SLOTTING MACHINE S8

Cold forming machinesSlotting machines

SLOTTING MACHINE S8

ERNST GROB AG

ERNST GROB AGCold forming machinesSlotting machinesRohrgasse 9, P.O. Box 830CH-8708 MännedorfSwitzerland

Phone +41 44 922 77 00Fax +41 44 922 77 88

[email protected]

Products and ServicesCold forming machines

ERNST GROB AG develops, designs and builds cold forming machines; from basic,

manually loaded units to fully automated production lines. The primary fields of

application for the sheet metal and solid components produced by cold forming

are to be found in the automotive industry. Our machines, however, are also opera-

tional wherever efficiency and quality are key considerations.

Slotting machines

Sheet metal parts that have been splined on GROB cold forming machines can be

transferred to our slotting machines for secondary operations, thereby ideally com-

plementing the cold forming process. Non-splined workpieces can also be slotted.

The design concept of our equipment is modular and can be optimally tailored to

suit the specific requirements of the application involved.

Tools

All tools used on GROB machines are developed and manufactured in GROB‘s in-house tool

shop in accordance with the specific requirements of the materials and applications involved.

An in-depth expertise, plus state-of-the-art toolmaking equipment combined with

continuous research and development allows ERNST GROB AG to provide optimal

tooling delivered in the shortest possible delivery times.

Subcontracting

At our subcontract facility we use our own cold forming and slotting machines to

produce components to customer order. We can take on your production needs

for individual components or small pilot runs. To overcome production bottlenecks,

we also process full-scale mass volumes. Our Quality Management System is certified

to ISO/TS 16949.

Engineering

A cornerstone of our success is the relentless search for optimal solutions to specific

engineering challenges. Our development department is key in this objective, as this is

where years of in-depth experience and the latest technological expertise are merged.

Close collaboration with our business partners invariably succeeds in generating innovative

results that our test department rapidly converts into prototype components, which

are already close to mass-production maturity.

ContentsPage

Company profile .................................................................................................. 2

Products and applications for the S8 ................................................. 4

Machine description ........................................................................................ 6

Layout, technical specifications ............................................................ 10

Installation, operation, service ................................................................ 12

Company profi le

CompetenciesERNST GROB AG develops, designs and

builds precision machines dedicated to

the cold forming of splined and non-

splined workpieces. The manufacture

of slotting machines for secondary

and finishing operations on cold

formed workpieces is yet another core

competence of the company.

From the initial idea through to its de-

velopment, and right up to the industrial

application – the entire concept is available

from a single partner: ERNST GROB AG

provides customer specific solutions,

from manually loaded single machines

to fully automated production lines.

GROB slotting machinesGROB slotting machines are employed to

finish cold formed splined or non-splined

hollow components.

Diverse slotting and coining

operations are undertaken at various

stations.

Separate stations for dedicated applica-

tions can also be integrated.

GROB cold forming machinesGROB cold forming machines are based

on the principle of the cold roll forming

in planetary type movement process.

The technology provides a solution for

the cost-effective production of splined

or reduction type cylindrical workpieces.

The founder of our company, Ernst Grob,

further developed and refined the

principle (see infobox «The GROB story»).

Diversity of finished productsApplications for GROB-Machines are

highly flexible, for example, when

producing:

Clutch disc carriers

Splined shafts

Gearbox shafts

Drive shafts

Steering system parts

Pump shafts

Extruder shafts

Splined shafts for:

– Printers

– Medical instruments

– Communal vehicles

– Helicopters

– Food processing equipment

– Torsion bars and progressive coil springs

Gearbox shafts

Thin-walled tubular components, cold rolled without support mandrels

Components for a wide range of vehicles

Machines for the automotive industryGROB machines are primarily used in

the automotive industry. Typical compo-

nents are clutch disc carriers in auto-

matic transmissions and other splined

components within the power train.

Slotted workpieces

GROB cold forming technology

2 © ERNST GROB AG • S8

S8

ERNST GROB AG • Rohrgasse 9 • CH-8708 Männedorf • Phone +41 44 922 77 00 • Fax +41 44 922 77 88 • [email protected] • www.ernst-grob.com

Dedicated partnershipsAt ERNST GROB AG the development

department is intensely focused on the

refinement of existing technologies,

plus the development of new processes

and applications. In close cooperation

with customers and other interested

parties, solutions are generated that

permit economic production of accurate

finished parts. When required, ERNST

GROB AG offers customer support

throughout the entire service life of

machines installed by our company.

Success factor employeesThe key success factor of ERNST GROB AG

is the professional competence and

dedication of its employees. A team of

highly qualified and experienced

specialists is the best guarantee for

meeting the most demanding challenges.

An innovative spirit coupled with an

inherent flair for technical solutions

are the foundation on which innumer-

able and unique developments are

based.

Headquarters in Maennedorf

LocationsERNST GROB AG plants are located in

Switzerland’s greater Zurich conurbation

where the company is able to benefit

from an outstanding infrastructure

with excellent transport facilities.

Headquarters (administration, research,

development, assembly) are located

in Maennedorf, while the subsidiary

(production, subcontracting) is to be

found in Oetwil am See.

Subsidiary in Oetwil am See

The GROB story

up to 1961 Dr. h.c. Ernst Grob develops cold forming machines at the machine tool works he founded in Munich in 1926.

1962 1962 Dr. h.c. Ernst Grob founds a company making cold rolling machines in Maennedorf and delivers the first one to Sulzer, Zuchwil, Switzerland.

1963 Further machine deliveries to Germany, Italy and Japan. Subsequent set-up of global sales and marketing network.

1979 Introduction of PLC technology and establishment of in-house electrical department.

1984 Introduction of multiple axis CNC technology.

1985 Following death of Dr. h.c. Ernst Grob: establishment of ERNST GROB AG. Business continued and expanded by his grandson and current owner, Mr. Daniel Dériaz.

1991 Acquisition and expansion of a subsidiary plant of ERNST GROB AG in Oetwil am See, Switzerland.

1999 Quality Management Certification to ISO 9001.

2001 Expansion of product portfolio with type S8 slotting machine for hollow parts and delivery of first slotting machine to General Motors Strasbourg.

2005 Start-up of production at the newly constructed workshop in Oetwil am See.

2006 Certification of subcontracting facility in Oetwil am See to ISO/TS 16949.

2007 Introduction of torque drive technology (NCT).

2008 Modern centralised office building in Maennedorf is occupied.

2009 Market roll-out of newly developed stroke-stamping process.

2012 Opening of our own Beijing representative office.50 years jubilee of ERNST GROB AG.Quality inspection using state-of-the-art methodology

3

Products and applications for the S8

Industries Machines from ERNST GROB AG are

used primarily in the automotive and

vehicles industries. Virtually all the well

known makers and their top suppliers

are using these installations to produce

gearbox components, steering systems

and numerous other parts.

Splined and slotted workpieces are also

used in a diversity of other applications,

for example in the plastics and paper-

making industries.

High and low production volumesWhereas ERNST GROB AG machine

customers tend to produce high

volume runs, the situation is different

when smaller production batches are

involved: components for a wide range

of applications are often subcontracted

direct and then produced by

ERNST GROB AG.

Finished productsExample clutch disc carrierThis double-clutch disc carrier for a

DSG (direct shift gearbox) was initially

processed on a GROB cold forming

unit and subsequently finished on a

GROB S8/4 slotting machine. It was

trimmed to length, its holes slotted and

the snap ring groove formed. Based

on customer specific requirements,

ERNST GROB AG designs, develops and

realises appropriate production pro-

cesses. Key considerations in these

solutions are economical output and

consistently high component accuracy.

Double-clutch for a direct shift gearbox (DSG) Slotted, smooth workpiece

Double-clutch disc carrier


S8

Slotted round and elongated holes, semi-sheared retention dogs and snap ring grooves generated by a combination of slotting and coining

Snap ring groove generated by a combination of slotting and coining (insertion chamfer cold rolled)

Selection of workpieces slotted on a S8 slotting machine Workpiece with castellations, elongated holes and snap ring groove

Examples of slotting direction: stop has been formed outside-in and the snap ring groove inside-out

Oil pockets semi-sheared without reducing spline length

ERNST GROB AG • Rohrgasse 9 • CH-8708 Männedorf • Phone +41 44 922 77 00 • Fax +41 44 922 77 88 • [email protected] • www.ernst-grob.com 5

Machine description

One or more workstationsThe single-station S8/1 slotting machine

is a 1 station configuration that is

ideally suited to individual processing

operations.

In the standard versions S8/2, S8/3 and

S8/4, additional dedicated worksta-

tions can be incorporated to handle

a diversity of combined processing

steps. These machines are generally

automated to assist loading and unloa-

ding. When required, however, they

can be operated manually. For reasons

of safety and noise attenuation, the

machines are normally installed in

sound damping cabins, into which the

electrical controls and the control pa-

nel are also integrated.

Modular, compact and flexibleThanks to their modular design and

ease of operation, the machines are

highly flexible and can be used univer-

sally for the slotting, coining, trim-

ming to length or cold forming of cup

shaped and ring shaped sheet metal

workpieces.

The machine design concept allows

them to be transported as completely

assembled units that can be installed

on anti-vibration pads, without any

need for foundations.

Slotting machine S8/4


S8


1 Station slotting machine S8/1, vertical layout

Slotting machines S8/2, S8/3 and S8/4With this machine concept, the design

of the individual workstations is ex-

tremely compact. This allows them to

be linked and automated in a minimal

space requirement to achieve a diversity

of slotting and coining operations.

All stations are linked by a machine-

internal automatic gripper system. If

required, special purpose workstations

can be integrated into the machine

layout.

1 Station slotting machine S8/1The slotting unit of the S8/1 is based

on the same concept as the standard

machines, but is designed as a single-

station model. According to the specifi-

cations, the S8/1 can be executed

either as a vertical stand-alone version,

or as a horizontal, integrated configu-

ration, for example in a 12-NCT cold

forming machine.

S8/1: Features and benefits

• Compact and rugged design concept

• Very short cycle times

• Very high process stability

• High tool life

• Affordable tool costs

• Universal application potential, minimal changeover times

• Extremely high slotting capacity

• Slotting direction inside-out or outside-in

• Mechanically defined stroke end position

• No lubricant or coolant needed

• Ease of service and maintenance (e.g. remote diagnosis)

S8/2, S8/3, S8/4: Features and benefits

• Very short cycle times

• Minimal downtimes

• Very high process stability

• High tool life

• Affordable tool costs

• Universal application potential, minimal changeover times

• Compact and rugged build quality

• Flexible machine concept: 1-4 worksta-tions, plus special purpose stations

• Extremely high slotting capacity

• Slotting direction inside-out or outside-in

• Mechanically defined stroke end position

• No lubricant or coolant needed

• Ease of service and maintenance (e.g. remote diagnosis)

7

Combined operationsAs this machine concept has a mecha-

nically defined stroke end position,

combined slotting and coining opera-

tions are possible. Typical applications

are the generation of snap ring groo-

ves in clutch disc carrier housings.

Application examples:

• Slotting of holes and forming

grooves

• Coining operations (e.g. for oil dams

and assembly location holes on

clutch disc carriers

• Combined slotting and coining ope-

rations (e.g. for snap ring grooves)

• Bending (e.g. of tabs)

Operator panel with colour screen and control elements

Horizontally configured 1 Station slotting machine S8/1, integrated into a 12-NCT cold forming machine

Control panelAll functions can be entered and

accessed via the control panel.

Tooling for elongated holes

Slotting stations of a model S8/31 Station slotting machine S8/1, integrated into a 12-NCT cold forming machine, horizontal configuration


S8


Slotting zone of 1 Station slotting machine S8/1

Oblique hole slotting station

Functions

Counterholder Workpiece Workpiece mandrel Tooling B axis C axis X axis Z axis

1234BCXZ

1

2

3

4

B

C

X

9

Technical Specifications S8/2, S8/3, S8/4 *

Machine model S8/2 S8/3 S8/4

Total installed rating (kW) 28 40 52

Power consumption (kW/h) 12 14 18

Weight (t) 11.0 12.5 14.0

Machine width W, range (mm) 1 900 1 900 2 200

Workpiece diameter (mm) 80–240 **

Max. Workpiece length (mm) 170 **

Stroke rates (strokes/min) 200 **

CNC controls Fanuc / Siemens

Slotting force (N) 90 000

* As GROB machine concepts undergo continuous development refinement, all technical specifications are subject to change without notice!

** Limits of range

Layout, technical specif ications

Layout S8/2, S8/3, S8/4

BX

C

Z

1050

2650

4650

4900

W

1320

2140

2000

1150

BX

C

Z

1050

2650

4650

4900

W

1320

2140

2000

1150

BX

C

Z

1050

2650

4650

4900

W

1320

2140

2000

1150


S8


Technical Specifications S8/1 *

Machine model S8/1 (stand-alone) S8/1 (horizontal)

Total installed rating (kW) 18 15

Power consumption (kW/h) 4–6 3–4

Weight (t) 5 2.5

Dimensions HxWxD (mm) 2 650 x 1 800 x 2 400 1 900 x 900 x 1 900

Workpiece diameter ranges (mm)

80–240 / 120–280 / 160–320 mm **

Max. Workpiece length (mm) 170 mm **

Stroke rates (strokes/min) 200 **

CNC controls Fanuc / Siemens

Slotting force (N) 175 000 90 000

* As GROB machine concepts undergo continuous development refinement, all technical specifications are subject to change without notice!

** Limits of range

11

Instal lat ion, Operation, Service

Up to transfer to enduserCustomised machines are built and set

up at the GROB facility by a team of

specialists. Our experienced service

engineers participate in every prelimi-

nary acceptance procedure together

with the customer. Following delivery

to the customer’s plant, they ensure

seamless installation and handover of

the equipment.

Assembly shop Machine assembly

Operation and serviceGROB machines are renowned for

their exceptional durability. Virtually all

machines produced since 1962 are still

fully operational across the globe.

ERNST GROB AG offers its customers

competent, prompt and comprehen-

sive repair and spare parts services

during the entire lifetime of the ma-

chine.

The slotting machine stands on

anti-vibration pads and can be installed

without the need for foundations.

Spare parts available to orderNo foundation required


S8

ERNST GROB AGCold forming machinesSlotting machinesRohrgasse 9, P.O. Box 830CH-8708 MännedorfSwitzerland

Phone +41 44 922 77 00Fax +41 44 922 77 88

[email protected]

Rapperswil

Männedorf

WinterthurAirportZürich-Kloten

A1

Chur

Bern/Basel

St. Gallen

Kreuzlingen

SchaffhausenSchaffhausen

Zürich

Horgen

Meilen OetwilA3

A3

A53

A1

A1

A7

A4

A51

ERNST GROB AGUster

2015.09.EGAG S8 de-en • v1.3 • ks

SLOTTING MACHINE S8

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