Profilator - The Flexible modular Design system The most compact combination for dry machining

of your process requirements

Profilator has developed a machineconcept that is exactly tailored to theserequirements. Using our know-how andaccording to process requirements, theappropriate process modules for gears,polygon milling, pointing, shifterstops,

deburring or SCUDDING® can be combined to form an efficient customer solution. The free programmable tool and work piece synchronisation affords the greatest level of flexibility.

Profilator 320 – Machine design with pick up swing loader and transport conveyor

Different processes combined through modular designPolygon & Face slot machining, Gear & Spline cutting, Gear tooth pointing,

Shifter stop machining, Chamfering and Deburring, SCUDDING®

Precision in modular design

Profilator is your partner, whenyou require complex machining pro-cesses to be carried out effectively, efficiently and with high precision using modern machine concepts.

Advantage through Technology

High Precision, flexible Manufacturingprocesses, short Cycle times, reducedInvestment and running costs:These are the requirements that theoperator asks of a modern machine tool.

Polygon & Face slot machiningThe polygon turning unit for example, is deployed for castle teeth machining on automotive gearbox parts. Here, the rotating cutterhead is synchronised with the workpiece spindle and a front face coupling is produced in accordance with the carbide insert arrangement and the transmission ratio. Then, with additional inserts on the same cutterhead the part can be deburred.

Gear tooth pointingThe pointing tower can be used in both rotative and indexing modes. All angle settings are digitally displayed. Because of different pointing angles and greater part diversity, both pointing units can automatically adjust in cycle through 10 CNC axis. The axis positions are determined following a CAD simulation using the data from the workpiece drawings. The CNC pointing tower is driven to the exact position by the data in the ergonomic control. Settings and corrections are through the new Ergo Control SIMPS® (WERA Simplified Integrated Machine Programming System) considerably simplified.

Chamfering and DeburringFor the Chamfering and deburring of splines, gear wheels and shafts, Profilator presents the ZEM series geardeburring machine. The machine is economically deployed in medium to large series production. The optimalmodular system offers the user clear advantages over conventional deburring machines.

SCUDDING® QmS - Quality meets Speed

Gear & Spline cuttingThe gear cutting unit is deployed both for Wera rotative gear cutting with inserts and for hobbing. Through the application of ,Schlagzahn tools’ and carbide inserts we can achieve the most economical manufacture of splines, gears, involute gears and Front face gears.

Shifter stop machiningThe shifter stop unit is a horizontal unit mounted alongside the workpiece spindle in the same horizontal plane and synchronised so that the tool machines each tooth flank respectively in the internal spline of a synchro sleeve. Thereby, an involute form is produced, according to the design requirement.

SCUDDING® is a continuous gear generating process. The SCUDDING® process can be used for a wide range of symmetrical gear applications as well as for non-symmetrical gear or profile applications such as belt pulleys and synchronizer gears. With the Wera Profilator machine design, the same machine can be used for internal and external SCUDDING® applications.

-20.340

-2.260

-20.340

-2.260

-20.340

-2.260

-20.340

-2.260

-20.340

-2.260

-20.340

-2.260

-20.340

-2.260

-20.340

-2.260

108.920

111.580

108.920

111.580

108.920

111.580

108.920

111.580

108.920

111.580

108.920

111.580

108.920

111.580

108.920

111.580

1218534242

Datei:

20.0

20.0

500:1

55371911193755

55371911193755

500:1

/

/

mm

mm

-2.260-20.340

111.700108.700

bu/bo

df/da

3

-1

3

3

-1

3

3

0

3

3

-1

3

2

3

4

2

6

6

4

5

6

3

3

5

18

±28

32

4665

7124

7667

456416

2112±14

5522Fα

fHα

ffα

Fβ

fHβ

ffβ

-11.30 -11.30 -11.30 -11.30 -11.30 -11.30 -11.30 -11.30

110.21 110.21 110.21 110.21 110.21 110.21 110.21 110.21

Auswertemodul:3.0.3.2310(involute)

Formularmodul:3.0.3.2412

6

7

7

5

5

5

2

1

3

Skalierung:Wälzweg

22

±14

16

32

±28

18

0.50

4.00

λc:

λc:

QaQn Qa6

4

7

9

9

9

Qn9

9

9

Qn9

9

9

Qn9

9

9

Bezugslänge fHβ: 22.600

µm

µm

µm

µm

µm

µm

mm

µm

mm

µm

65

Ø Fα fHα ffα6 2 5 Fα 7 fHα 3 ffα 5

Fβ fHβ ffβ3 -1 3Ø Fβ 5 fHβ 4 ffβ 3

(DIN 3960)

1.00

1.00

v: 1 mm/s

v: 6 mm/s

11.08.08 - Standmenge Teil 153

DAIMLER Gleichlaufkoerper A 902 262 1135 komplett ohne Nut

QS Profilator GmbH / ZEISS Prismo Bediener Hochheim / Jungk

20.0:1

2.5:1

[...]

[...]

[...]

[...]

DIN_3962

DIN_3962

Zeiss - GEAR PRO 3.2.2.17 vom 28.04.2008

Abweichungen im Stirnschnitt

Abweichungen im Stirnschnitt

+ links - - rechts +

+ links - - rechts +

oben

unten

Qa Qa

Bezugslänge fHα: 108.920 - 111.580

αn 30.000 °z 72

mn 1.500

b 22.600

mm

mm

außen

β 0.000

x 0.737

db 93.531

°

mm

Auftrag: V 15661

Datum:12.08.2008 11:44:02

Seite:

1/

2

a4_std2.frm

Quality meets Speed

110.21 110.21 110.21 110.21 110.21 110.21 110.21 110.21110.21 110.21 110.21 110.21 110.21 110.21 110.21 110.21110.21 110.21 110.21 110.21 110.21 110.21 110.21 110.21

α6 2 5 Fα6 2 5 Fα

SCUDDING® QmS

Superior quality and speed in gear cutting

Gear quality DIN 5-7SCUDDING® produces non-comparable, opposed results:High cutting force, high gear quality (DIN 5-7) and a low surface roughness (Rz 2-3).

External GearInternal Gear

Your advantages:

• Development of system solutions to your requirements

• Operator and maintenance friendly modular system

• Different processes carried out on one machine

• Clear reduction in set-up and process time compared to conventional machining

• Complex processes can run parallel

• Easy access from every side

Combinations that totallyfit your agenda

You decide the requirements,we make them a reality:

• Machining operation• 3 machine sizes• Single- or multispindle• Workpiece flow direction• Position of the electrical cabinet

Profilator GmbH & Co. KG Maschinenbau

Postfach 14 41 22 D-42310 Wuppertal Buchenhofener Straße 35 D-42329 Wuppertal

Phone: +49 (0)202 27 88-0 Fax: +49 (0)202 27 88-100Internet: www.profilator.de E-Mail: info@profilator.deCertificated acc. to DIN EN ISO 9001