Klingelnberg – VIPER 500

The VIPER 500 cylindrical gear grinding machine is designed for component diameters up to 500 mm and is optimally suited for small to medium-sized batches. To suit individual requirements, the machine is available in three different configurations: Profile grinding with small grinding wheels for custom jobs and multiplewheel technology (K), as well as generating grinding (W) or (KW). The VIPER 500 W / KW configuration allows both profile grinding and continuous generating grinding on the same machine – with minimal retooling time.

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Overview

Features

Specifications

Convertible Machine for Individual Requirements.

Convertible machine for generating, profile, and internal grinding (VIPER 500 W)Retooling from generation grinding to profile grinding in less than 5 minutes (VIPER 500 W)Retooling to internal grinding in less than 15 minutesHighly dynamic axes at 5 m/sec² acceleration and 20 m/min rapid traverseLow-maintenance machine concept due to separation of working chamber from drive technologyNo pump station needed for grinding oilOptimal energy efficiency (e²) thanks to recovery and on-demand powering of units

Technical Specifications

Range of Application	VIPER 500 K	VIPER 500 W	VIPER 500 KW
Workpiece diameter (max)	Ø 500 mm	Ø 500 mm	Ø 500 mm
Grinding stroke	430 mm	500 mm	430 mm
Work area over table (min. – max.)	370 – 800 mm	300 – 800 mm	370 – 800 mm
Distance between center above table (min. – max.)	42 – 1,042 mm	42 – 1,042 mm	42 – 1,042 mm
Module (min. – max.)	0.5 – 22*	0.5 – 22*	0.5 – 13*
Swivel angle	–180°/+ 45°	–180°/+ 45°	–180°/+ 45°
Grinding wheel diameter (max.)	Ø 300 – 25 mm	Ø 300 – 21 mm	Ø 300 – 25 mm
Grinding wheel width (max.)	60 mm	75 mm	60 mm
Grinding worm diameter		Ø 350 – 221 mm	Ø 200 – 111 mm
Grinding worm width		150 mm	80 mm
Grinding spindle	35 kW	37 kW	35 kW
Grinding wheel speed	17,000 rpm	6,000 rpm	17,000 rpm
Table diameter	Ø 400 mm	Ø 400 mm	Ø 400 mm
Table load (max.)	500 kg	500 kg	500 kg
Table hole (diameter x depth)	Ø 100 x 500 mm	Ø 100 x 500 mm	Ø 100 x 500 mm
Table rotation speed (max.)	120 rpm	1,000 rpm	1,000 rpm
Axial feed rate (max.)	20,000 mm/min	20,000 mm/min	20,000 mm/min
Radial feed rate (max.)	12,000 mm/min	12,000 mm/min	12,000 mm/min
Tangential feed rate (max.)	20,000 mm/min	20,000 mm/min	20,000 mm/min
Total connected load without filter system	60 kVA	60 kVA	60 kVA
Net weight approx.	19,300 kg	19,300 kg	19,300 kg
Machine dimensions (L x W x H) approx	4,220 x 3,120 x 2,526 mm	4,220 x 3,120 x 2,526 mm	4,220 x 3,120 x 2,526 mm
Dimensions filter unit (L x W) approx	3,450 x 2,100 mm	3,490 x 2,250 mm	3,490 x 2,250 mm

Key Features

Intelligent Production Process with Extremely Cost-Effective Energy Efficiency (e²)

Productivity gains of up to 25% over comparable machines of
other models
Automatic grinding wheel threading and machine-integrated correction program
Low tool and maintenance costs, reduced storage and variety of spare parts
Optimal axis weight compensation, intelligent grinding oil drainage design with energy-optimized grinding oil nozzles
Efficient energy recovery and cooling units

Dynamic, Accelerated Production Processes

Special machine axis arrangement guarantees high reliability in the production process
Automatic adjustment of the grinding oil nozzles ensures the same process for every grinding wheel diameter
Automatic grinding stock analysis
Adaptive process sequences thanks to variable stroke rate and dressing
Measurements taken during the production process itself (including optional correction calculation in the machine) provide quick assurance of a successful production run

Convenient, Clearly Laid-Out Operating Concept

Intelligent control technology with fast, rational and intuitive dialog input and job engineering
Clear navigation and visual workflow support prevent user errors
Continuous graphical display of machine statuses and processes
Graphical display of possible workpiece clamping collisions before the problem occurs on the machine

Minimal Retooling Times

Quick changeover from generating grinding to profile grinding just by swapping out the grinding wheel, grinding wheel flange, and diamond dressing roll in less than 5 minutes (VIPER 500 W)
Quick grinding wheel changes using the swivel axis, which moves the grinding wheel 180 degrees toward the operator
Tool quick-clamping system enables fast and easy tool changes (VIPER 500 W)
Short retooling times for internal grinding in less than 15 minutes

Maximum Production Technology, Minimal Footprint

Small setup dimensions means less floor space needed at the installation location
Self-contained construction for ultra-easy machine transport and setup
Fast cleaning time, since all installations are accommodated outside the working chamber
All machine components are quickly and easily accessible
Easy, ergonomic adjustment of the oil supply

Technology Platform for Profile and Generating Grinding

Extensive configurations enable profile and continuous generating grinding on the same machine (VIPER 500 W)
Application-appropriate machine design allows tremendous variety in the work range
Easy, ergonomic handling ensures quick and seamless product changeover
Powerful dressing unit for cost-effective, precise dressing of the grinding wheels with all the usual modifications
Highly dynamic drives for maximum precision

Closed Loop Quality Control in Line with Industry 4.0

Central gearing and process design
Networked connection in the Klingelnberg production system (GearEngine®)
Knowledge management with central production data acquisition
Digitization of gear production through automated machine correction

VIPER 500 – Convertible Machine for Individual Requirements

The VIPER 500 cylindrical gear grinding machine is designed for component diameters of up to 500 mm and is optimally suited for small to medium-sized batches. To suit individual requirements, the machine is available in three different configurations: profile grinding, small grinding wheels for custom jobs and multiple-wheel technology (K) and generation grinding (W) . The special machine axis arrangement is a contributing factor to the machine’s tried-and-tested precision, consistent quality and tremendous flexibility. The highly dynamic axes allow optimized 5-axis machining of wide variety of modifications in the shortest possible grinding time.