Motor Spindle Safety System MS³

The most common accidents involving the use of machine tools include spindle crashes. Common causes include programming errors, incorrectly defined tools, disregarded interference contours, or unintentional high-speed operation. The forces involved are so enormous that components of the motor spindle, ceramic spindle bearings, shafts, encoders, clamping system and the entire machine geometry can be affected or even completely destroyed. A case study from RWTH Aachen shows that repair costs after a crash in the amount of five-digit euro amounts are not uncommon. Collision avoidance systems for machine tools minimize damage and reduce downtime and repair costs in the event of a collision. Nevertheless, only very few machine tools have a spindle collision protection at all. This is usually based on compression elements that act like a car bumper and are completely destroyed in the event of a crash.

Although the spindle components remain intact, downtime still occurs. The motor spindle protection system MS³ from JAKOB Antriebstechnik GmbH detects collisions by means of several sensors and reports them electronically to the machine control. This can bring the feed axes of the machine tool to a halt with measures such as braking and reversing the drives. But beyond that, the motor spindle protection system can immediately interrupt the power flow at the interface between the spindle box and the motor spindle by means of 3D deflection in the event of a collision-induced overload, even before the electronic emergency stop, mechanically and energy-autonomously.

This effective combination of mechanical protection system and active electronic sensor monitoring makes the system superior to purely electronic collision avoidance systems and effectively protects the shock-sensitive components of the motor spindle from the high force peaks of the collision. The resulting kinetic energy of the crash intercepts a built-in shock absorber. The difference is made by a double flange system with built-in permanent magnets. They can guarantee the required high holding forces and rigidity. During the disengaging process, compression springs guide the motor spindle and then return it to its original position. The downtime is limited to the exchange of tools, additional external service is no longer needed. The system is energy self-sufficient, maintenance-free and adaptable to all common motor spindle geometries.

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Web-based Calculation Software eAssistant Comes with New Features

GWJ Technology GmbH, the engineering specialist, headquartered in Braunschweig, Germany, is committed to constantly improving the quality of its software products for the calculation of machine elements like gears, shafts, bearings etc. The updated version of the web-based software eAssistant has been released now.
The latest software release introduces multiple enhancements making the life of engineers easier than ever before. One example is the new menu item "New". Clicking the menu item "New" closes the current calculation and opens the calculation module with the internal eAssistant default setting or the user´s own default file.
The calculation modules for single cylindrical gears (external/internal), three- and four-gear train systems and gear racks now include DIN 58405 for fine mechanics, ISO 1328 and ANSI/AGMA 2015 in addition to DIN 3961 for gear tolerances/gear qualities.
The definition of the basic rack profiles for the cylindrical gear pair and the single cylindrical gear (external) was supplemented by the semi topping flank and topping. Using the definition of the semi topping flank, the corresponding hobs can then be specified, and
they generate an addendum chamfer during the cutting process.
The option "Topping" allows to define the tip diameter directly with the dedendum coefficient of the tool, making it impossible to subsequently modifiying the tip diameter. The result, at the same time, will be tip diameter allowances analogous to the root diameter allowances directly from the tooth thickness allowances.
The eAssistant 3D CAD plugins for various CAD systems support the new function and the semi topping flank can be considered in the 3D CAD model.
Visit for more information or contact GWJ at +49 (0)
531 1293990 or send an email to

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The New Benchmark in Crankshaft Finishing

A new line of tape finishing machines for the microfinishing of crankshafts with the narrowest bearing clearances has now been developed by Thielenhaus Microfinish. With the CrankStar HP (High Productivity) and the CrankStar HF (High Flexibility), the market leader in the field of high-precision machine tools for surface microfinishing meets the requirements of many engine manufacturers in terms of a flexible machine solution which is suitable for smaller crankshafts. Particularly narrow finishing units with an extremely large opening angle (80°) allow, for the first time, the economic and process-safe machining of crankshafts with a mere 33 mm depth gauge, which is required by the trend towards more compact engines with higher efficiency.

In addition, on the innovative microfinishing machine, all crankshafts made of cast iron or steel with a tip width of 500 mm (HP) to 800 mm (HF) and a maximum revolution diameter of 210 mm as well as a stroke of up to 100 mm can be finished in one step or more. Crankshafts for engines with three to six cylinders can even be processed without changing the set-up. In addition to the usual surfaces, such as main, lifting and fitting bearings, the front pins can also be finished and the flange bores can be deburred as part of the single-step or multi-step process.

A special highlight of the CrankStar HP is the optional decoupled loading system, which allows for a main time-neutral loading/unloading via an external portal. This allows reductions of the cycle time of up to 17 seconds. This saved time can be used as extended machining time, which can even enable you to dispense with an entire station.

Apart from its extra-slim and flexible tape finishing units, the CrankStar gained a lot of attention due to its innovative and ergonomically designed tape management system. A particularly ample belt capacity, various belt monitoring options and the best accessibility to the workspace guarantee the shortest downtimes. Tape end, tape feed and tape tear monitoring reports imminent and unforeseen interruptions in the tape feed and ensure consistently good results. All tape rolls can be replaced from the front of the machine, meaning complete operation can take place ergonomically from just one side. The innovative tape cutting system in the CrankStar HF also works reliably and without problems, even with different tape thicknesses. Depending on the requirements, the hard and/or soft tape pressing shoes can be easily exchanged without any tools by means of a quick-change system.

The CrankStar HP is designed for high output with the shortest cycle times and, with a width of 2,000 mm per station, has an extremely compact design. The modular design allows all the processing stages to be displayed. The CrankStar HF is designed for cycle processing and can therefore be integrated into flexible production lines.

The loading can take place via portal, robot or by hand into the machine. The standard new tape finishing machine is delivered with a particularly energy-efficient periphery.

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