Hei

nz

Berg

er M

asch

inen

fabr

ik

Heinz Berger Maschinenfabrik

GmbH & Co. KG

Kohlfurther Brücke 69

42349 Wuppertal

Germany

Tel.: +49 202 24742-0

Fax: +49 202 24742-42

info@heinzberger.de

www.heinzberger.de

Machines forgrinding and polishing of workpieces

GmbH& Co. KG

• 2 •

Milestones

For more than 80 years BERGER has been building grinding and polishing machines designed primarily for the machining of cutlery, hand tools, and related components.

The idea to manufacture machines for cutlery actually came at an earlier date. In 1928 Heinz Berger began working as an engineer at the Julius Berger Company, which had been founded by his father and continues to produce gardening tools to this day.

Grinding was – and is – a key process in the production of cutlery items and hand tools. The manual machining that was used at the time required a great deal of skill and physical exertion.

After 1950 design and manufacture of grinding machines were advanced, in addition to the production of gardening tools, based on the experiences made in their production facility.

The machine manufacturing branch, which had developed well over the years, was separated from the Julius Berger Company in 1957 and continued by Heinz Berger as an independent company, called the Heinz Berger Maschinenfabrik.

Rapidly increasing product demands required greater produc-tion capacity. In 1959 the plant was moved from its location in Berghausen to the new facilities at the Kohlfurther Bridge. It then became possible, as a result of new developments in the product line, to expand to the global marketplace. Machine exports played an important role at the time and have increased to 75% of the business today.

1930

1950

1960

www.heinzberger.de

ongoing development in collaboration with the customer – vertical grinding machine of the series DG-CNC

grinding machine 1930

Heinz Berger and Karlheinz Berger

• 3 •

Progress and Innovation

1990

1970

www.heinzberger.de

head office in Wuppertal (Germany)

After the death of Heinz Berger in 1970, his son Karlheinz Berger assumed control of the company. The years following saw the completion of new machine designs with mechanical and hydrau-lic drive technology. The number of machines with automatic part loading is increasing each year.

Since the beginning of the 90’s, the third generation has become involved in the company with daughters Claudia and Heike and sons-in-law Dr.-Ing. Andreas Gross and Marco Chiesura.

New machine designs based on CNC technology contribute to a product line today of more than 40 models with up to 6 servo axes.

The integration of innovative technologies, such as robotic auto-mation and modern gaging processes, continue to be company priorities. Based upon production demands, robotic assemblies with 4-7 axes are implemented. Initially used to automatically feed parts to grinding and polishing machines, robots are now used to grind and polish parts. Additional processes continue to be developed as a result of the opening of the Center for Robotic Applications.

In the area of drive technology, servo motors on machines are more commonly replaced with state-of-the-art linear motors, which pro-vide reduced cycletime increased availability, are maintenance-free, and extremly fast speeds.

Continuous development and design enhancements are made possible by a staff of highly qualified employees, who are commit-ted to finding advanced engineering solutions and place a high priority on their ability to develop customer-specific machining applications.

As a result, the Heinz Berger Maschinenfabrik has become a global partner in the production of cutlery items, hand tools, machine knives, surgical instruments and circular knives and provides customer service from its Cronenberg location.

The company currently delivers machines to more than 70 countries and is represented throughout the world. Berger L.L.C. was formed as an independent division in 2003 to provide sales and service support within the United States. As the Berger Group has been completed by more companies, the group is more than ever a competent partner for metal processing.

Marco Chiesura and Dr. Andreas Groß

worldwide presentation of the Berger Group on trade fairs

today

• 4 •

Manufacturing Areas

construction

software development

test department and process development

assembly

development and automation

service und starting up

• 5 •

Manufacturing Areas

mechanical chipping

mechanical chipping

production of grinding wheels

electrical cabinet design and build

assembly

service und starting up

• 6 •

Flat bevel grinding machines BG-CNC page 8–13 DG-CNC page 14–15

Rotary table grinding machines HDS-CNC page 16 DRG-CNC page 17 RTS page 18–19 RMS-CNC page 20 VR-CNC page 21

Peripheral grinding machines RFS-CNC page 22–23 WSM-CNC page 24–25 WSL-CNC page 26–27

Rotary index table grinding machines RST-CNC page 28–29

Hollow grinding machines HG-CNC page 30

Glazing machines PLM-CNC page 31

Contour grinding machines CG-CNC page 32

Sharpening machines SM-CNC page 33

Robots grinding and polishing systems RSP page 34–35

Applications page 36–37

Profile generating centers LP-CNC page 38–41

Measuring technique page 42

Magazine systems page 43

Content

• 7 •

Workpieces household knives• pocket knives• hand tools• surgical instruments• gardening tools• machine cutting tool• circular knives•

Industries

cutlery industry• hand tool industry• surgical industry•

• 8 •

Flat bevel grinding machines

BG-CNC/NT

surface grinding

CNC-grinding machine with three to five axes grinding table for bevel grinding of knives, scissors, hand tools or related parts

• user-friendly, Windows-based controlls with interfaces for robotics, PLC, measuring technologies or other ap-plications

automatic grinding wheel compensation with indepen-• dent CNC axis

• wear-free main axis drive with linear motor, achieving rapid traverse speeds of 80 m (240')/min

• precision, backlash-free positioning, using direct mea-suring system

compact, precision gearbox with high rigidity to control • rakle angle

BG-CNC/NT with 360° rotating workpiece carrier block for the reception of up to four workpiece supports for further processing

BG-CNC/NT

• 9 •

• 10 •

BG-CNC/RH/NT

radii grinding

CNC-grinding machine with four to six axes grinding table for grinding of curved blades, e.g. pruners, hedge shears, axes, hand tools and circular knives

BG-CNC flat bevel grinding machine with an additi-• onal fifth axis (rotary C-axis)

grinding of cutting edges with a constant radius or • compound shapes

grinding of multiple bevels in one clamping, e.g. outside • bevel and cutting edge on pruner blades

rotary cutter blades with a diameter up to 200 mm (7.87") • or complete segment of 360°

convertable to bevel grinding with model BG-CNC (four-• axle) by simple exchange of structural fixture supports

Flat bevel grinding machines

BG-CNC/RH/NT

• 11 •

• 12 •

BG0/RV/NT-CNC-grinding machine with automatic loading and unloading, feeding by a vibration magazine, position sensoring on conveyor belt by camera system

grinding of extremely curved workpieces

Four-axle grinding table for extremely curved workpieces, e.g. surgical scissors, instruments, pliers, inner side of garde-ning shears, manicure or hair scissors

BG-CNC/RV/NT

Flat bevel grinding machines

• 13 •

BG0/RV/NT-CNC grinding machine for curved scissors

BG0/RV/NT-CNC grinding machine for the outer treatment of nippers

BG0/RV/NT-CNC grinding machine for tweezer grinding

grinding of extremely curved surfaces requires four axes, • two linear and two rotational axes

sensor programming, probing of contour shape and • directly generating of necessary program data

grinding carriage arranged to swivel +/- 50° program-• mable angle e.g. inside of scissors

efficient throughput and economical processing of • small batches

four-axle digital Windows control for movement of • grinding carriage

wheel wear compensation by integrated CNC axis with • sensor system, digital read out of wheel wear

automatic central grease lubrication system•

remote control, monitoring, and diagnostic via modem•

• 14 •

Flat bevel grinding machines

DG-CNC

space-saving surface grinding

CNC-grinding machine with three or four axes and vertical grinding spindle for surface grinding of knives, scissors, hand tools and related parts

30% less required space in comparison to the horizontal • arrangement of the grinding spindlegood stability thanks to a solid welded construction of • the machine housingprevention of vibrations during processing due to a • machine housing filled up with mineral castuser-friendly, Windows-based controls with inter-• faces for robotics, PLC, measuring technology and other applications"Esprit" CAM interfaces• wear-free main axis drive with linear motor, achieving • rapid traverse speeds of 80 m (240')/minprecision, backlash-free positioning, using direct measu-• ring systemcompact, precision gearbox with high rigidity to control • rake angleas a single or a double machine available due to two • separate machine housings

DG-CNC

• 15 •

• 16 •

double sided flat grinding

CNC-grinding machine with three axes for economic dou-ble sided flat grinding of parallel surfaces of e.g. spanner wrenches, pliers, hammers, chisels, swords or flat grinding of conical surfaces such as adjustable spanner wrenches

single grinding (e.g. nippers) or continuous process • (e.g. swords)

grinding wheel diameter 400–700 mm (16"–28")•

automatic grinding wheel compensation with two inde-• pendently operating measuring systems

CNC-control or hydraulic system•

central grease lubrication system•

designed for wet processing with grinding emulsion•

two grinding wheels for bilateral processing•

different automatic loading systems•

Rotary table grinding machines

HDS-CNC

HDS-CNC

• 17 •

flat grinding

High productivity CNC-double rotary table grinding machine with two axes for grinding flat or conical sur-faces on a great variety of parts such as table-knives, insides of stamped scissors, wood chisels, spatulas or connecting rods

possibility to set nominal part dimensions on the •circular tables with up to four independent gage controls

electromagnets with interchangeable pole plates•

mechanical, hydraulic or pneumatic clamping fixtures•

table diameter 500–800 mm (20"–32")•

DRG-CNC

DRG-CNC

• 18 •

Rotary table grinding machines

RTS

flat grinding

Grinding machine with vertical adjustable spindle for effici-ent surface and angle grinding in continuous production of pocket knife components, hand tools and similar parts

grinding machine type RTS3 with fixture for grinding of mower blades with automatic loading/unloading and turning device grinding motor power 37–55 kW•

adapter flange for grinding wheel 600 mm (23.6") • Ø

rotary table speeds, variable up to 18 revolutions/min •

mechanical fixture plates or electromagnetic pole plates • 600-1.200 mm (24"–48")

mechanical measuring sensor to gauge the grinding • wheel and to adapt to the wear (option: motor adjust-ment with digital indication)

central grease lubrication system•

designed for wet processing with grinding emulsion•

RTS

• 19 •grinding machine type RTS3 with automatic loading and unloading grinding machine type Typ RTS3 for flat grinding of coils

• 20 •

RMS-CNC

Rotary table grinding machines

user-friendly, direct programming by indicating the •technical data/parameters of the workpieces

CNC-controlled adjustment of the angle range •0°–30° with hydraulic clamping

workpiece diameter up to 1.000 mm (39") •

automatic compensation of the grinding wheel•

clamping of workpieces by permanent magnet, •electromagnet, mechanical or pneumatic devices

rotation speed of the workpieces adjustable •100–240 revolutions/min

grinding wheel diameter 400 mm (15.7")•

flat and bevel grinding on circular knives

CNC-grinding machine with three or four axes for grinding of blades and bevels on circular knives by employing a cup wheel for high chipping; programmable angle adjustment for following processing

RMS-CNC

• 21 •

VR-CNC

flat and bevel grinding

CNC-grinding machine with two axes for grinding of bevels and edges on circular knife blades with a max. diameter of 400 mm (15.7") by employing a cup wheel for high chipping

VR-CNC

e• asy parameter programming by indicating the techni-cal data/parameters of the workpieces

manually adjustable bevel angles up to 45°•

automatic wheel wear compensation•

mechanically or pneumatically activated clamping of • workpieces

rotational speed of workpieces adjustable •

grinding wheel diameter 300–400 mm (12" –18")•

robotic loading system available for stacking magazines •

additional deburring station for edge grinding available • (both processes at the same time)

• 22 •

grinding machine type RFS4, noncontinuous grinding of e.g. cutter knives

two axes CNC-dresser to shape grinding wheel

Peripheral grinding machines

RFS-CNC

surface and bevel grinding

CNC-peripheral grinding machine with six axes for grinding of surfaces, cutting edges and contours on circular knives, saw blades or blanks with oscillating or plunge grinding process

horizontal grinding wheel, positioning by AC servo • motor driven by pre-loaded precision ball screw

automatic compensation of workpiece plunge travel • after each dressing cycle and maintenance of selected rotational wheel speed (by frequency variation)

• 23 •

simple workpiece oriented programming •with parameter entries

grinding of multiple bevels on one clamping •with additional grinding axis

blade diameter up to 1.200 mm (48")•

circular knife blade is held on a rotational •fixture by permanent magnet, magnetic chuck, or mechanical clamping

rotational speed of workpiece adjustable •with frequency converter or servo motor

different dressing systems, interval controlled •or permanent

processing of intermittent grinding by •means of the measuring system Marposs

RFS-CNC

• 24 •

XX

X

Z

A

A

X

A

Z

Peripheral grinding machines

WSM-CNC

CNC-controlled with display of all opera-•ting information on monitor screen

horizontal wheel motion by AC servo motor •driven by preloaded precision ball screw

standard maximum grinding width •360 mm (14"), other lengths by option

simple workpiece oriented programming •with entry of discrete dimensions/para-meters

dressing of the grinding wheel with dia-•mond coated dressing roll, tool steel crush roll or programmable single point diamond

CNC orientation against a straight grin-•ding wheel e.g. in order to grind steak knives

automatic compensation of workpiece •plunge travel after each dressing cycle and maintenance of selected rotational wheel speed (by frequency variation)

vertical blade transport axis available as •an option

WSM-CNC

single axis CNC-grinding machine•

pick up of workpieces by pneuma-• tic clamping device

dressing of grinding wheel by • diamond coated shape roll made of tool-steel

scalloped and pointed serrated grinding

CNC-peripheral grinding machine with up to three axes for plunge grinding of serrated edges on knife blades (e.g. bread or steak knives), scissors or similar workpieces

• 25 •

XX

X

Z

A

A

X

A

Z

XX

X

Z

A

A

X

A

Z

two-axle CNC-grinding machine•

A-axis 360° rotary for simultaneous • grinding and loading/unloading of workpieces

scaling down of non productive time • to one second

dressing of grinding wheel by diamond • coated shape roll made of tool-steel

WSM-CNC A/AV

three-axle CNC-grinding machine•

A-axis 360° rotary•

programmable dressing of grinding • wheel by displaceable dresser (Z-axis) with rotating or fixed tool

grinding of secateurs partsloading of 2 × 2 workpieces

WSM-CNC/Robot

uniaxial CNC grinding machine•

mouvement of workpiece against • straight grinding wheel with six-axle robot

programming interface for robot programming

grinding of granton edge

WSM-CNC/A

WSM-CNC

• 26 •

scalloped and pointed serra-ted grinding

CNC-grinding machine with grinding stations of the series WSL-CNC with up to two axes each. The grinding stations can be employed in different machines to produce scallo-ped or pointed serrated grinding.

achieving each cutting angle desired thanks to the inter-•polation of Y and Z-axis

dressing of grinding wheel by diamond roller dresser or •single point dresser

can be integrated into a rotary index table grinding ma-•chine of the series RST or into a CNC-grinding machine type WSL1-CNC for grinding blades up to a length of 1.800 mm (70.87")

solid welded construction•

special drive power 15 kW with spindle running •in bearings and hub flange for grinding wheel 450 mm (17,7") Ø (usable up to 250 mm (9.8") Ø)

max. grinding width 100 mm (3.9")•

direct ring wheel drive (without ring wheel)•

programmable, constant circumferential speed •of 30–45 m (1181"–1771")/s when wheel diameter decreases

dressing/shaping of the grinding wheel with dia-•mond coated shape roll 140 mm (5.5") Ø, drive 0,75 kW; dressing interval preprogrammable with automatic compensation of grinding wheel wear

each grinding station equipped with a vertical •and a horizontal carriage:

Y-axis = vertical carriage for grinding movement•

Z-axis = horizontal carriage to move to work-•piece/section roll

CNC-Axis movement by AC servomotor with •prestressed ball bearing spindle

Modular peripheral grinding station

WSL-CNC

• 27 •

blades with flat edges, scalloped serrated edges,pointed serrated edges

CNC grinding machine with up to seven axes for grinding blades up to 1.800 mm (70.9") in length and for serrated edges on circular blades up to 250 mm (9.5") diameter

grinding of blades with either flat or toothed edges •using programmable angles

dressing of grinding wheels with frequently used •tooth profiles by dressing device and diamond-coated dressing roll

option: two-axle CNC dresser for programming of tooth •forms with userfriendly menu

hereby grinding of small piece lots or prototypes with •arbitrary tooth profiles on long blades possible (in parti-cular pointed or scalloped serrated edges)

serrating of circular knife blades possible by adding •another axis of rotation (C-axis)

WSL1-CNC

Peripheral grinding machines

• 28 •

Example of use: rotary index table grinding machine of the series RST

two grinding stations of the series WSL-CNC•

positioning of the grinding station for staggered •tooth system e.g. in 25 °

positioning of the grinding station for relief •grinding

feeding by stacking magazine with loading •capacity of 1.000 mm (3.28")

separating of workpieces•

feeding of workpieces by pick- and place unit•

precision rotary index table with four positions•

unloading into stacking magazine•

capacity: app. 300-350 saber saw blades/hour•

Rotary index table grinding machine

RST-CNC

serrated grinding

Rotary index table grinding machines available in various configurations for grinding of steak knives, fret saws or grin-ding of blades with serration

attribution of an adequate grinding station to a pre-• cision rotary index table

working with cup wheels (grinding station SS0 or SS1) • or as plunge grinding process with profiled wheels with grinding station of the series WSL

integration of manual and automatic loading and unloa-• ding systems possible

RST-CNC

• 29 •

Example of use:

rotary index table grinding machine type RST3 for grinding of steak knives

three-axle grinding station of the series WSL for •peripheral grinding

cutting angle by workpiece support•

feeding by stacking magazine•

workpiece separation•

feeding of workpieces by pick- and place device•

turning device 180°•

precision rotary table•

dropping•

capacity app. 550–600 knives/hour•

• 30 •

Hollow grinding machines

hollow grinding

CNC-grinding machine with four axes for double-sided hollow grinding of kitchen and steak knives, hunting and sports knives, pocket knives as well as hand tools like e.g. saw blades

grinding with two cup wheels, each wheel at an angle •of 45° to the blade

thereby a consistent hollow bevel shape over the enti-•re wheel life

dimension of the grinding wheel depending on blank •thickness, bevel width and thickness

programmation with contour caliper installed on the •grinding machine

HG-CNC

grinding wheel outside diameters: • 80, 125, 175, 200 or 220 mm (3.15", 4.9", 6.89", 7.87" or 8.66")

spindle motors completely closed and •equipped with moisture protection

two digital measurment controls integra-•ted into the CNC-control to supervise the wear of the grinding wheels

integration of a CNC-controlled scotch •brite station in order to polish the work-piece in the same clamping

wheel wear is automatically compensated •after each grinding cycle with a digital measuring system

automatic central grease lubrication system•

digital four-axle Windows controllers (X, Y, •and the two spindle axes)

grinding length up to 430 mm (16.9")•

sensor programming, probing of contour •shape and direct generating of necessary program data

grinding wheels activated by special mo-•tors with precision mounted spindles

• 31 •

Glazing machines

PLM-CNC

working length up to 480 mm (18.9")•

easy, direct programming by indicating •the technical data/parameters of the workpieces

diameter of glazing wheels 530 mm or •800 mm (20.87" or 31.5")

automatic compound feeding for grease •glazing or adjustable for wet glazing

glazing

CNC-glazing machine with three axes for glazing grinded knife blades

• 32 •

Contour grinding machines

CG-CNC

wet belt grinding machine with belts of •2.000 mm x 200 mm (78.7" x 7.87") or with grinding wheel

two-axle digital Windows control•

contact wheel support in two versions: •100–200 mm (3.94"–7.87") or 30–100 mm (1.18"–3.94") with additional bearing

workpiece clamping in magazines with a •grinding width of 180 mm (7,1") and a grin-ding length of 500 mm (20")

automatic central grease lubrication system•

automatic cross oscillation•

adjustable belt arm 0–45°•

identification system for magazines for auto-•matic program recall

sensor programming, measuring of contour •shape, and feeding data directly to the CNC program by finished or raw parts

remote control, monitoring, and diagnostic •via modem

CNC-grinding machine of the series CG-CNC, sensor programming by gauging a reference piece

CG-CNC

contour grinding

CNC-grinding machine with two axes for contour grinding of knives, scissors, hand tools, tweezers and other work-pieces

• 33 •

Sharpening machines

SM-CNC

sharpening

CNC-sharpening machine with up to three axes for sharpening of blades and mounted knives

two servomotors to activate coated CBN-•spiral wheels with a diameter of 200 mm (7.87")

digitally synchronized servo spindle•

mechanical adjustment of the cutting •angle 20°–50°

designed for manual treatment or in •combination with a robot

Example of use (picture on the right side): Automatic sharpening line type SM3-CNC

sextuple ABB robot type IRB 140 F•

two spiral grinding machines type SM3•

rotary index magazine•

laser measurment system for controlling of •blade positioning and program adjustment

• 34 •

Robots grinding andpolishing systems Machining cells with robots used to machine

workpieces

robot grinding and polishing stations either • integrated in existing production lines or built as a separate cellstandard interfaces for all established manu-• facturers of robots such as ABB, Kuka, Stäubli and Fanucprogramming in the touch-in processor with a • CAD/CAM interfaceintegration of measuring systems for the com-• pensation of workpiece location and measure-ment tolerancesvarious machining stations with a variety of • tools available (e.g. grinding belts, grinding stones, polishing discs)

RSP

• 35 •

robot grinding and polishing system for the machining of grippers with measurement station, grinding belt station, grinding wheel station, cleaning and drying station

• 36 •

Applications

grinding•

polishing•

deburring/brushing•

sharpening of knives•

serrating0•

grinding of secateur parts

indentation, serrating, fluting; robot guides the workpiece along a straight edged wheel

deburring of cable cutters sharpening with CBN coated spiral wheels, patented gripper design

deburring of die cast parts with spindles

picture right side: polishing of knife handles with buffing wheel and polishing paste

Applications

• 37 •

convex grinding of wrench surfaces grinding of forged shears at a belt grin-ding station

grinding of torque wrench tools grinding of curved grippers

• 38 •

combination of many different operations in one center • due to rotary machining processes

electronic synchronisation system incorporated controlling • workpiece spindle and tool spindel

CNC compound slide rest with tempered flat guides•

improvement of cycle times•

cylindrical parts fed through the spindle by hollow • spindle system

possibility of manual load f• or special or small series wi-thout configuration thanks to open access to operation center

tooleslide designed to accumulate additional tools for a • variety of operations such as drilling, milling, threading etc.

Profile generating

Universally applicable production machine with fixed workpiece spindle head and dramatically improved cycle times thanks to very short machining and storing times

Profile generating center

LP-CNC

• 39 •

Example of use:Profile Generating Center LP130-CNC

compact spindle nose•

rugged, heavy duty horizontal and vertical tool •heads

powerful motors•

large diameter bore in part spindle•

computer assisted design (CAD) engineered for •maximum rigidity with vibration free machining

• 40 •

Universal generating system

Dual spindle system

Heavy duty polygon system

The manually swivelled universal generating system is easily changed from vertical to horizontal with minimum of downtime. For machining polygons, the generating head is swivelled to the horizon-tal position.

This system incorporates a special heavy duty spindle designed for pro-duction machining of a variety of work of polygons, clutch lugs etc.

To machine outside teeth, the generating head is easily swivelled to the vertical position.

This system consists of the vertical and horizontal spindles both mounted in position ready for use. The machine control can then be programmed to use either system. This arrangement means that polygonal and radial machining can be carried out on a workpiece with only one clamping.

Using computer assisted design (CAD) machine components are enginee-red to eliminate vibration and maximize rigidity. This allows use of state-of-the-art carbide tooling with optimum tool life.

LP 110 CNC

universal generating system with drill and hollow mill

LP 130 CNC

dual spindle system with vertical and horizontal spindles

LP 130 CNC

heavy duty polygon system with deburring tool

Generating systems

Efficient and versatile

Fixed horizontal spindle

Fixed horizontal and vertical spindle

• 41 •

1

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6

13

14

15

21 22 23 24 25 26

16 17 18 19

12

11

10

9

87

Typical workpiecesUniversal Generating System

The LP 110 CNC and LP 130 CNC Generating Machines are ideally desi-gned for screwdriver bla-des and bits.

Blades length up to approx. 400 mm (15.7“) and Bits up to approx. 75 mm (2.9“) are auto-matically fed through the hollow shaft of the work-piece spindle nose.

This reduces magazine changing times considerably. The components available for the screwdriver indu-stry include:

Phillips, Pozidriv, Torx, Tamper Torx, hexagonal ball-ended, flat blades (dihedral), Torq-Set, Tri-Wing, square, hexagonal etc.

1

123456789

10111213

Type of operation

Triple square tipScrewdriver blade Phillips size 2Screwdriver blade Phillips Size 1Screwdriver blade Pozidriv Size 2Screwdriver blade Torx Size T 25Tamper Torx blade Size T 40Flat screwdriver blade with turningFlat screwdriver blade with turningFlat screwdriver blade with turningPhillips Size 1 and 2 with turningFlat screwdriver bladeBall end on hexagon shankSquare recess screwdriver blade

7,02,02,03,72,06,06,07,07,0

7,0/6,57,04,54,5

Machining time in secondsPosition

14151617181920212223242526

Type of operation

Screwdriver blade, Tri WingFlat Bit bladeFlat Bit blade with turningTorx Bit Size T 30 with turningTamper Torx Bit Size T 40Torq Set BitPhillips Bit Size 3Pozidriv Bit Size 1Pozidriv Bit Size 3Phillips Bit Size 0 with turningTorx Bit Size T 6 with turningPozidriv Bit Size 2Special hexagon Bit Phillips Size 2

8,010,0

6,56,56,5

10,02,53,54,06,08,03,73,0

Machining time in secondsPosition

screwdriver tools

• 42 •

camera measuring system used to measure parts

picture below: camera measuring system to measure contours

Measuring technique

Development of standard measuring sy-stems for various applications for the mea-surement and compensation of automated measurements/contours

mechanical measuring sensor used to measure parts

camera measuring system for robots used to identify the location of forceps

laser measuring system for robots used to take the outer measurement of gripper elements

measuring system used to take automatically the centre measurement of grippers with BG0/RV/NT-CNC

laser measuring system for robots used to take the outer measurement of hard metal shears

• 43 •

picture below: camera measuring system to measure contours

Magazine systems

indexing chain magazine for conical material or forged workpieces, load capacity 2.000 mm (78.74") with adjustable length stops

indexing vertical rotary table magazine with 6 or 12 loading and 3 or 4 unloading bars used to hold shears or shear blades in the ring

vertical stacking magazine for circular blades

indexing rotary table Ø 1.500 mm (59") with ad-justable stops, holds approx. 160 workpieces

loading tower used with magazine cartridges

Berger feeder used to feed loose material, location detection by way of a camera system, positioning in grinder by robot

stacking magazine for flat material, load capa-city 500–2.000 mm (19.69"–78.74"), adjustable length stops

circulating chain magazine with 24 load bars each 300 mm (11.8") e.g. for grippers

circulating bar magazine for forceps

The design of the loading/unloading magazine depends on various requirements:

required magazine capacity (e.g. one hour or one com-• plete shift)

shape of the workpiece (forged, conical, or flat)•

variety of workpiece shapes / dimensions, that should • be processed

integration in the preceding stage of production (e.g. • stamping) or subsequent processing (e.g. polishing, dry-fining)

in which way the pieces are orientated • (e.g. disordered in a glide grinding line)

Magazine systems

Strong partners

under one roof ...

The 4 companies in the Berger Group consist of the leading ma-chine tool manufacturers for ma-chining and refining metal coils and tools, e.g. household and machine blades, cutting tools, surgical instruments, cast or for-ged tools. Their in-house robotic capabilities provide solutions to automation and process integra-tion tasks.

Trend-setting innovations in the fields of robotics and CNC ma-chines for grinding and polishing tools, as well as state-of-the-art technology for coil edge chip re-moval and surface finishing, are available for coil stock and tools that demand high quality.

The first automatic grinding ma-chines from Berger in 1957, the development of the Julius edge trimming machine in 1980, the first CNC-controlled double-scal-lop polishing machine by Hau-schild in 1987, the use of more than 300 robots for automating Berger grinding machines since 2000, as well as Nell’s develop-ment of the BSM 3000 CNC grin-

ding machine for micro-grinding coil stock with camera control – all important milestones for the Group and key driving forces for the metalworking industry.

Thanks to a broad product line, the synergistic effects in our engineering, R&D, and produc-tion departments, and a compe-tent customer service team, the Berger Group provides complete solutions – particularly for custom requirements – all from a single source.

Heinz Berger Maschinenfabrik GmbH & Co. KG

Hauschild GmbH

August Nell jr. GmbH

Julius Maschinenbau GmbH

... the Berger Group!

Kohlfurther Brücke 69 • 42349 Wuppertal • Germany

Tel.: +49 202 24742-0 • Fax: +49 202 24742-42

info@bergergruppe.de • www.bergergruppe.de