Gear Technology and

Automation Systems
 Liebherr-Verzahntechnik GmbH
offers a comprehensive range of
machine tools, tools, and auto-
mation systems. The independent
business unit of the Liebherr Group
employs approximately 1350 em-
ployees at the production sites
in Kempten (Germany), Ettlingen
(Germany), Bangalore (India), Sali-
ne (USA), Seoul (South Korea), and
Collegno (Italy).

Thanks to the high level of in-

house vertical integration, the ma-
jority of mechanical production,
sheet metal forming, paintwork,
and component assembly takes
place directly at the Kempten site.

1. Kempten (Germany)
2. Ettlingen (Germany)
3. Collegno, (Italy)
4. Saline (USA)
5. Bangalore (India)
6. Seoul (South Korea)
2 3 4

2 Gear Technology and Automation Systems

 Sales per Business Unit of
Liebherr-Verzahntechnik GmbH

7 %

30 %

63 %

 Gearing technology machines

 Automation systems
 Gearing technology tools

Sales according to Industry of

Liebherr-Verzahntechnik GmbH

6 %
10 %
26 %

5 %

13 %

22 %

18 %

 Automotive
 Automotive suppliers
 Truck
 Agricultural and construction machines
 Aerospace
 General mechanical engineering
 Other

5 6

Gear Technology and Automation Systems 3

Programme

Gear Cutting Machines Automation Systems

• Gear Generating- and Profile-Grinding Machines • Machine and System Solution
• Gear Hobbing Machines • Gantry Robots
• Gear Shaping Machines • Conveying and Storage Systems
• Gear Skiving Machines • Pallet Handling Systems
• Deburring and Chamfering Machines • Robot Applications
• Software
Gear Tools
• Shaping Cutters Service
• Wafer Cutters • Training
• Solid Wafer Cutters • Preventive Maintenance
• Rolling Dies • Global Presence and Spare Parts Availability
• Shaving Cutters
• Rolling Deburring Discs
• Rolling Chamfering Discs
• Master Gear
• CBN Grinding Tools
• Customized Grinding Tools
• Skiving Tools
• Rolling Racks

4 Gear Technology and Automation Systems

Gear Generating- and
Profile-Grinding Machines

The LCS line from Liebherr is an optimal machine concept for Type Module Workpiece-Ø Axial distance
the hard-fine machining of bore- and shaft-type gears. The (mm) (mm) (mm)
gear grinding machines are suitable for workpieces up to a LGG 180 6 / 12 180 660
diameter of 1250 mm, plus they are versatile and extremely LGG 180 L 6 / 12 180 1.000
productive. LGG 280 6 / 12 280 660
Liebherr machines for grinding gears can be individually con-
LGG 280 L 6 / 12 280 1.000
figured for every customer.
LGG 400 M 6 / 12 400 660
The LGF line allows profile grinding of external and internal LGG 400 LM 6 / 12 400 660
gears. The basis for this is the directly driven table, which in
conjunction with the machine bed made of mineral casting LCS 200 8 / 14 200 600 / 1.000
guarantees maximum precision over the entire service life.
LCS 300 8 / 14 300 600 / 1.000
LCS 380 8 / 14 380 600 / 1.000
LCS 500 8 / 14 500 600 / 1.000
LCS 600 10 / 20 600 1.000
LCS 700 10 / 20 700 1.000
LCS 1000 10 / 20 1.000 1.000
L = Long version LCS 1200 10 / 20 1.200 1.000
M = Manual loading

Type Profile depth Workpiece-Ø Axial distance

(mm) (mm) (mm)
LGF 800 75 / 120 800 1.000 / 1.400
Video:
LGG 280 LGF 1000 75 / 120 1.000 1.000 / 1.400
https://go.liebherr.com/dF18F7 LGF 1250 75 / 120 1.250 1.000 / 1.400

Gear Technology and Automation Systems 5

Gear Hobbing Machines

For machining workpieces with a pitch diameter of max. Gear hobbing with integrated workpiece chamfering up to Ø 500 mm
12  metres, Liebherr offers a choice of gear hobbing ma- Type Module Workpiece-Ø Axial distance
chines with individual concepts for machine automation. (mm) (mm) (mm)
LC 80 DC 3 80 250 / 400
LC 120 DC 3 120 250 / 400
Workpiece up to Ø 180 mm
LC 150 DC 3 150 250 / 400
Type Module Workpiece-Ø Axial distance
(mm) (mm) (mm) LC 180 DC 3 180 250 / 400

LC 60 2,75 60 200 LC 200 DC 5* 200 600

LC 80 3 80 250 / 400 LC 280 DC 5 280 400

LC 100 2,75 100 200 LC 300 DC 5* 300 600

LC 120 3 125 250 / 400 LC 380 DC 5* 380 600

LC 130 2,75 130 200 * limited by ChamferCut, DC = integrated ChamferCut unit

LC 150 3 150 250 / 400
LC 180 3 180 250 / 400

Video:
Workpiece up to Ø 500 mm LC 280 α
https://go.liebherr.com/rVg4ZY
LC 200 7 / 12 200 600
LC 280 5 280 400
LC 300 7 / 12 300 600
LC 380 7 / 12 380 600
Video:
LC 500 7 / 12 500 600 LC 180 ChamferCut
https://go.liebherr.com/87V3V3

6 Gear Technology and Automation Systems

Workpiece up to Ø 2,000 mm Workpiece up to Ø 12.000 mm
Type Module Workpiece-Ø Axial distance LC 1500 24 / 30 1.500 1.200 – 1.800
(mm) (mm) (mm)
LC 2000 24 / 30 2.000 1.200 – 1.800
LC 600 16 / 22 / 27 600 1.000
LC 2500 30 / 40 2.500 1.200 – 1.800
LC 700 16 / 22 / 27 700 1.000
LC 3000 30 / 40 3.000 1.200 – 2.400
LC 800 16 / 22 / 27 800 1.000 – 1.400
LC 4500 30 / 40 4.500 1.200 – 2.400
LC 1000 16 / 22 / 27 1.000 1.000 – 1.400
LC 6000 30 / 40 6.000 1.200 – 2.400
LC 1200 16 / 22 / 27 1.200 1.000 – 1.400
LC 8000 50 / 60 8.000 1.200 – 2.400
LC 1400 16 / 22 / 27 1.400 1.000 – 1.400
LC 10000 50 / 60 10.000 1.200 – 2.400
LC 1600 16 / 22 / 27 1.600 1.000 – 1.400
LC 12000 50 / 60 12.000 1.200 – 2.400
LC 2000 16 / 22 / 27 2.000 1.200 – 1.400

Video:
LC 4000
https://go.liebherr.com/Qa78gy

Gear Technology and Automation Systems 7

Gear Shaping Machines

Gear shaping machines are employed primarily in the production of internal and external gears on work-
pieces with limited tool overrun. That means that the special workpiece geometry or interference condi-
tions only make machining possible using the shaping process. Gear shaping machines are equipped
with cutting tools from our own production which are optimally matched to the process and the machine.

Workpiece up to Ø 180 mm Workpiece up to Ø 500 mm

Type Module Workpiece-Ø Stroke length Axial distance Type Module Workpiece-Ø Stroke length Axial distance
(mm) (mm) (mm) (max. mm) (mm) (mm) (mm) (max. mm)
LS 80 3 / 5 80 30 / 55 – LS 200 F/E 5 – 12 200 70 – 240 –
LS 120 3 / 5 125 30 / 55 – LS 300 F/E 5 – 12 300 70 – 240 –
LS 150 3 / 5 150 30 / 55 – LS 400 EM 5 400 70 275
LS 180 F 5 180 70 275 LS 500 F/E 5 – 12 500 70 – 240 275
LS 180 E 5 180 70 275

Video:
LS 180 E
https://go.liebherr.com/4nB37b

8 Gear Technology and Automation Systems

Workpiece up to Ø 1.600 mm Workpiece up to Ø 4.500 mm
Type Module Workpiece-Ø Stroke length Axial distance Type Module Workpiece-Ø Stroke length Axial distance
(mm) (mm) (mm) (max. mm) (mm) (mm) (mm) (max. mm)
LS 600 F/E 8 / 12 600 120 – 240 1.050 LS 1800 H 22 1.800 440 / 600 1.800
LS 700 F/E 8 / 12 700 120 – 240 1.050 LS 2000 H 22 2.000 440 / 600 1.800
LS 800 F/E 8 / 12 800 120 – 240 1.050 LS 2500 H 22 2.500 440 / 600 1.800
LS 800 H 22 800 270 / 440 1.400 LS 3000 H 22 3.000 440 / 600 1.800
LS 1000 F/E 8 / 12 1.000 120 – 240 1.050 LS 4500 H 22 4.500 440 / 600 1.800
LS 1000 H 22 1.000 270 / 440 1.400 F = Shaping head slide with mechanic shaping head
LS 1200 F/E 8 / 12 1.200 120 – 240 1.050 E = Shaping head slide with electronic shaping head
H = Shaping head slide with hydraulic shaping head
LS 1200 H 22 1.200 270 / 440 1.400 EM = Shaping head slide with electronic shaping head and manual loading
LS 1400 F/E 8 / 12 1.400 120 – 240 1.050
LS 1400 H 22 1.400 270 / 440 1.400
LS 1500 H 22 1.500 440 / 600 1.800
LS 1600 H 22 1.600 270 / 440 1.400

Gear Technology and Automation Systems 9

Skiving Machines

Liebherr now offers this complex technology and will be presenting a skiving machine in 2017. Every-
thing from a single source: machine, tool and process. The machine represents excellent quality and
productivity when skiving internal and external gears.

Skiving³
Type Module Max. outer-Ø Tooth-Ø
Machine: (mm) (mm) (mm)
automation, deburring and tool changer rigidity LK 300 5 500 300
Tool: LK 500 5 600 500
design, machining, processing
Process:
technology configuration, implementation, optimization

Video:
LK 300/500
https://go.liebherr.com/j636wC

10 Gear Technology and Automation Systems

Deburring and Chamfering Machines

This method, established for many years and well-known for its very high chamfer quality, is combined
with proven machine technology. The chamfering operation is now available as a stand-alone machine.
The Chamfercut tools, which can be easily re-sharpened multiple times, create precise chamfers with
high consistency, a long tool life and facilitate optimum economy.

Type Module Workpiece Workpiece-Ø

(mm) length (mm) (mm)
LD 180 C 5 200 180
LD 280 C 5 200 280
LD 300 C 5 600 300

Video:
LD 180/280 C
https://go.liebherr.com/Zl2481

Gear Technology and Automation Systems 11

Gear Cutting Tools

Liebherr is a reliable partner offering an Tools Module range (mm) Tool-Ø (mm)
extensive range of gear cutting tools Shaping cutters 0,25 – 30 max. 360
which are characterised by quality Wafer cutters 0,30 – 6 max. 220
down to the finest detail and by their Solid wafer cutters 0,25 – 30 max. 360
long service life. Many years of experi-
Rolling dies 1–4 max. 127
ence and sound technical expertise in
the field of gear production are the ba- Shaving cutters 0,75 – 13 max. 320
sis for these innovative products. Rolling deburring discs 1 – 6,5 max. 280
Rolling chamfering discs 1 – 6,5 max. 280
Master Gear 0,75 – 20 max. 360
CBN grinding tools 1–6 40 – 200

Skiving tool 0,8 – 8 20 – 200
Services

• Sharpening and coating Rolling racks 0,75 – 1,5 12" – 48"
• Reconditioning of CBN tools

New at Liebherr: Gear skiving tools

• Two to five times faster than gear shaping
• One to two quality grades better than gear shaping
• Excellent single indexing quality at the workpiece
• Tool life similar to gear shaping
• Available tool designs: conical and cylindrical
• Process-optimized tool design
• Tools available in PM-HSS and carbide (also with indexable inserts)
• Dry skiving possible
• Pressure angle and lead modification possible

12 Gear Technology and Automation Systems

Automation Systems:
Machine and System Solution

Liebherr gear cutting machines with flexible robot automation in the gear manufacturing

Our core area is the delivery of turkey system solutions for ing to customer requirements. The international collaboration
flexible production cells and manufacturing systems. As a with leading manufacturers of machine tools revealed invalu-
complete provider, we integrate all upstream, intermediate, able potential for operational experience, from which all cus-
and downstream processes into the overall concept accord- tomers now benefit.

OEM Automotive engine block line, China. Source: MAG IAS GmbH

Gear Technology and Automation Systems 13

Gantry Robots

LP 100 LP 200 LPR 200 LP 2000

Liebherr gantry robots can be deployed in a variety of ways: For transporting, palletizing, goods han-
dling, loading and unloading, or storing. Linear robots in five sizes and gantry area robots in three sizes
for workpiece weights from 0.5 kg to 1,500 kg perform a wide range of automation tasks. Liebherr offers
a modular system for all sizes with which the automation system can be adapted to the respective ap-
plication, e.g. cylinder head, engine block, or gear unit manufacturing.

Linear Payload Traverse Speed X Acceleration X

Gantry Robot (kg) (m / min) (High Speed) (m / s²) (High Speed)
LP 10 40 240 5
LP 20 240 180 4
LP 100 280 180 (300) 2.5 (4.5)
LP 200 600 180 3
LP 2000 1,500 120 2
Other weights available upon request

Gantry Area Payload Traverse Speed X Acceleration X Traverse Speed Y Acceleration Y

Robots (kg) (m / min) (m / s²) (m / min) (m / s²)
LPR 20 240 180 240 120 3
LPR 200 600 180 180 120 3
LPR 2000 1,500 180 120 120 2
Other weights available upon request

14 Gear Technology and Automation Systems

Conveying and Storage Systems

Conveying systems Storage systems

Liebherr conveying systems are adapted not only to the Storage systems for workpieces can be deployed in a vari-
shape, position, weight and size of the range of parts, but to ety of ways: whether it is for loading/unloading function, de-
the material as well. Standardised assembly groups provide coupling module, in-process buffers or automated storage
an ideal enhancement to the programme. retrieval system.

• Plastic chain conveyor (KKB) • Palletising cell (LPC)

• Pallet accumulating conveyor (PSB) • Shelf magazine system
• Indexing chain conveyor (TKB) • Decoupling module (EKM)
• Hinged chain conveyor (SKB)
• Tooth chain conveyor (ZKB)
• Accumulating conveyor (SFB)
• Drag frame conveyor (SRB)
• Friction roller conveyor (FRB)

Video:
LPC 3400
https://go.liebherr.com/v34C1y

Gear Technology and Automation Systems 15

Pallet Handling Systems

Liebherr pallet handling systems are deployed to automate Rotary Loading System (RLS)
processing centers in the area of individual part production Rotary loading systems from Liebherr are distinguished by
and small batch production. The basis is a workpiece their high storage density in relation to the footprint and are
clamped on a machine pallet. The cell concept enables pallet designed for one to two processing centers. In combination
loading in parallel to machine processes, and can include with the Liebherr rotary storage tower (RST), the storage
resource and order planning. The customer benefits from areas can be configured individually to meet specific needs.
increased productivity and lower labor costs. Pallet handling The rotary loading system is available in two sizes and
systems from Liebherr are offered in two versions: as a designed for transport loads between 800 and 1,500 kg.
rotation loading system (RLS) or as a linear loading system
(PHS). Both versions have a modular design and can be
adapted to the respective requirements of the manufacturing
concept.

Rotation Workpiece Diameter Transport Load

Loading System (mm) (kg)
RLS 800 600 / 800 800
RLS 1500 900 / 1,300 1,500
Video: Rotary Loading System RLS
https://go.liebherr.com/2N1z63

16 Gear Technology and Automation Systems

Pallet Handling System PHS PRO Pallet Handling System PHS Allround
On the linear-type pallet handling system, the modular design The pallet handling system PHS  1500 Allround makes it
allows for multiple machines and expandable set-up and possible for customers to implement multiple CNCs and
storage areas. The PHS can be extended to manage raw, in- complex inventory tracking, and parallel / serial manufacturing
process and finished part inventory. All of the requirements strategies. This can result in reduction to your part costs,
of a modern production system can be integrated. The lin- and increase your competitiveness.
ear system is manufactured in four sizes for transport loads
between 500 kg and 13,000 kg.

Pallet Workpiece Diameter Transport Load

Handling System (mm) (kg)
PHS 750 PRO 1,000 500 / 700 / 1,000
PHS 1500 PRO 1,150 / 1,700 1,500 / 2,000 / 2,500
PHS 3500 PRO 1,900 / 2,400 3,500 / 5,000 / 6,500
PHS 10000 PRO 3,000 / 3,500 / < on request 10,000 / 13,000 / < on request

Pallet Workpiece Diameter Transport Load

Handling System (mm) (kg)
PHS 1500 Allround 1,400 1,500
Video: Pallet Handling System PHS Pro
https://go.liebherr.com/yBF8Bn

Gear Technology and Automation Systems 17

Robot Applications Software

Liebherr Manufacturing System (LMS 4.0)

Parts Handling, Palletizing, Random Bin Picking Software Application increases Reliability
In parts handling Liebherr performs loading tasks for a wide Complex production systems require increased functional-
range of machine tools. In recent years solutions from ma- ity in their software systems. With the Liebherr Manufactur-
chining centers, turning machines, gear cutting machines, ing System (LMS 4.0), Liebherr offers user-friendly additional
rotary transfer machines through to grinding machines have software which guarantees process reliability in a production
been implemented here. or assembly line. The LMS  4.0 is able to record temporary
Liebherr uses 2D and 3D vision systems to perform palleti- parts tracking, as well as save specific data and make this
zing and depalletizing tasks. Whether it be to detect and grip available to all system-based users. The system offers a
unsorted parts from Euro pallets or transport presorted parts range of assessments and can be deployed, for example,
in blisters. so that correct adherence of the production process can be
"Random bin picking" replaces complicated sorting systems, monitored.
heightens productivity, and relieves the strain on personnel. Thanks to the extension with new functions such as
In order to be able to remove unsorted workpieces from a "Production Monitoring App" and "Info Board App", the
transport container, a complex interaction between image processes can be easily tracked on mobile end devices and
recognition system, software, and robot is required. Based interfaces.
on the range of parts, all steps required for the process
complement each other so that an optimal removal and
positioning result is achieved.

Video: Video:
Bin Picking LMS 4.0
https://go.liebherr.com/977A92 https://go.liebherr.com/8dGmbv

18 Gear Technology and Automation Systems

Service

Training technician can have quotations created immediately for nec-

We offer a comprehensive range of training courses both at essary procedures. Any repairs extending beyond this are
the customer's premises and in our subsidiaries. The prac- discussed in detail with the customer within this framework
tical technical training courses are delivered by our expe- and agreed upon with regard to deadlines. This reduces un-
rienced system technicians who are very familiar with the necessary costs and downtime to a minimum. The customer
systems and applications owing to their many years of ex- receives service that is precisely coordinated with them. The
perience. These training courses enable you to help yourself field experience of the service technicians is continuously fed
and use systems safely in emergency situations, e.g. a power back into product improvements.
failure.
Global Presence and Spare Parts Availability
Customer Hotline and Remote Maintenance With our headquarters in Kempten and global subsidiaries,
Our experts on the customer hotline provide professional ini- as well as service outlets, we guarantee a fast response
tial assistance when needed. Many faults can be eliminated time in order to be able to deploy a service technician to
with the support of our experts via remote access. the customer's premises if necessary. A rapid replacement
parts service is guaranteed thanks to the consistent modular
Preventive Maintenance system of the products and the use of basic components
Liebherr deliberately focuses on the proven inspection by from well-known, global manufacturers. Original spare parts
experienced service technicians, who have an excellent are stocked in the subsidiaries and can be delivered to your
understanding of the machines and their control systems. production sites within a short period of time. Included in the
They proceed according to a systematized checklist involv- services offered are the provision of spare parts, inspections,
ing over 100 inspection criteria. The status assessments are maintenance, or modifications to systems.
carried out using a color-coded ranking system, that rap-
idly and clearly displays the current status of the machine to
the customer through a visualization process and highlights
when there is an acute need for action. Following this, the

Gear Technology and Automation Systems 19

Your solution provider
Moscow

Paris Ettlingen
Kempten
Saline Collegno
Seoul Tokyo
Yongchuan Shanghai

Bangalore

São Paulo

Liebherr-Verzahntechnik GmbH Liebherr-Gear Technology, Inc. Liebherr Machine Tools and

Gear Technology and Automation Systems Liebherr Automation Systems Co. Automation Korea Ltd.
Kaufbeurer Strasse 141 1465 Woodland Drive 174-30, Saneop-ro, Gwonseon-gu
87437 Kempten Saline, MI 48176–1259 Suwon-si, Gyeonggi-do
Germany USA Korea
 +49 831 786-0  +1 (734) 429-7225  +82 31 294 9888
+49 831 786-1279 +1 (734) 429-2294 [email protected]
[email protected] [email protected]

Printed in Germany by Typodruck  BK  LVT-Verzahntechnik und Automationssysteme-1.0-09.18_en

Liebherr Machinery Service
Liebherr-Verzahntechnik GmbH Liebherr Brasil Guindastes (Shanghai) Co. Ltd.
Plant Ettlingen / Gear Tools e Máquinas Operatrizes Ltda. Building 1, 88 Maji Road
Hertzstrasse 9–15 Rua do Rocio, 288 Salas 81 / 82 Waigaoqiao FTZ
76275 Ettlingen Vila Olímpia 200131 Shanghai
Germany 04552-000 São Paulo - SP P.R. China
 +49 7243 708-0 Brazil  +86 21 2893 8088
+49 7243 708-685  +55 11 3538 1509 [email protected]
[email protected] [email protected]
Liebherr Japan Co. Ltd
Liebherr-Utensili S.r.l. Liebherr Machine Tools India 3-7-8, Kudan-Minami
Via Nazioni Unite 18 Private Limited Chiyoda-Ku, Tokyo
10093 Collegno TO 353 / 354, 4th Main, 9th Cross, 102-0074
Italy 4th Phase Japan
 +39 114 248711 Peenya Industrial Area  +81 3 6272-8645
+39 114 559964 Bangalore – 560 058 [email protected]
[email protected] India
 +91 80 41 1785-91 OOO Liebherr-Russia
Liebherr-Verzahntechnik GmbH +91 80 41 272625 Bolshoy Palashevskiy pereulok 13 / 2
6 Place Du Village [email protected] 123104 Moscow
92230 Gennevilliers Russia
Subject to modifications.

France  +7 495 280 18 91

 +33 1 412110-35 +7 495 280 18 92
[email protected] [email protected]

Liebherr-Verzahntechnik GmbH
Verzahntechnik und Automationssysteme
Kaufbeurer Straße 141, D-87437 Kempten Liebherr-LinkedIn Liebherr-Twitter Liebherr-Youtube
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