to change without notice!
** Limits of range
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Instal lat ion, Operation, Service
Up to transfer to enduserCustomised machines are built and set
up at the GROB facility by a team of
specialists. Our experienced service
engineers participate in every prelimi-
nary acceptance procedure together
with the customer. Following delivery
to the customer’s plant, they ensure
seamless installation and handover of
the equipment.
Assembly shop Machine assembly
Operation and serviceGROB machines are renowned for
their exceptional durability. Virtually all
machines produced since 1962 are still
fully operational across the globe.
ERNST GROB AG offers its customers
competent, prompt and comprehen-
sive repair and spare parts services
during the entire lifetime of the ma-
chine.
The slotting machine stands on
anti-vibration pads and can be installed
without the need for foundations.
Spare parts available to orderNo foundation required
12 © ERNST GROB AG • S8
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ERNST GROB AGCold forming machinesSlotting machinesRohrgasse 9, P.O. Box 830CH-8708 MännedorfSwitzerland
Phone +41 44 922 77 00Fax +41 44 922 77 88
Rapperswil
Männedorf
WinterthurAirportZürich-Kloten
A1
Chur
Bern/Basel
St. Gallen
Kreuzlingen
SchaffhausenSchaffhausen
Zürich
Horgen
Meilen OetwilA3
A3
A53
A1
A1
A7
A4
A51
ERNST GROB AGUster
2015.09.EGAG S8 de-en • v1.3 • ks