Liebherh LS 180E Gear shaping machine

Gear skiving according to the Liebherr concept has proven itself. The specialists from Kempten, Ettlingen, and Collegno offer competence from a single source in a full-service package. For successful gear skiving, users need more than just a good machine, summarizes Dr.-Ing. Oliver Winkel, Head of Application Technology. With skiving, we do not sell the LK 300 or 500, but a process. The customer presents a gear, and we supply a machine, tools, and technology for its production. The holistic approach from Liebherr has already been tried and tested in practice. For many customers, the process of skiving is new; the operators of the machines need comprehensive training and assistance. On top of that, the tool design is a very complex issue. We have organized our division of labor very well, reports Oliver Winkel. In Kempten, we calculate the tools, which are then designed and manufactured in Ettlingen or in Collegno in Italy - we have the entire process under control, for both cylindrical and conical tools.

Skiving machines have to endure a lot. The gear skiving machines LK 300 and 500 are based on the tried-and-tested components of the corresponding large hobbing machines. However, process-related modifications were essential. For instance, the entire machine had to be more rigid and equipped with extremely powerful spindles. A gear skiving machine requires a table with a direct drive owing to the high workpiece speeds required. This drive works with an automatic control, which constantly has the optimal parameters: The clamping fixture which links the workpiece and the machine is extremely complex and is designed by Liebherr. As skiving is a highly dynamic process, the machine is practically supplied on a turnkey basis, with individual clamping fixtures for each workpiece, precise rigidity, and contour accuracy. This overall view is an important part of the success of production, explains Siegfried Schmidt, Team Leader in Development and Design of Skiving. A complex process such as skiving has many specific obstacles, which we overcome with very specific mathematical solutions. The newly developed LH Geartec control system also contains the mathematical formulas for pressure angle corrections. This way, quality improvements can be easily achieved via the kinematics of the machine.

The optional tool changer, which can be used to change between roughing and finishing tools, for example, is new. Liebherr offers a ring loader as a standard option for the workpiece changing device; other automation solutions, such as belts and robots, can also be realized upon request. Skiving is popular, especially for internal gearing with medium size and quantity, as it is much faster than shaping and more economical than broaching. In situations where gear skiving is not possible or appropriate owing to interfering contours or if quantities are too low, Liebherr still offers technological alternatives with gear shaping and gear shaving machines. Liebherr can supply customers with the LC 280 a gear hobbing machine within three to four months.

The LS 180 E gear shaping machine is a small machine for big jobs. Liebherr can offer maximum flexibility on one machine. It can machine spur and helical gears in one setting and thus shape several gear teeth out of one workpiece. This is particularly interesting for automotive shafts because, for example, the reverse gear must have straight teeth and the first gear must have helical teeth. With the LS 180 E, developers can effortlessly try out different amounts of crowns, also asymmetrical, on the gear flanks for the prototype production. The machine offers many application possibilities with a maximum stroke number of up to 1,500 double strokes per minute.

Liebherr opens a new chapter in the evolution of gear hobbing with the LC 280 a. The machine equipped with the well-known Liebherr quality offers maximum flexibility and maximum productivity. It is available to the customer at short notice, making it an ideal choice for gear cutting needs in various industries. The fully electronic shaping head control panel eliminates the time-consuming replacement of mechanical helical guides and reduces the setup procedure for changing a workpiece to a minimum. The LS 180 E gear shaping machine can handle internal, external, spur, and helical gears, offering the flexibility needed for a variety of gear cutting applications. The machine's electronic shaping head allows for helical movements without any additional mechanical effort, making it an efficient and cost-effective solution for gear cutting needs. With Liebherr's LS 180 E gear shaping machine, manufacturers can enjoy high precision and productivity in their gear manufacturing processes. The machine is designed with versatility in mind, allowing for the machining of various workpieces with ease and efficiency.

The gear cutting market has been experiencing a trend towards outsourcing in recent years, resulting in many suppliers receiving orders for the soft machining of gears. In response to this shift, Liebherr has developed the LC 280 a, a new generation of gear hobbing machines that offer maximum flexibility and short delivery times. The machine is designed to meet the criteria of quality, flexibility, and productivity, allowing manufacturers to quickly respond to customer demands and deliver high-quality gears with efficiency.

With the LC 280 a, Liebherr offers a complete solution for gear cutting needs. The machine is equipped with a directly driven spindle, allowing for helical movements without additional mechanical effort. This feature makes it ideal for machining gears with various helical angles and asymmetrical geometries. The machine's electronic shaping head control panel eliminates the need for time-consuming replacements of mechanical helical guides, reducing setup times and enabling the machining of several gears with different helix angles in one clamping. Additionally, the machine's versatility allows for the machining of internal, external, spur, and helical gears, offering manufacturers a wide range of application possibilities.

Liebherr's LC 280 a gear hobbing machine offers maximum flexibility and productivity, making it an excellent choice for manufacturers seeking to improve their gear cutting processes. The machine's advanced features and reliable performance ensure high precision and efficiency in gear production, enabling manufacturers to meet customer demands with ease and deliver high-quality gears in a timely manner. With Liebherr's LC 280 a gear hobbing machine, manufacturers can stay competitive in the fast-paced and demanding gear cutting market.

This machine is also very well positioned in production. If a shaft minute, the machine can efficiently achieve a high quantity production rate. The LS E is versatile and can work in both wet and dry modes, though it should be noted that the tool experiences heavier loads during dry machining, which may somewhat limit its performance. However, the machine's compact design makes it highly adaptable, allowing for seamless integration into small factories.

In today's rapidly evolving landscape, manufacturers continuously strive to enhance their gear development processes. As a result, gearboxes are often supplied by dedicated suppliers to automotive manufacturers. These suppliers, in turn, must machine a wide array of different workpieces. Therefore, a flexible machine with a broad range of functions is often the preferred choice for such operations, especially when compared to utilizing two machines with limited capabilities. The LS 180 E, designed to accommodate various production needs, serves as an excellent solution for such challenges and offers a more streamlined approach to machining.

Furthermore, manufacturers face the ongoing challenge of reduced batch sizes combined with an increasing number of variants. Consequently, the demand for machines that can respond effectively to these trends while maintaining efficiency has grown significantly. The LS 180 E is precisely tailored to meet these requirements. It serves as a versatile solution that can cater to prototype development, series production, and flexible productions for suppliers, showcasing its adaptability and robust performance in various scenarios.

Among the notable advantages of the LS 180 E is its ability to facilitate possible tooth trace modifications such as symmetrical crowning, symmetrical taper, asymmetrical crowning, and tooth alignment modifications. This feature enables manufacturers to produce highly customized and precise gear profiles, supporting a wide range of applications across different industries.

Additionally, the LS 180 E employs an electronic helical guide, which offers several key benefits. One of the most significant advantages is its ease of programmability, allowing for straightforward adjustments or corrections via CNC axes. This contributes to the machine's exceptional accuracy, ensuring consistent and high-quality gear production. The precise μ correction feature further enhances the tooth trace quality, resulting in smoother, better-performing gears with minimized deviations.

Moreover, the LS 180 E boasts a column swivel axis that allows for a stroke position traversing range. This further adds to the machine's flexibility and precision during operation. The feed radial axis column slide with a speed of 5,000 mm/min (option D1N 1 to 3) ensures reasonable chip formation, leading to superior profile quality and longer tool life, thus optimizing the overall machining process.

The machine's user-friendly software streamlines the setup and programming process, making it easy for operators to utilize its advanced capabilities. With straightforward adjustments and controls, manufacturers can achieve highly customized gear profiles with minimal effort, reducing setup times and enhancing production efficiency.

Regarding automation, the LS 180 E's design ensures seamless integration into various production environments. Its loading can be effectively achieved through belts, robot cells, or other automation solutions, providing manufacturers with the flexibility to choose the most suitable automation method based on their specific requirements. Moreover, the machine's versatility allows for both wet and dry machining, further expanding its range of applications.

Liebherr's commitment to continuous improvement and innovation is evident in the development of the LS 180 E. By listening to customers' needs and carefully customizing the machine to meet these demands, Liebherr has created a cutting-edge solution that delivers exceptional performance, precision, and cost-effectiveness. The LD 180 E's debut at EMO in Hanover in 2017 marked a significant milestone in gear manufacturing, and it continues to be a valuable asset for the industry, offering manufacturers the tools they need to thrive in today's dynamic and competitive market.

As Liebherr continues to lead the way in gear technology and automation systems, the LD 180 E stands as a testament to the company's dedication to excellence and its commitment to supporting manufacturers in their pursuit of superior gear solutions. With the LS 180 E, Liebherr has once again proven its position as a reliable and innovative partner for the industry, offering gear manufacturers a cutting-edge solution that empowers them to shape the future of gear production.

Geometry data can be imported and exported using the GDE format.

In pursuit of enhancing safety in manufacturing, the focus is on connecting systems for intelligent production at this year's EMO. Liebherr's LH Geartec software plays a crucial role in this endeavor, offering new features like digital data import that open up more opportunities for users to embrace the Smart Factory concept.

One of the primary sources of faults in production is human error. To mitigate this, the control system acts as a central operating system. Human errors like transposed digits can lead to defective workpieces and damage. To address this issue, Liebherr-Verzahntechnik GmbH integrated a digital data import feature into the LH Geartec machine control panel. Now, when creating tools, operators can import parameter lists from tool manufacturers, minimizing errors and enhancing user convenience.

Digital data import streamlines the process of creating tools at the machine. The required parameters are imported as a digital datasheet from the tool manufacturer. The operator's responsibility is limited to performing a visual check, reducing the chances of incorrect inputs. The ease of use is improved, and potential errors are minimized, leading to more efficient and reliable production.

Additionally, the LH Geartec software enables importing and exporting geometry data of the workpiece via the GDE format GearDataExchange at the machine. This innovation enables comfortable workpiece creation during work preparation, using an offline version of LH Geartec. Digital work preparation becomes a viable and valuable option, enhancing the future capabilities of the production process.

Liebherr-Verzahntechnik GmbH offers various discs designed for use with the new grinding head generations 1G, OPAL, and for internal grinding. These discs utilize CBN (Cubic Boron Nitride), a superhard grinding material that outperforms conventional materials like corundum and silicon carbide in terms of hardness. Notably, the CBN profile grinding discs deliver high process stability and a high rate of metal removal, with the added advantage of a longer tool life compared to traditional materials.

Moreover, Liebherr's REMAN program provides customers with a range of options to rejuvenate and enhance the performance of their machines. The program includes reconditioned used machines, general overhauls, and repairs to restore the machines to their original manufacturer quality. These reconditioned machines not only look like new but also come with new warranties, ensuring reliability and durability.

Highly skilled and experienced technicians form the backbone of Liebherr's REMAN area. Their expertise in working with the assembly of machines and familiarity with older control systems ensures the successful reconstruction of machines or components. With outstanding technicians at their disposal, Liebherr can provide machines with a second life at top performance, delivering increased efficiency and a reduced turnaround time for customers.

In the context of linking machines with systems for process monitoring, resource management, and order management, Liebherr adopts the approach of providing standard interfaces in different formats. Unlike competitors who create their own communication paths, Liebherr's strategy allows for smoother communication between machines and cloud systems. By offering standard interfaces, Liebherr facilitates the interconnection of various customer requirements and system specifications, thereby enhancing overall communication efficiency in manufacturing processes.

Gear Technology Costs for adaptations cannot be estimated in advance. Software modules are standardized, and data profiles are offered for various applications, from monitoring machining progress to process analysis.

Standards for M2M data transmission are discussed, mainly MTConnect and OPC Unified Architecture. Liebherr offers solutions for both transmission paths. OPC Unified Architecture is a standard for manufacturer-independent communication in automation technology. MTConnect is a license-free platform popular in America, Asia, and Europe. Liebherr also offers data transfer with ProfiNet and Profibus coupler, and other methods like MOTT or AMOP are planned to satisfy customer requirements.

The Liebherr solution sets up all possibilities in advance to respond flexibly to each market. It offers configurable pre-processing of signals in the machine, allowing users to put together information from standard signals through logic gates, resulting in high flexibility and simple configuration.

Liebherr's innovative solution, LH Geartec, features an intuitive touch-based operator guidance with visual support for inputting machining parameters. The operator can track the progress of a workpiece using a 3D model and customize the process display to their requirements.

The LH Geartec interface also offers features like pinpointing defective hob areas to optimize machine and tool use. Defective hob areas can be defined for partly worn tools, ensuring intact areas can still be used, maximizing tool service life.

Liebherr Automation Systems expands its range of pallet handling systems for increased efficiency and simple operation. The goal is to increase machine capacity utilization and reduce workforce levels, leading to cost per part reductions of more than 20 percent. Machining centers with pallet handling systems prove to be an excellent solution for automation in small-scale series production. These systems shift the workpiece setup to a separate station and store pre-fitted workpieces in an intermediate storage area, optimizing production efficiency.

The machine decoupling is achieved by storing pre-fitted workpieces in the system, compensating for varying machine running times. As a result, shifts can be managed with little or no manpower, optimizing unit prices by up to 20 percent.

Advantages:

• Machine capacity utilization increases to over 90 percent
• Modular design allows customization and expansion
• Cost reduction per part by optimizing cycle and lead time
• Continuous machine loading during breaks or unmanned shifts
• Full monitoring of production schedule, resources, machine utilization, and manufacturing process
• Improved working conditions and employee relief by decoupling work assignment and machine cycle time

Liebherr Magazine 2017/2018 Gear Technology and Automation Systems

New technology for RLS cutting tools and NC data management. A rotary loading system for one or two machine tools is the entry-level model. This RLS has an optimized fork for better accessibility to the working area in the machining center. The longer telescopic lift allows machines to be incorporated in the automation system that was not possible previously due to the working area and cab characteristics. For example, the operator's area now includes direct-loading vertical five-axis machining centers.

The modular design of the RLS series allows for a combination of different interference diameters in the shelves and increased storage space with a turret in a single system. The system requires two set-up stations despite the limited available space.

Liebherr pallet handling systems, RLS, PHS Pro, and PHS Allround, will have a new cell control introduced in 2017. The user-friendly interface concentrates main computer functions and provides full production control, including resource planning and shift operations. Additionally, there are interfaces to ERP systems.

Liebherr focuses on the combination of robots and gantry solutions or rail systems to handle multiple functions, enhancing automation capabilities. The 3D vision system for Bin Picking solution is now operational with customers. The emphasis is on positioning robots on the gantry beam or rail for increased flexibility and efficiency in production facilities. The automation system uses robot arms from Kuka and Fanuc, embedded within the system, offering various combinations and user-friendly adaptability without extensive programming. Safety and danger prevention are key considerations in assembling and modifying automation systems, with a new concept ensuring safe work worldwide.

Liebherr Magazine 2017/2018 Gear Technology and Automation Systems

Health and Safety is an important and critical topic in the industrial sector, particularly in Great Britain and the United States. Recognizing the significance of ensuring workplace safety and minimizing potential hazards, the automation division of Liebherr took a proactive approach and made necessary adjustments to its processes and organizational structures last year.

The catalyst for these changes came from Great Britain, where Liebherr's customer Ford placed great emphasis on a strong risk awareness and understanding of safety. Consequently, Liebherr's team, led by Stefan Bischof, sought to create an environment of safety-consciousness among their workforce and the customers they serve.

To achieve this objective, Liebherr extended its product line and began conducting training sessions not only for their own employees but also for all the individuals involved in the installation process. This comprehensive training program ensures that certified personnel are always available on-site, thereby maintaining a safe and secure work environment.

Stefan Bischof, along with his team, developed new training materials tailored to the unique safety requirements. After successfully completing the training course, participants receive a training certificate, indicating their competence to work in various safety-sensitive areas.

Liebherr's commitment to safety further extends to the adoption of Risk Assessments and Method Statements (RAMS) for new installations. This systematic approach involves evaluating each work step for potential risks and defining appropriate safety measures. The plans are meticulously tailored to individual projects, ensuring compliance with safety regulations and client-specific requirements.

For large customers such as Ford and Jaguar Land Rover, safety documentation, and adherence to safety guidelines are non-negotiable. The development of a consistent culture of safety and the establishment of a robust safety structure enables Liebherr to provide enhanced support to customers and subcontractors alike. Proactively addressing safety concerns has allowed Liebherr to better meet the needs of their clients and provide efficient solutions.

In Germany, Liebherr's commitment to safety remains unwavering. The German technicians' extensive knowledge and expertise, along with the rigorous training provided, ensure a high level of safety awareness and compliance with industry standards. To meet the increasing global safety standards, Liebherr has aligned its internal processes, reorganizing its safety officers from Production and Manufacturing to collaborate with the Design team and on-site installation safety officers. This integrated approach ensures that safety is at the forefront of every project, from conception to execution.

Liebherr Magazine 2017/2018 showcases the company's remarkable achievements in the automation of manufacturing crank cases for large diesel engines. The collaboration between Liebherr and BURKHARDT+WEBER BW resulted in the creation of a state-of-the-art production line that sets new benchmarks for handling heavy workpieces. This revolutionary automation concept has paved the way for increased efficiency and productivity in the machining of large components.

With Liebherr Machines Bulle LMB introducing new diesel engines, including the V20 version of the D98 series, the need for advanced automation solutions became evident. The integration of PHS 10000 Pro, the pallet handling system, has revolutionized the production process, simplifying logistics, reducing set-up times, and ensuring flexibility in operations.

Through this system, workstations and machines are efficiently managed, providing operators with clear guidance and instructions, enhancing safety and productivity. The PHS 10000 Pro streamlines the manufacturing process, contributing to improved efficiency, reduced operational risks, and a safer working environment.

The successful implementation of the automation system has garnered widespread acclaim in the industry. By leveraging the expertise and capabilities of both Liebherr and BURKHARDT+WEBER BW, the automation concept has become a beacon of innovation, transforming the way heavy workpieces are handled and machined.

With its ongoing commitment to safety and continuous improvement in automation, Liebherr remains at the forefront of the industry, providing cutting-edge solutions that prioritize safety, efficiency, and customer satisfaction.

The suspended shuttle fork positions itself precisely at the designated set-up station, utilizing the prepared clamping fixture with impeccable accuracy. Stefan Jehle, in his explanation, highlights the pivotal role of their precise system, as it eliminates the necessity for an additional handling device within the system. The tool, essential for the process, is thoughtfully stored separately in the PHS (Pallet Handling System) on a designated pallet and only transferred to the machine when its presence is required. Notably, the inclusion of long drill bits in the system was made possible by their integration, as these particular tools do not fit into the conventional tool magazine.

For Liebherr Machines Bulle SA, this remarkable project marked the dawn of a new era in their production capabilities. Their system efficiently manages both long and short machining operations, ensuring an optimal level of machine utilization while easing the workload for operators. The team at Liebherr developed a specialized and ingenious system specifically to position the crankcase in the two-piece clamping fixture with the aid of support bearings in the oil pan area. Furthermore, the automation experts at Liebherr-Verzahntechnik GmbH ingeniously designed a unique solution for integrating the handling of the lid in the PHS. Whenever the machining process requires the lid, the PHS adeptly retrieves it from its designated storage location within the system.

Remarkably, the machines operating within the system share identical functionalities, differing only in their respective dimensions. The utilization of the same tools across these machines further enhances their synergy and operational fluidity. In this advanced system, Liebherr ingeniously integrates up to seven machines, showcasing their prowess in optimizing productivity and spatial efficiency. Sebastien Bussard from LMB shares their excitement about the system's future prospects, emphasizing its adaptability and potential for expansion.

The efficient rotary loading system (RLS 800) from Liebherr gains immediate recognition from its distinctive large windows and its integral role within the machining center. It possesses the capacity to mill up to 63 distinct components for various water pumps. Michael Wizany, as a machine operator, skillfully clamps a fresh raw part at the set-up station of the RLS 800. The system then promptly moves the part to one of its 21 storage locations using a rotation shuttle or directly to the machine for machining, showcasing its seamless automation capabilities.

Michael Wizany passionately elucidates the myriad benefits of Liebherr's system, emphasizing the time-saving advantage of up to 50%. With the rotary loading system in place, the machining center can receive parts without any manual intervention, a critical advantage during the end of a shift. The automation continuously enables production up to four hours beyond the shift's end, accentuating the efficiency and productivity of the entire process. The adaptability and dynamic nature of the system ensure it smoothly accommodates varying delivery dates and priority levels, underscoring its exceptional versatility.

Moreover, the intelligent system recognizes recurring components automatically, further streamlining the production process and reducing the chances of human error. Rosenbauer International AG, known for its pioneering role in firefighting equipment, reaps the benefits of this sophisticated automation solution in its pump manufacturing. Their Panther, a highlight product, specifically designed for airport use, can transport an impressive 19,000 liters of water in its tank. The flawless integration of automation in the manufacturing process enables the production of pump parts critical for constructing these firefighting vehicles.

In conclusion, Liebherr's ingenious automation system has significantly transformed the manufacturing landscape for Rosenbauer International AG, driving increased productivity and efficiency while maintaining the crucial human element at the heart of their operations. As firefighting technology continues to evolve, Liebherr remains at the forefront, pioneering innovative solutions that revolutionize the industry. Through collaboration with experienced and dedicated experts, both from Rosenbauer and Liebherr, the future of firefighting will continue to be characterized by unmatched reliability, resilience, and utmost safety, ensuring the well-being of communities worldwide.

Industries: World's leading manufacturer of systems for tire tightening and disaster protection. Company size: Employees Founded: 1866 Headquarters: Leonding, Austria Production plants: Europe, North-America, Asia Production facilities: Austria, Germany, Slovenia, Slovakia, USA, South Korea, and Singapore CEO: Dieter Spleil Website: www.rosenbauer.com

Up to 63 different parts can be machined with the help of the RLs 800. 36 Liebherr Magazine 2017/2018 - Gear Technology and Automation Systems In Practice Pioneers of skiving3 technology The first LK 500 skiving machine is in use at the Italian gear specialists S1AP. An innovative investment that will increase both productivity and quality. S1AP's machine park comprises more than 200 machines - about 30 are from Liebherr. The town of Maniago, Italy, is principally known for two things: Knives and cutting tools. The whetstones of cutlers at the Còlvera stream, at the foot of the Carnic Alps, have been operated with hydropower since the 15th century, the start of a big handcraft tradition from which an industrial center developed. Since 1960, S1AP has been manufacturing gears, and since 1988 as part of the international Carraro Group. Gearboxes, axles, and contract manufacturing are the businesses conducted by the Italians. Liebherr Magazine 2017/2018 Gear Technology and Automation Systems 37 In Practice The first LK 500 in serial operation at S1AP - another one is already on the wish list. Partnership with a long history to the machine, and to the process and tools. The Liebherr "We have a long history with Liebherr. Firstly, two Liebherr skiving machine, tool, and technology approach is also very companies are our customers; the connection to the Group effective in the collaboration with S1AP. has therefore existed for a very long time. Secondly, we opened a plant in India in 2004, which we equipped with Focus on costs and quality around 25 Liebherr machines," states Paolo De Col. The Luca Cadelli, sales manager of S1AP, responds to the question parts were manufactured in Germany and assembled in India. about why S1AP is mainly introducing the new technology: Liebherr Machine Tools India was set up in Bangalore at the "The market requires this machining method. Gear skiving same time as our subsidiary. We believe in Liebherr India and promises better quality while reducing costs. This combination Carraro, who was confident of the excellent quality of the ma- is irresistible for our customers because everyone pays atten- chines in our production, released an order of 25 machines, tion to costs and quality." Cadelli and De Col expect that a thereby opening up the Indian market. successful introduction of the skiving process will be critical for gaining a competitive edge in the medium term. In addition, when it comes to gear skiving, S1AP demonstrat- ed its huge confidence in the Kempten-based technologies. At S1AP, the LK 500 produces various internal gearings - The company's first manufacturing gear skiving machine is in a classic application for gear skiving, as here only the consid- Maniago. "For us, skiving is a new and very interesting topic. erably slower gear shaping technology can be used. We are Together with Liebherr, we have the opportunity to jointly de- extremely satisfied with the production speed," reports the velop a new machine with a new process. Liebherr is familiar- COO. The machine works roughly five times faster than our ized with all challenges of mass production - we have access shaping machines. If we want to expand our production, we to the developers and can bring about improvements, both compare the procurement of a skiving machine to the pur- 38 Liebherr Magazine 2017/2018 - Gear Technology and Automation Systems In Practice chase of three shaping machines in the latest generation. Other costs are included in this comparison: the number of operators, installation space, tool costs, and setup times. A single machine has clear benefits, of course. Even without the gear skiving machine, S1AP currently has a daily production capacity of 3,000 internal gears. Skiving will partly replace the broaching process S1AP uses five broaching machines for large quantities. As the broaches are very expensive for low volumes due to the high tool and sharpening costs, S1AP uses broaching for straight gears. The company expects a partial replace- ment of the process in the future with skiving. In the future, broaching will only also happy to pursue the skiving path be worthwhile for mass productions of As S1AP not only produces toothed with Liebherr. A display of trust which part numbers with high volume. Espe- gears but also complete gearboxes - Liebherr appreciates and led to a fruit- cially for large toothed gears, the tool for example for forklifts - the company ful partnership. The machine should be costs will decide whether we broach or has extensive process and quality com- fully integrated in production by the end skive," predicts Paolo De Col. From a petence. The latter is also reflected in of the year and manufactures the entire certain size, the broaching tools become the production equipment: Test engi- range of parts. Then S1AP will decide so expensive that the process is no lon- neers examine the products in labs for about more procurements - another LK ger worthwhile. metallurgy, measurements, and purity. 500 is also on the wish list. One project is clean production, the Another decisive benefit of skiving: The contamination-free production for pref- quality remains consistently excellent erably pure components. across the entire tool life. The process is completely stable. Skiving thus satisfies We are always open to innovative four requirements: quality, cost benefit, approaches and technologies," high- consistency, and reliability of the process. lights Paolo De Col. "We are therefore S1AP S1AP Industries: Automotive, Trucks, Agricultural Equipment, Construction Equipment, Renewable Energies, Rail, Industrial, Material Handling Company size: About 350 employees Founded: 1960 Headquarters: Maniago, Italy Parent company: Carraro Group CEO: Paolo De Col Website: www.siapgears.com Liebherr machines Paolo De Col explains the production schedule at S1AP. At work 30 Liebherr Magazine 2017/2018 Gear Technology and Automation Systems

Machíne tools and automation systems from Kempten Since 1952, Liebherr has been manufacturing gear cutting machines - initially in Kirchdorf an der Iller, Germany. In 1962, production was relocated from Kirchdorf to Kempten in the Allgäu. Since 1969, the company has been operating under the name Liebherr-Verzahntechnik GmbH. At the Kempten site, Liebherr has more than 1,100 employees and more than 1,300 employees worldwide. Liebherr World İ Liebherr is part of mine, Arıcí Gü rhan came to Liebherr in Kempten from Turkey in 1997. His career took him to many places - most recently to Korea. 1973 was not an easy year. In Vietnam, Fíve years in Algeria of my experience and flew to Korea, a ceasefire had been agreed to, in the USA, Initially, he was only meant to spend one states Arici Gürhan. A real adventure, President Nixon found himself caught year in Algeria to help build a plant there. because he does not speak any En- up in the Watergate scandal, in Chile, Ultimately he stayed, five years and glish. 1 know many languages. Turkish General Pinochet came to power, and those proved to be personally decisive and German of course, French and Ar- the world struggled with the oil crisis. In years for Arici Gürhan. 1 met my wife abic through my wife and the long time Istanbul, the President of Turkey, Fahri there and got married. Algeria was a very 1 spent working in Algeria. However, En- Korutürk, opened the bridge over the special time. The Liebherr family came glish and Korean? 1 quickly had to learn Bosporus, a symbol of renewal and con- once a month and visited and supported a few words. Greeting his Korean boss nection - but unemployment rates in the us. We watched videos together in the correctly in Korean every morning with country were huge at that time. As such, evening, which Willi and Hubert Liebherr Annyeonghaseyo, was appreciated Arici Gürhan was unable to find work in brought from Germany. At the time we just as much as his meticulous work. his homeland. Fortunately, the qualified felt very appreciated and developed a electrician received an offer from strong bond with the company. We are always growing," explains COO Paolo De Col. In recent years, the premises underwent constant expansion. We have to add a new hall practically every year. This, of course, also means a continuous expansion of the fleet, which now includes over 200 machines - around 30 of which are from Liebherr. The most recent acquisitions were an LCS 500 generating grinding machine, an LC 300 gear hobbing machine, and the LK 500 gear skiving machine - the first of its kind in a production environment. 1n addition, when it comes to gear skiving, S1AP demonstrated its huge confidence in the Kempten-based technologies. At S1AP, the LK 500 produces various internal gearings - a classic application for gear skiving, as here only the considerably slower gear shaping technology can be used. "We are extremely satisfied with the production speed," reports the COO. "The machine works roughly five times faster than our shaping machines. If we want to expand our production, we compare the procurement of a skiving machine to the purchase of three shaping machines in the latest generation. Other costs are included in this comparison: the number of operators, installation space, tool costs, and setup times. A single machine has clear benefits, of course. Even without the gear skiving machine, S1AP currently has a daily production capacity of 3,000 internal gears. Skiving will partly replace the broaching process S1AP uses five broaching machines for large quantities. As the broaches are very expensive for low volumes due to the high tool and sharpening costs, S1AP uses broaching for straight gears. The company expects a partial replacement of the process in the future with skiving. "In the future, broaching will only be worthwhile for mass productions of part numbers with high volume. Especially for large toothed gears, the tool costs will decide whether we broach or skive," predicts Paolo De Col. From a certain size, the broaching tools become so expensive that the process is no longer worthwhile. Another decisive benefit of skiving: The quality remains consistently excellent across the entire tool life. The process is completely stable. Skiving thus satisfies four requirements: quality, cost benefit, consistency, and reliability of the process. "We are always open to innovative approaches and technologies," highlights Paolo De Col. "We are therefore also happy to pursue the skiving path with Liebherr. A display of trust which Liebherr appreciates and led to a fruitful partnership. The machine should be fully integrated in production by the end of the year and manufacture the entire range of parts. Then S1AP will decide about more procurements - another LK 500 is also on the wish list.

Designed to provide exceptional value, Liebherr's versatile vertical turning centers are tailored for machining large workpieces found in the construction machinery, aerospace, and energy industries. One of the key features of these turning centers is the optional automatic tool changer, which effectively eliminates interference of boring bars with large workpieces, enhancing the machining efficiency and precision.

At Liebherr-Verzahntechnik GmbH, there is a strong emphasis on international educational exchange, and the company actively participates in the Erasmus+ program. This program offers trainees an excellent opportunity to gain exposure to different cultures and work environments, making them more versatile and adaptable professionals in today's globalized world.

Among the trainees at Liebherr-Verzahntechnik GmbH, Lena Leid1 stands out as an ambitious and aspiring electronics technician in production engineering. As part of her two-year training course, Lena had the privilege of spending four weeks in Trondheim, Norway, immersing herself in the Norwegian training system and work practices. This experience not only deepened her technical knowledge but also provided her with valuable insights into the culture of the Scandinavian country.

Comparing the training systems in Germany and Norway, Lena noted some significant differences. In Norway, students attend a secondary school for two to three years, similar to the German vocational school, and then they embark on shorter but intensive training programs offered by respective companies.

During her stay in Trondheim, Lena and her fellow trainees had the opportunity to visit the vocational school, where they were exposed to various training programs and gained a detailed insight into the automation area. Collaborating in small groups, they exchanged knowledge and worked on programming tasks, including the intriguing challenge of "chocolate transportation."

In addition to the vocational experience, Lena had the chance to work at the Nidar chocolate factory, where she was fascinated by the old machines still in use. The contrast to Liebherr, where the focus is on state-of-the-art machinery, provided an exciting perspective on the evolution of technology.

As Lena reflects on her experience, she acknowledges that the Erasmus+ program has been instrumental in broadening her horizons and preparing her for an increasingly interconnected world. Furthermore, it has instilled in her a deeper appreciation for the value of international cooperation and cultural exchange.

Liebherr-Verzahntechnik GmbH takes pride in its involvement in the Erasmus+ program, which has consistently proven to be a win-win situation. Not only do the trainees benefit from exposure to diverse work environments, but the company also gains more adaptable and open-minded employees with an understanding of different cultures and work practices.

In the spirit of mutual growth and collaboration, the Erasmus+ program continues to be an invaluable platform for nurturing talent and fostering intercultural competencies among the trainees. As Lena and her Norwegian counterparts share their experiences and knowledge, they contribute to building a more inclusive and dynamic future for the engineering industry and beyond.

With its commitment to providing exceptional training opportunities and promoting international cooperation, Liebherr-Verzahntechnik GmbH stands as a role model for the industry, emphasizing the importance of preparing the next generation of professionals for the challenges and opportunities of a globalized world.

Discover the exciting new world of automation brought to you by Liebherr! Step into the interactive application, "World of System," and embark on a captivating journey through the realm of Liebherr Automation Systems. Whether you're at a trade show or exhibition, this cutting-edge tool is designed to immerse you in a virtual factory environment, showcasing the diverse range of solutions offered by Liebherr.

With a mere touch of your finger, the interactive application provides a comprehensive overview of the various systems, from start to finish. It offers an opportunity to explore the mesmerizing technology behind Liebherr's product portfolio, including the innovative gantry robots and efficient pallet handling equipment. The seamless user experience of this tool earned it the prestigious Annual Multimedia Award in 2017, a testament to its exceptional value in the world of digital advertising.

But that's not all; Liebherr has gone beyond traditional boundaries with the launch of their SmartDeviceBox. Embracing the wonders of the Internet of Things, Liebherr refrigerators and freezers can now interact with mobile devices, taking grocery management to a whole new level. The new generation of SmartDeviceBox facilitates a novel household grocery management system that is both convenient and forward-thinking.

By employing cameras equipped with advanced object recognition and a voice module, Liebherr refrigerators provide an interactive grocery management experience. Now, stored groceries can be effortlessly recorded and monitored. With just a glance, you can access a detailed inventory list of what's inside your refrigerator. Through the voice module, you can easily add additional groceries to your shopping list. With the convenience of an app, accessible on iOS, Android, or Windows devices, you can access and manage your shopping list on the go.

But there's more to the story than just technology. Liebherr's approach to digitalization revolves around enhancing the daily routines of consumers. It's about offering a holistic experience that seamlessly integrates technology into everyday life. By understanding the unique needs and preferences of consumers, Liebherr ensures that each technological advancement serves a practical purpose.

This collaborative effort with Microsoft further strengthens Liebherr's commitment to revolutionizing the household appliances industry. Together, they are pioneering new digital offerings and mobile services that cater to the evolving needs of consumers. Liebherr's dedication to open standards and modular units means that their long-life appliances are not only adaptable but also expandable, keeping you up-to-date with the latest advancements.

Step into the world of tomorrow's intelligent refrigeration and discover a whole new dimension of convenience and efficiency in managing your groceries. Liebherr continues to be at the forefront of innovation, providing solutions that simplify your life and elevate your overall experience. Join Liebherr's digitalization offensive and be a part of the remarkable transformation of your kitchen into a smart, interconnected space of the future.