Common Platform
The Genesis machines share the same single-piece frame, cast from an advanced polymer composite material. The polymer composite is an ideal substitute for conventional cast-iron because the castings can be made to very tight finished tolerances faster and more precisely. In addition, the column, typically machined separately and then assembled, is instead integrated right into the casting, helping ensure maximum rigidity. The use of the same common platform design is an important element of lean manufacturing, dramatically reducing leadtimes for the Genesis machines.
Designed for Wet or Dry
The Genesis series of machines has been designed to deliver exceptional performance in either wet or completely dry cutting conditions. The work area is contained by an internal guard and funnel that is completely separate from the machine's base/frame to minimize the thermal expansion that results from hot chips coming in contact with the base. In addition, the funnel that directs chips to the chip conveyor has been designed with a steep inclination to ensure that chips fall completely clear of the work area.
Faster floor-to-floor Times
Significant advances in machine and cutting tool performance have combined to reduce the time spent cutting a gear. As a result, the non-productive time required for the load operation can become an increasingly large portion of overall floor-to-floor times. This is why the Genesis 130H machine is equipped with an innovative new mechanical cam-driven double-gripper loader full integrated into the machine. The new Genesis double-gripper loader system can perform the load/unload sequence in as little as 2 seconds. In addition, it can easily accommodate disk or shaft-type gears, and readily integrates with all types of common parts handling systems including palletized, gantry, blue-steel and robot systems for maximum throughput.
Faster speeds
Direct-drive, high speed, high torque motors are used on the hobhead and workspindle to achieve hob speeds up to 4,000 rpm and take full advantage of the most advanced tool materials and coatings. Direct-coupled axis drives are used to achieve higher travel speeds. This, combined with faster spindle speeds and higher acceleration/deceleration rates, results in even further reductions in non-productive time.
Hob drive system breakthrough
A new (patent-pending) hob drive system has been developed for the Genesis 130H machine to improve hobbing performance and simplify the overall design. Conventional hob drives have relied on complicated systems to provide the clamping force on the drive end of the hob. The new Genesis hob drive system eliminates collets, rotary couplings, springs, and all other mechanical and hydraulic clamping components. The drive end of the hob is designed with a taper having a "D" shaped end. This fits into a tapered spindle pocket, where a floating rotary key makes contact with the additional surface area created by the "D" shaped end. The result is a spindle that can transmit considerably more torque, with less runout, than possible with conventional designs. Larger diameter hobs can be used for greater performance and improved tool life.
New hob clamping system
In addition, the 130H uses a completely new clamping system in conjunction with the new hob drive design. Now, both the cutter spindle and outboard support slide both travel tangentially on the same set of linear guide ways, on identical roller bearing assemblies, to clamp the hob. This differs significantly from conventional hob clamping designs, where the spindle slide and support slide each travel on their own independent set of guide ways with different bearing diameters. The end result is a simpler, extremely rigid clamping system that delivers more consistent gear quality across the entire shift pass and longer tool life.
Powerful, user-friendly controls
The Genesis 130H is available with the latest FANUC or SIEMENS CNC control system to meet customer preference anywhere in the world. In addition, Gleason provides new operating software and network capabilities to allow easy integration into any modern production environment: Equipped with the Gleason software to make setup and operation control easy and intuitive by running in a true Windows® environment. Fully network-ready to support remote diagnostics. This allows quick, on-line access to Gleason engineers, or the customer's own off-site personnel for software upgrades and technical support.
Designed for serviceability
Servicing and maintaining hydraulics, lubrication, coolant and electrical services has been made easier and more efficient on the Genesis 130H. By locating all of the service components in one modular sub-assembly, operations and maintenance personnel can more quickly and effectively locate and react to any maintenance issue.
Fast, simple installation and relocation
The Genesis common-platform construction offers several other advantages, including: The machine is readily transportable with no special lifting equipment, and can be installed on three mounting pads without the need for special foundations. Designed into the base are provisions to re-locate the chip conveyor from either the side or rear of the machine to meet any cell/system arrangement, now and in the future. On-board chamfering or de-burring capability. With the 130H comes the option to integrate post-hobbing operations such as chamfering or de-burring into the machine.