Klingelnberg exhibits high-productivity generating grinding in an Industry 4.0 environment at EMO

Fully integrated digitization in gear production: Machine manufacturer Klingelnberg will be presenting the latest machines in the Speed Viper family at the EMO trade fair. Thanks to their integration into a cyber-physical Closed Loop production system, these machines optimize cylindrical gear machining.
Following a four-year hiatus, EMO, the world’s leading trade fair for metalworking, will once again open its gates in Hanover/Germany, from September 18 to 23, 2017. Taking full advantage of this forum, Klingelnberg will be launching an innovation offensive aimed among others at elevating generating grinding to a completely new level. In the latest machines in the Speed Viper family, the system supplier has taken an innovative, Industry 4.0 approach, highlighting the potential improvements in cost and efficiency that can be achieved in cylindrical gear production.

Generating grinding in the age of Industry 4.0
Higher standards for power-to-weight ratio, efficiency and noise emission in transmissions can be met with special tooth flank modifications, and these require maximum precision to manufacture. The newly developed Gear Engineer software program provides design engineers with a tool that allows them to take into account all the characteristics of generating grinding right in the design phase. The result is a precisely described digital twin of the gearing created as early as the transmission’s development phase. Along the entire process chain, this digital twin continually links the real world of gears with the virtual world of data. It includes not only the geometry of the relevant process step, but also the gear’s “DNA”: the manufacturing specification for the tooth flanks. The cyber-physical production system (CPPS) developed based on this philosophy carries on the duality between the real world and the digital world, starting with design engineering and continuing to production and quality assurance.  Whereas Gear Engineer is the tool for development, Gear Operator is its seamless counterpart for the shop floor. Gear Operator is the tool on the shop floor that ensures the real world gear wheel corresponds to the geometry of the digital twin in the virtual world with the utmost precision.

Maximum transparency and safety with Industry 4.0  
Klingelnberg presents GearEngine as the IT platform for the CPPS. It provides all the data management services for the software modules, production equipment, and parts history. With data analyses in GearEngine, sources of anomalies or errors can thus be identified and corrected.
To ensure that faulty gears do not go unnoticed until the end-of-line test stand, quality gates can be introduced in the CPPS along the entire process chain. At these quality gates, the characteristics of the real gear are compared against those of its digital twin. In the event of deviations, Closed Loop assistance systems such as Gear Correction help bring the production process safely back on course.

The all new Speed Viper is fit for Industry 4.0
Klingelnberg has implemented the full potential of this innovative, digitally supported approach in the latest generation of the Speed Viper, which will be presented for the first time at EMO. A new construction, a completely updated, ergonomically optimized design and a newly developed operating concept – with this machine, Klingelnberg is celebrating a true premiere on the market. These generating grinding machines are designed for high productivity and robustness in the grinding process. For integration into the CPPS, a new concept was custom-developed with the Gear Operator software. The focus was on the easy, intuitive operating philosophy inspired by smartphones: Help texts, explanatory drawings and wizards for tooling, setup and processing appear on a multitouch screen. Instead of teaching the desired tooth topography through extensive experience to the control software of a generating grinding machine or entering corrections even manually, data previously generated by Gear Engineer are simply imported by Gear Operator. Measured production deviations are minimized by the Gear Correction Closed Loop software through modified machine movements and imported from GearEngine with the touch of a button. In terms of the overall operating concept, Klingelnberg has set yet another new standard for machine operation.

Klingelnberg will be exhibiting this state-of-the-art technology at EMO in Hanover, Hall 26, Stand B82. The on-site team is looking forward to interesting “shop talk” and stimulating discussions.