HELLER solutions at Knödler-Getriebe
The strength of the HELLER H 14000 power pack is in the detail
Gear units with torques of up to 400,000 Nm and outputs up to 1,000 kW are the calling card of Knödler-Getriebe GmbH. The primary aim of investing in the HELLER H 14000 4-axis machining center was to create reserves in a universal and reliable manner.
Task
- to produce gear housings with torques of 500 to 400,000 Nm and unit weights of up to 12 t
- high daily load with very high chip removal rates and incredible cutting performance
- long service life and highest possible machine precision
- universal flexibility with adequate reserves to meet one-off customer requests
Project scope & solution
- H 14000 4-axis machining center with 4-speed gear unit/machining unit: 6,000 rpm, 2,292 Nm, 60 kW
Result
- The performance, the mechanical structure and the structural analysis support sustained use of the machine.
- The H 14000 paved the way to pre-milling bearing seats with diameters of up to 600 mm with an insert miller in one cut and then finish-milling with a special solid carbine end milling cutter in a circular fashion. This puts roundness of 5 μm and outstanding Rz surface qualities in the range of 6 to 8 μm on the test records.
- The H 14000 also offers reserves for applications such as the milling of spiral conveyors that involves the use of a severely protruding special tool of 600 mm in length.
Customer testimonial
Werner Knödler
Managing Director at Knödler-Getriebe
"We have known HELLER for years and appreciate the quality of the machines, as we challenge them every day with very high chip removal rates. Believing that slideway guides are the best solution for heavy-duty machining, we went down the retrofitting route some time ago and have our HELLER BEA-series overhauled on a regular basis. We soon changed our minds, though, when we purchased a HELLER MCH 450 with roller guides. Encouraged by positive findings, our confidence in HELLER and the 840D sl control system from Siemens, we were confident that the H 14000 would fit seamlessly into our workpiece spectrum. Not least because certain functions had been rethought and expanded based on experience."
More references
Peter Arnold
Head of Mechanical Manufacturing at Komax
"If you have to deal with 30 pallets containing, at times, up to 50 different clamping points per clamping cube, you need the right tools in the magazine to avoid having to constantly change the tool sets. Our tool count currently stands at 409. Comparable or smaller machines simply do not achieve capacities such as these."
Günter Muhr
Managing Director at Franz Haas Waffelmaschinen
"HELLER has exceeded our expectations. Everything went well, the machines run extremely reliably and our throughput times have also measurably reduced."
Thomas Kaysser
Managing Director at H.P. Kaysser
"Our experience with HELLER, including Service, has been nothing but positive. We speak the same language, so there was simply no reason to change supplier. The entire team has now identified with the HELLER machining centers – because they deliver what HELLER promises!"
Frank Brunner
Head of Manufacturing and Production Engineering at Bitzer
"For me, it was much more important to have found, in HELLER, a manufacturer whose machines are able to meet our high standards without extensive options."
Gerhard Aigner
Head of Production at Engel Austria
"We consider quality to be fundamental. The tolerances for our core components are between two and three hundredths of a millimeter. That's why we made the conscious decision to go for HELLER machines, which are renowned for their stability."
Nicholas Warnken
Nicholas Warnken, Project Manager
"Key contributors to these massive savings are fewer setups thanks to the 5th axis and higher achievable cutting parameters. On the other hand, however, it was the overall package, including the automation system and new tool technologies, that was able to optimize the processes in this way."
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