The First China-made 5-meter CNC Gear Grinding Machine

China's First 5-Meter CNC Profile Gear Grinding Machine

Introduction

With the rapid advancement of precision manufacturing, the demand for high-precision and large-scale gear processing equipment has significantly increased. In response to this, China's first 5-meter CNC profile gear grinding machine has been developed, filling a critical gap in the domestic market. This machine is designed for grinding internal straight gears, external straight gears, and helical cylindrical gears with exceptional precision and efficiency.

Innovative Dual-Column Design

The CNC profile gear grinding machine features an advanced dual-column design:

• One column is equipped with an internal grinding head, capable of grinding internal straight cylindrical gears.

• The other column is equipped with an external grinding head, enabling the grinding of external straight and helical cylindrical gears. This dual-functionality allows for a broader range of applications, making it suitable for industries such as construction machinery, forging, wind power, and port equipment, all of which require high-precision gears.

Technical Specifications

• Maximum external gear diameter: 5 meters

• Maximum module: 30

• Maximum internal gear ring diameter: 5 meters

• Grinding precision:

Internal gears:

• For diameters ≤ 3500mm: National Standard 6-7 (GB/T10095.1-2008, ISO 1328-1:1995)

• For diameters > 3500mm: National Standard 7 (GB/T10095.1-2008, ISO 1328-1:1995)

External gears:

• For diameters ≤ 3500mm: Straight gears: National Standard 5-6, Helical gears: National Standard 6

• For diameters > 3500mm: Straight gears: National Standard 6, Helical gears: National Standard 6-7

Advanced Spindle Technology

Internal Gear Grinding Spindle:

• Mechanical spindle driven by a servo motor with belt transmission.

• Stepless speed regulation with circulating water cooling and air sealing.

• Comes with one grinding wheel.

External Gear Grinding Spindle:

• Electric spindle for enhanced performance.

• Stepless speed regulation, circulating water cooling, and air sealing.

• Comes with one grinding wheel.

Internal Gear Dressing Spindle:

• Two mechanical spindles driven by a servo motor with belt transmission.

• Stepless speed regulation and air sealing.

• Comes with two diamond dressing rollers.

External Gear Dressing Spindle:

• Two electric spindles for precise dressing operations.

• Stepless speed regulation, circulating water cooling, and air sealing.

• Comes with two diamond dressing rollers.

Precision CNC Rotating Worktable

A core feature of this machine is its high-precision CNC rotary indexing table, designed with a dual-worm and dual-worm gear structure to eliminate backlash and enable precise angular positioning.

• Radial bearing technology: Constant-flow hydrostatic guideways ensure high dynamic response and oil film stiffness, eliminating wear and tear.

• Axial support: Utilizes constant-flow and constant-pressure closed-loop hydrostatic guideways for superior stability.

• Closed-loop control system: Integrated Heidenhain high-precision circular grating for superior accuracy.

• Maximum rotational speed: 0.6 revolutions per minute.

Enhanced Functionalities and Key Features

1.High-Precision Gear Grinding: This machine offers excellent accuracy in grinding both internal and external gears, making it ideal for high-performance applications such as wind turbines and heavy machinery.

2.Automated and Intelligent Operation: The CNC system ensures full automation, minimizing manual intervention while improving efficiency and repeatability.

3.Stable and Durable Mechanical Design: The finite element analysis (FEA) optimized structure ensures rigidity, vibration resistance, and longevity.

4.Energy-Efficient Cooling and Lubrication System: A state-of-the-art circulation cooling system ensures optimal temperature control, reducing thermal deformation and extending tool life.

5.Eco-Friendly and Cost-Effective: By optimizing material usage and reducing waste, this machine contributes to sustainable manufacturing while lowering operational costs.

Economic and Industrial Impact

The introduction of this 5-meter CNC profile gear grinding machine significantly enhances China's gear manufacturing capabilities.

• Increased Productivity: With its high-speed operation and precision, it reduces production time while maintaining top-tier quality.

• Cost Reduction: Enhanced efficiency lowers overall manufacturing costs by minimizing material waste and energy consumption.

• Market Competitiveness: The machine enables Chinese manufacturers to compete with global leaders in precision gear manufacturing, further advancing China's industrial capabilities.

Future Prospects in Smart Manufacturing

As Industry 4.0 continues to shape the manufacturing landscape, this gear grinding machine is designed to integrate seamlessly with smart factories.

• IoT Integration: Real-time monitoring and predictive maintenance ensure maximum uptime.

• AI-Based Optimization: Intelligent algorithms can optimize grinding parameters for improved efficiency.

• Remote Diagnostics: Cloud-based connectivity allows for remote troubleshooting and performance analysis.

Conclusion

The development of China's first 5-meter CNC profile gear grinding machine represents a significant milestone in precision manufacturing. With its state-of-the-art design, superior grinding accuracy, and intelligent functionalities, it is set to revolutionize high-precision gear production across multiple industries. By embracing this technology, enterprises can enhance productivity, reduce costs, and position themselves at the forefront of modern manufacturing.