Control 2025
06.05.–09.05.2025, Hall 7, Booth 7310
When the first generation of the Klingelnberg Precision Measuring Center P 26 was developed 25 years ago, it was impossible to foresee how much this development would ultimately shape Klingelnberg's metrology offering. Compact and tailored to the needs of the automotive industry, this precision measuring center has always been extremely popular among customers. Its 25-year success story was built on a foundation of new measurement and evaluation methods, the implementation of innovative measuring systems, and uniform quality and reliability. It is because of their accuracy and reliability that Klingelnberg Precision Measuring Centers are used as a reference around the world, not just by countless customers, but also by renowned metrology institutes.
The well-established combination of tactile metrology (3D NANOSCAN) and optical metrology (HISPEED OPTOSCAN) for measuring cylindrical gears is now also available for this model series as well.
Measuring times have been significantly reduced through the introduction of hybrid metrology with optical pitch measurement. It is now possible to perform optical pitch measurement on almost all surfaces using the second-generation white light sensor technology (HISPEED OPTOSCAN) developed by Klingelnberg and partners, along with other innovative measuring strategies that enable optical pitch measurement on cylindrical gears with almost all surfaces. The tactile measuring method for reliable detection of pitch deviations on cylindrical, conical and beveloid gears is of course still available.
With the current release, the pitch, tooth thickness, and radial run-out of gears can be measured optically on most cylindrical gears. So, depending on the number of teeth, this reduces the measuring time for a complete gear measurement by up to 40%. For pitch measurement, even greater time savings are achieved on a consistent basis. The measurement and evaluation are still conducted using an advanced, certified Klingelnberg cylindrical gear software that is easy to use in the way customers are accustomed to. The optical sensor extends fully automatically and positions itself according to the chosen measurement procedure, and the required measuring task is performed. The accuracy of the pitch measurement complies with the requirements of VDI/VDE 2612:2022 Class A and is therefore comparable to tactile measurements.
All Klingelnberg Precision Measuring Centers in the P 26 to P 65 series can be optionally retrofitted with the optical sensor (HISPEED OPTOSCAN). For new machines, the "Ready for Optic" option is also available, providing a factory-installed setup for subsequent retrofitting. Through the systematic use of the standardized Gear Data Exchange (GDE) interface when importing and exporting data and measurement results, Klingelnberg has set a higher standard in Metrology 4.0 in the area of measurement results diagnostics and networking of production machines and metrology – a system it calls the Closed Loop.
In addition to the already established optical pitch measurement, Klingelnberg is giving an outlook into the near future at this year's Control. A spiral-shaped optical topography measurement is carried out on face gears across the entire tooth width. The results are processed in the “Gear Deviation Analysis” (GDA) software and provide quick and reliable information about waviness on the tooth flanks. These wavinesses can lead to disturbing noises, particularly in gearboxes of electrically powered vehicles. The time saving compared to tactile topography measurement on all teeth is striking
The increasing cost pressure on large components for wind power requires new technologies that will enable proven principles for high-volume and mass production of smaller components to be transferred over to large components. The newly developed Klingelnberg Precision Measuring Center P 152 closes the gap in the portfolio between the mid-sized and the large precision measuring center model series.
The latest addition to the family is capable of measuring components with a maximum outside diameter of 1,520 mm and workpiece weights up to 8,000 kg with the usual measurement precision. Despite this heavy workpiece weight, no special foundation is required. Klingelnberg has succeeded in scaling the technology concept of the small and mid-sized series to the larger component dimensions. The inherently rigid machine bed with its 3-point support plays a key role here. The bed design and floor support are so cleverly designed that even when loaded with heavy workpiece weights, the angular position of the individual machine axes to each other does not change significantly. The machine bed's 3-point support enables the integration of an active vibration platform into the machine bed. This means that even the low-frequency oscillations from the shop floor can be safely absorbed without the use of a vibration-isolating foundation. Consequently, all changes visible in the measurement results can actually be attributed to the component and are not induced by the ambient conditions.
The P 152 for mid-sized gears such as planet gears used in wind power combines dimension, form, and position measurements with gear measurement, making the operating principles used in high-volume and mass production applicable to large gears as well. Form measurements, such as roundness and cylindricity measurements on machine elements, are becoming increasingly important. Special measurements and evaluations on gears with a bearing function have therefore been developed, and are also available for the P 152. And the P 152 also offers all the possibilities of the "Done-in-One" principle in its diameter range. With its broad range of varied workpiece diameters and measuring tasks, it is also an ideal machine for contract gear manufacturers. It ensures high precision across the entire component spectrum from small to large gears, as well as for dimension and form measurements. Of course, software solutions for tool measurement are also available.
The metrology on the Höfler Cylindrical Gear Roll Testing Machine R 300 provides a reliable way to determine the root causes of gearbox noise. Due to the short measuring time, it can be easily integrated into any manufacturing process and enables 100 % quality control of the gears produced. The R 300 is designed for all roll testing processes that are relevant for evaluating the running behavior and noise behavior of gears. These include the single-flank test, the structure-borne noise test, and the torsional acceleration test.
The double-flank test can also be performed if needed. Depending on its equipment, the R 300 enables testing of gears and shafts, a particularly important factor for components from an electric vehicle drivetrain system (eDrive). For testing the eDrive intermediate shaft, Klingelnberg will demonstrate a process for roll testing both gears on the shaft in one test cycle. This saves the time that would otherwise be required for a second loading and unloading and for re-tooling the machine, and reduces test costs.
Last but not least, Klingelnberg will also be presenting its services and software solutions. This year will also see the return of Prof. Dr.-Ing. Günther Gravel, Managing Partner of pt&v GmbH. Again in 2025, the expert in measured value analysis will spend two full exhibition days at the Klingelnberg booth, where he will be on hand to take part in stimulating discussions.