WELTERINNOVATIVE DRIVE TECHNOLOGY

WELTERINNOVATIVE DRIVE TECHNOLOGY

www.welter-lahr.comwww.welter-lahr.com

At our production sites in Lahr /Black Forest and at our factory SPIROTEC in Valff /France we employ more than 120 qualified and highly motivated employees on latest machine tools.

Of course we are always at your disposal for any further questi-ons.

How to contact us:

WELTER

maschinen

WELTER

z a h n r a d

WELTER zahnrad GmbHKarl-Kammer Straße 7D-77933 Lahr/Schwarzwald

Phone: +49 (0) 78 21/923 -0Fax: +49 (0) 78 21/923 -129Email: zahnrad@welter-lahr.de

WELTER maschinen GmbHKarl-Kammer Straße 7D-77933 Lahr/Schwarzwald

Phone: +49 (0) 78 21/94 28-0Fax: +49 (0) 78 21/49 45Email: maschinen@welter-lahr.de

SPIROTEC S.A.R.L.13, Rue LargeF-67210 Valff

Téléphone: +33 (0) 3 88 08 26 13Télécopie: +33 (0) 3 88 08 71 21Mail: spirotec@spirotec.fr

Frankfurt

Rhin

e

Rhine

StuttgartMunich

Nuremberg

BaleMulhouse

Strasbourg

Freiburg/Breisgau

Lahr

Valff

Karlsruhe

Zurich

Germany

Switzerland

France

WELTER

SPIROTECSSPIROTECCSPIROTEC

SPIROTEC

Saarbrücken

We deliver drive technology for:

Mining technology, Marine technology,Rolling stock, Construction machines,Raw material production and power generation,Machine toolsWELTER WELTER

G

F

We perform complete machining on latest CNC machines in our mechanical workshop:

• Turning and milling centres • 5 axis machining• Boring and milling machines• External and internal grinding machines• Gear hobbing and gashing milling• Gear shaping• Gear grinding• Grooving and broaching

In addition to the selection of suitable raw material, the heat treatment process is one of the most important factors in the production of highly stressed geared parts.

So we treat our products in the most advan-ced process-controlled furnace units:

• Gas carburizing in shaft and batch furnaces• Gas and plasma nitriding• Bath and short-term nitriding• Low-distortion press hardening• Levelling up to 100 t

GEAR COMPETENCE

PRODUCTION OF GEAR WHEELS AND ENGINEERING

www.welter-lahr.com

Heat treatment Manufacturing Dimensions

The international reputation of our compa-ny is based on our continuous efforts to achieve quality. We rely on long-term experience, expertise and reliability of our employees.

Since 1999 we are certified according to DIN EN ISO 9001/2008.

The quality of our products is systemati-cally planned, monitored and tested during production.

The results are documented in measure-ment reports and certificates:

• Material certifications according to DIN EN 10204• Heat treatment protocols• Annealing records• Dimension records• Gear measurement diagrams• Certificates for classification societies such as ABS, DNV, GL, BV, etc.• Certificates according to DB quality inspection I

TOOTHEDQUALITY

WELTER

Turning Ø up to 3000 mm; Length up to 3000 mmMilling L=1400 mm W=3000 mm H=1500 mmExternal grinding Ø up to 600 mm; Length up to 3000 mm Bevel gears: Klingelnberg Palloid Ø up to 500 mm, module 2-8Klingelnberg Cyclo Palloid Ø up to 2500 mm, module 2-33Gleason Ø up to 2500 mm, module 2-33

Toothing cylindrical gears: External Ø up to 180 mm, module 2-40,internal Ø up to 1300 mm, module 2-14, herringbone gearing (Sykes)Ø up to 2500 mm, module 2-40

Gear grinding: External Ø up to 2000 mm, width up to 950 mm, module 2-34, internal Ø 200 - 1800 mm, module 2-10

Worm gears: Gear Ø up to 3000 mm, module 1-34Worms: Grinding Ø up to 500 mm, module 1-34

Gear Manufacturing

Bevel gear setsKlingelnberg Cyclo-Palloid and Palloid, Gleason, Kurvex,Face couplings

Gear WheelsSpur and helical gears (external and internal),double helical and herringbone gears

Worm gearsetsCAVEX, Duplex, standard profile

In 1946 the mechanic master Richard Welter laid the foundation for our company under modest circumstances with a small shop. Due to the consequent realization of his demand “Highest quality and performance” nowadays WELTER is one of the well-known companies of the machine tool building and drive technology. At the sites Lahr/Black Forest and Valff/France we manufacture tailor-made machine tools and customer-specific gears on latest production and heat treatment machines with about 120 highly qualified employees.

Our worldwide operating customers in the branches mining technology, vessel’s technology/marine technology, rolling stock, construc-tion machines, raw material production and power generation as well as machine tools comply with highest demands and therefore appreciate their long term partnership with us. We also act as partners in the automobile, commercial vehicle and agricultural equipment industries, as well as with gearbox manufacturers.

We hope you’ll place your trust in us as well!

Engineering

Overhauls, maintenance, modernization and new building of gear cutting machines.The frames of well-known manufacturers form the basis for the new machine after through overhaul and maintenance. Due to the equipment with latest control and measurement technique as well as overhaul of all guideways and drives the “New one” offers state-of-the-art efficiency.The integration of new technologies or additional axes allows economic and technically perfect production of all components.

FROM 50 TO 3000 MM

BEVEL GEAR PRODUCTION

www.welter-lahr.com

For demanding applications not only the capacity calculation is important, but also the definition of the flank geometry is of determining importance for noise and temperature behaviour. We will be glad to support you in calculating and designing as well as in the production of your gears. Our experts are using high performance software packages e.g. KISSOFT® and KIMOS® for satisfying your demands.

Achieving best possible properties regarding strength and stiffness and minimized noise emission requires comprehensive adaptati-on of the gear geometry and the flank topography. We take into account the continuously increasing demands of our customers by being able to realize almost all necessary modifications, such as crowning and depth crowning, tip relief and root relief as well as exact root radius with our grinding technology.

Max. Ø: 900 mm

5-axis milling offers new options in processing gear teeth. Beside the known profiles including their modifications it is possible to realize any geometries at highest precision which were impossible to manufacture before. The procedure is well suitable for green cutting as well as for hard cutting. Combined with latest measuring technology it is possible to perfectly adapt gear teeth of the new part to existing (run-in) gear teeth. Cost and procurement lead times for expensive spare parts are considerab-ly reduced.

Max. Ø: 3000 mm

Special tools are used for hard cutting; the tips consist of polycrystalline boron nitride. The HPG-S method guarantees complete removal of the distortions after heat treatment at which exactly defined load capacities and outstanding surface qualities can be achieved which is having positive effects on the reliability and quiet running.

Max. Ø: 1400 mm

Bevel gear Optimized HPG-S bevel gear sets for rail application Single flank test

5-axis CNC milling

We deliver drive technology for:

Marine technologyRaw material production and power generationConstruction machinesMining technologyRolling stockMachine tools

According to the manufacturing processes

• Klingelnberg Cyclo Palloid • Palloid • Gleason • Kurvex• Oerlikon• 5-axis machining • up to 3000 mm, module 2-33

We manufacture spiral bevel and hypoid bevel gears in almost any required qualities and types

• from subcontract machining up to fully-finished system components• from precision gears to high load face couplings• batch sizes from 1 to several hundreds and from module 0.8 to 33

WELTER

Bevel Gear Grinding HPG method / skiving

tens

ion

T1=

191

0 N

m

THE GEAR TEETH ARE IMPORANT

SPUR GEAR PRODUCTION

www.welter-lahr.com

We produce pinion gears, pinion shafts, wheels, internal geared wheels and lots of special parts of spur gear or helical gear type, with internal and/or external gears, with milled, shaped,planed or ground gears.

Dimensions in a diameter range of up to 3000 mm and shaft lengths of up to 3000 mm are feasible.

Already some years ago customer-specific quality requirements in gear and surface quality have induced us to produce on latest tooth flank grinding machines of the leading machine tool manufacturers.

The reproduction of necessary profile requirements such as depth crowning, tip and/or root relief as well as root radius, etc. guarantees smooth running adapted to the special application, which may give you the decisive competitive edge e.g. regarding increasing requirements for reduced noise emission.

As your partner for drive solutions, we offer you:

• A comprehensive program of toothed wheels and components• Competent advice for drives and repair solutions• Tailored customer solutions• New developments and optimisation of drive solutions

Highly loaded pinion gear for tunneling machines Spur wheel for locomotive drive

We deliver drive technology for:

Rolling stockMining technologyMarine technologyConstruction machinesRaw material production and power generationMachine tools

For us shaped internal geared wheels of quality 7 according to DIN are state-of-the-art.Our specialists guarantee the required quality and economic production depending on the most important technical parameters.

The considerably increased requirements in transfer accuracy and smoothness of gears also demands considerably higher quality of the internal gear - we offer you the quantum leap for noise optimized precise gears.

Internal gears

Economic production at highest precision. We meet these requirements in particular in de-manding branches such as railway technology, vessel’s technology and mining. At this, we at-tain highest fatigue strength.

Our customers estimate the reliability of our employees and the quality of our work. In key questions you are welcome to rely on our tech-nical knowledge.

Helical and Double Helical Gears

5-axis milling offers new options in processing gear teeth. Beside the known profiles including their modifications it is possible to realize any geometries at highest precision which were impossible to manufacture before. The proce-dure is well suitable for green cutting as well as for hard cutting. Combined with latest me-asuring technology it is possible to perfectly adapt gear teeth of the new part to existing (run-in) gear teeth. Cost and procurement lead times for expensive spare parts are consider-ably reduced.

Herringbone pinion toothed by 5-axis milling

5-axis machining Tooth Profile GrindingInternal gears

WELTER

CUSTOMER-SPECIFIC

WORM GEAR PRODUCTION

www.welter-lahr.com

WELTER

We produce worm gear sets according to customer designs of high variability with all common standard profiles. By the new CAVEX GmbH & Co. KG with the CAVEX® wheel set program we offer a range of worm gears which has proven successful for decades. Due to its power density and the long service life CAVEX® wheel sets are always the first choice of experienced engineers for demanding machines and plant designs such as

• Packaging machines• Food processing machines• Rolling mills (scissors, winders, roller tables)• Mixers and agitators• Shipbuilding

In machine tools with increasing requirements in accuracy and stiffness have prevailed in lots of applications of the DUPLEX wheel sets. In this wheel set the worm is realized with a variable pitch and thus allows a wheel set with a clearance free setting. In this way, the conditions for highly precise production are given.

The tooth profile of the CAVEX® wheel sets is decisive for the long service life and the high strength of the wheel sets. Due to the hollow flank profile it is possible to fully use the material properties of the high quality bronze of the wheel and the cased- hardened worm, since the contact stresses are considerably reduced and the lubrication of the gear is considerably improved in all operating conditions.

A particularly high root width of teeth is achieved due to the hollow flank profile. Therefore, the wheel sets are extremely resistant to high impact load at little speed.

The range of products of CAVEX® toothed wheels includes:

• Centre distance 40 - 1400 mm• Gearing from 1 to 180• Module from 1 to 40• Number of worm starts from 1 to 12• Increased accuracy • Reduced backlash• Finished dimensions according to customer requirements• Special models

CAVEX® wheel sets are designed for highest loads. We optimise the profile of the gear using latest calculation tools. As the reliability of the CAVEX® wheel sets is of great importance even under rough operating conditions. Each wheel set is entirely quality proofed. After geometrical testing of worm and wheel the contact pattern is checked.

CAVEX® profileComparison of standard and hollow flank profile

CAVEX® Conventional worm drive

We deliver drive technology for:

Raw material production and power generationMining technologyMarine technologyRolling stockConstruction machinesMachine tools

Worm gear-milling Worm-TestingWorm-grinding

Purchase and trade of machine tools

We are always looking for used gear cutting machines for new customer projects. If you are planning to sell your machine, please contact us. You are yourself looking for a used or moder-nized machine tool? We always keep a choice of machines available - with a focus on gear cutting. Furthermore we have access to thousands of used machine tools being a member of the professional association Fachverband des Deutschen Ma-schinen- und Werkzeuggroßhandels e.V. (FDM).

Engineering

You have a special machining task - we assume the engineering tasks. We develop new assemblies such as capping heads, hobs and other drive elements on modern CAD - sets for the existing machine up to a complete new machine such as the modern bevel gear cutting machine KF 1400 and the bevel gear testers UHT 1000 and EFPG 2000. At this our target is always to react on the current signals of the market and to achieve optimum performance by using latest technologies and electronics.

ENGINEERING

WITH WELTERTO THE TOP

www.welter-lahr.com

Modernization

For this we use the basic components (cast constructions) of the well-known machine manufacturers as basic machines which we reconvert to CNC gear cutting machines after thorough redesign/renewal and optimisation by implementing latest technologies.

Significant advantages of an overhaul:

• Significant cost advantages compared to a new machine• The efficiency, the value and the productivity are adapted state-of-the-art• Comfortable operation• Little downtimes • Use of latest technologies• Warranties• Availability of spare parts

Maintenance & Service:

• Major and partial overhaul • Measurement of machines• Geometry with grinding/ scraping of the slideways • Modernisation of controls, electrics• Reconverting to special machines • Preventive servicing and maintenance • Delivery of spare parts

This is the right address for you!

You have a problem with your gear cutting machines and need service, immediate advice and support in repair and mainte-nance of the machine?

We are your partner for all system solutions. In the engineering we are dealing with overhaul, maintenance, modernisation and new development of gear cutting machines. Our machines increase the productivity of your production and the quality of your products.

P900 CNC

Gear hobbing machine WS 3000 CNC

Modernization

Gear shaping machine WS 1500 CNC including new shaping head

Gear shaping machine MCS 60

New production machines

WELTER

KF1400

Single flank testing machine EFPG 2000

Bevel gear cutting and measuring machines

WELTERINNOVATIVE DRIVE TECHNOLOGY

WELTERINNOVATIVE DRIVE TECHNOLOGY

www.welter-lahr.comwww.welter-lahr.com

At our production sites in Lahr /Black Forest and at our factory SPIROTEC in Valff /France we employ more than 120 qualified and highly motivated employees on latest machine tools.

Of course we are always at your disposal for any further questi-ons.

How to contact us:

WELTER

maschinen

WELTER

z a h n r a d

WELTER zahnrad GmbHKarl-Kammer Straße 7D-77933 Lahr/Schwarzwald

Phone: +49 (0) 78 21/923 -0Fax: +49 (0) 78 21/923 -129Email: zahnrad@welter-lahr.de

WELTER maschinen GmbHKarl-Kammer Straße 7D-77933 Lahr/Schwarzwald

Phone: +49 (0) 78 21/94 28-0Fax: +49 (0) 78 21/49 45Email: maschinen@welter-lahr.de

SPIROTEC S.A.R.L.13, Rue LargeF-67210 Valff

Téléphone: +33 (0) 3 88 08 26 13Télécopie: +33 (0) 3 88 08 71 21Mail: spirotec@spirotec.fr

FrankfurtRh

ine

Rhine

StuttgartMunich

Nuremberg

BaleMulhouse

Strasbourg

Freiburg/Breisgau

Lahr

Valff

Karlsruhe

Zurich

Germany

Switzerland

France

WELTER

SPIROTECSSPIROTECCSPIROTEC

SPIROTEC

Saarbrücken

We deliver drive technology for:

Mining technology, Marine technology,Rolling stock, Construction machines,Raw material production and power generation,Machine toolsWELTER WELTER

G

F