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.
New Shaving Head Design
In the past, shaving heads have been equipped with a separate cradle to generate corrections on the tooth flank. But the 130SV’s shaving head has been simplified. Instead of using a cradle, the Y-axis is controlled by Gleason Spheric™ Shaving software, which provides the linear motion to make precise corrections. As a result, the new design enables customers to do both plunge shaving and diagonal shaving on the same machine, with no additional costs.
Faster floor-to-floor times
Significant advances in machine and cutting tool performance have combined to reduce the time spent shaving 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. That’s why the Genesis 130SV machine is equipped with an innovative new mechanical cam-driven double-gripper loader fully integrated into the machine. The new Genesis double-gripper loader system can perform the load/unload sequence in as little as 4 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.
POWER SHAVING™
POWER SHAVING™. As an option, the 130SV can be equipped for POWER SHAVING™, a proprietary Gleason process proven in the popular ZS series of Gleason shaving machines. This process is designed to greatly reduce the time typically required to shave the gears. This is accomplished with precise speed control and adjustment to optimize each portion of the shaving cycle. With POWER SHAVING™, both the work spindle and shaving cutter are driven, such that the workpiece is “auto-meshed” to the continuously rotating cutter on-the-fly. In addition, the shaving cutter continuously applies a torque on the workpiece during the shaving cycle, thus ensuring more consistent results.
Fast, flexible stock dividing system
Faster, more flexible stock dividing is now possible with a new-design stock dividing system that mounts to the shaving head. Typically, the stock dividing operation extends the loading time and needs to be adjusted from part to part. But the new Genesis stock dividing system adds just one second to the loading time. Adjustments from part to part are no longer necessary. During loading, the stock divider sensor swivels in a position between the cutter and part, finds the tooth gap and “jumps” back to its parking position as cutter and part are brought into mesh. Since the stock divider is mounted to the shaving head, no adjustment is necessary. It is moved by machine NC axis. No manual operations are required. Its position is automatically adjusted by CNC using actual part data.
Powerful, user-friendly controls
The Genesis 130SV is available with the latest SIEMENS Sinumerik 840D 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 Spheric™ Shaving software to help make set up 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 arrrangement, 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.