The Giants

Profile grinding
machines
RAPID 2500 - 6000

Maximum precision very fast:

The RAPID compact profile grinding machines

Todays global economy is presenting the machine-

machine table is running in both axial and radial hydro-

gears. Specially developed HFLER software allows the

building industry with many new challenges, and

static bearings and has a through table bore, with a

table drives to be adjusted quickly and automatically for

innovative answers are coming from southwest Germa-

bore diameter of 750 mm and a depth of about 1300 m.

the weight and inertial mass of the workpieces. The

ny, the heartland of German engineering know-how.

The hydrostatics can withstand constant loads of up to

advantages: minimal configuration time, faster quality

This is where HFLER is based, one of oldest and

50 tons, and offer the highest possible rigidity for an

achievement. Torque motors are wear-free and never

best-known suppliers of gear grinding machines. The

almost unlimited service life.

lose their accuracy and this kind of security is an excel-

company has been manufacturing advanced gear

lent argument in favor of the investment.

grinding machines for the world market since it was

Greater accuracy: torque motor table drives

founded in 1958. Today HFLER is regarded as the lea-

HFLER machine table drives with torque motors and

Greater flexibility: grinding head with living axes

ding producer of high-precision gear profile grinding

direct measuring systems are smooth-running and

There are additional advantages to the new RAPID grind

machines, a position it defends vigorously through

backlash-free. The indexing precision of the table drives

ing head with torque motor swivel action. The helix

significant investments in research and development.

is accurate to within a millionth of a degree. With the

angle of the head can be adjusted during grinding, while

high motor torque, the table can rotate at up to 70 rpm,

at the same time, the grinding spindle can be shifted

The most recent example of this is the ongoing improve-

which reduces the time needed for alignment and index-

tangentially. The result: living axes, or true 5-axes grind

ments to the compact RAPID series, known to gear

ing, and even enables external cylindrical grinding of

ing! The advantages: The new RAPID allows for topologi-

manufacturers around the world for robust construction

cal modifications to the toothing depending on the

and maximum precision. With its modular design and

allowable deviations in single- or double-flank grinding.

interchangeable components, the new RAPID series is

A measuring device with a 3D probe integrated into

one of the most powerful and economical production

the grinding head permits testing of even those most

lines for workpieces of up to 6000 mm diameter. A brand-

difficult topologies.

new, ultra-flexible grinding head allows genuine 5-axes

machining and opens the way to processing and pro
duct options that would have been unimaginable just a
few years ago. What was once just a specialized tool
has become a high-speed precision instrument for the
detailed machining of hard materials.
More advanced: mineral casts for machine beds
2

Progress at HFLER starts with the materials: high-quality

mineral casts are superior to the otherwise standard
cast iron. Advantages: same stability but 10 times better
damping properties and 25 times better thermal behavior
for machine bed and mechanical components. Process
ing heat and ambient heat in the machine hall have a
significantly lower effect on the machine geometry. Result:
a measurable increase in process security in profile
grinding.
Greater stability: two-bed design
The machine is erected in a thermally separated two-bed
design. The common machine bed is a foundation built
into the factory floor, which isolates it thermally. The

RAPID 2500

Function

Advancing the process:

Gear grinding with RAPID

fitted with two dressing rolls. The result: freely dressable

The new RAPID series for large and heavy workpieces

profile heights on the grinding wheel. The traverse paths

incorporates the best from 50 years of experience,

C4

to make a good machine even better. The HFLER

research and development. But the goal is not simply

are shorter, as are the dressing times. The dressing unit

Y2

profiles the grinding wheel using various parameters

quickly, with low wear and extremely accurately.

development engineers aim to provide the many users

of these machines with modular, process-specific and
thus extremely economical solutions applicable to

Greater functionality: internal gear grinding arm

both standard and specialized tasks.

A special, easily mounted internal grinding head converts

C2

Greater productivity: operating range

wheel is dressed on the RAPID in the same way as for

extremely flexible grinding head work together to yield

helical internal gears and clutches. The internal grinding

The enormous axial stroke length of the RAPID and the

the RAPID to a powerful machine for grinding spur or

C1

external grinding, including all corrections. Different in-

product options that are unique for this class of machines. Double helical gears or long pinion shafts can

ternal gear grinding arms are available depending on

now be ground in one clamping operation. Worm gears,

alignment journals, thrust collars and bearing shoulders

can also be ground with the standard grinding head.

the application or industry, e.g. aviation.

+
Z

Running cleaner: vacuum oil filtering system

We offer for every RAPID a powerful system for vacuum
filtering of the grinding oil, an oil cooler, and an oil system

Superior design: torque motor grinding head rotation

and double dressing system

for the interior.

C5
+

Up to now, torque motors have been used primarily for

table rotation. HFLERs pioneering innovation is to in-

corporate torque motors in the grinding head. Position

ing accuracy, wear-free operation, rigidity, and accelera

CNC Axis

tion these unique advantages of torque motors can

X
Y
B
A
Z
Y2
C, C1 + C2

now be applied to optimize the rotation of the RAPID

grinding head. Monitored by a direct measuring system,
the grinding head positions itself quickly and with maxi6

mum accuracy even while grinding. A double dressing

system is integrated directly into the grinding head and

Tool slide
Stroke slide
Machine table
Helix angle
Shift axis
Dressing axis
Controlled grinding wheel and
dressing wheel drives

Standard performance profiles

Cylindrical gears and shafts

Standard modifications in profile and lead
Siemens electronics, Siemens 840 D control
Optional performance profiles
Cylindrical internal gears [spur and helical]
Gear inspection for external and internal gears
Double helical gears [apex grinding]

External measuring

Dressing

Internal grinding head of separate

internal grinding unit

Worm grinding
Internal grinding attachment

Cylindrical grinding
Thrust collar grinding
Alignment journal grinding
Bearing shoulders
Splined shaft gearing, clutch gearing
Special profiles
Inspection of special profiles, spline shaft,

clutch and worm gearings

Technology

RAPID 2500 - 6000:

Functionality and precision in numbers

The new RAPID series also offers the legendary HFLER

Technical Data

precision but in a more compact format and with

RAPID 2500 - 6000

RAPID 2500

RAPID 3000

RAPID 4000

RAPID 5000

RAPID 6000

even greater convenience for the operator. The machine

is erected in a thermally separated two-bed design.

Gear outside diameter

max. mm

2600

3000

4000

5000

6000

Root diameter

min. mm

580**

580**

580**

580**

High speed Grinding [HsG] is an attractive option for

Axial stroke length

mm

1500 [2020]*

1500 [2020]*

1500 [2020]*

1500 [2020]*

1500 [2020]*

fast, high-precision production. HsG reduces grinding

Working range above table

mm

540 - 2040 [2560]*

540 - 2040 [2560]*

540 - 2040 [2560]*

540 - 2040 [2560]*

540 - 2040 [2560]*

times by up to 40%. Find out for yourself: come to the

Center distance above table

mm

1000 - 2300

HFLER technology center for a test run.

Profile height

max. mm

100

100

100

100

100

Module approx.

min. - ca. max.

1 - 50

1 - 50

1 - 50

1 - 50

1 - 50

Pressure angle

degr.

No restriction

No restriction

No restriction

No restriction

No restriction

Helix angle

degr.

- 45 / + 120

- 45 / + 120

- 45 / + 120

- 45 / + 120

- 45 / + 120

Grinding wheel diameter

max. mm

450

450

450

450

450

Grinding wheel diameter [shoulder]

min. mm

206

206

206

206

206

Grinding wheel thickness

max. mm

130

130

130

130

130

Grinding spindle drive power

max. kW

24 [37]*

24 [37]*

24 [37]*

24 [37]*

24 [37]*

Stroke speed of tool slide

max.

6000 [12000]*

6000 [12000]*

6000 [12000]*

6000 [12000]*

6000 [12000]*

Table diameter

mm

1850

2350

2350

2350

2350

Workpiece table load

kg

25000

40000

40000

50000

50000

Table bore diameter x depth

mm

750 x 1300

750 x 1300

750 x 1300

750 x 1300

750 x 1300

min. - max. rpm

0 - 50

0 - 36

0 - 36

0 - 36

0 - 36

Dressing roll diameter x width

mm

120 x 26

120 x 26

120 x 26

120 x 26

120 x 26

Machine weight

kg

65000

70000

70000

75000

80000

lxwxh

9.6 x 8.9 x 5.2

10.2 x 9.7 x 5.2

10.2 x 9.7 x 5.2

12 x 12 x 5.8

12 x 12 x 5.8

Internal grinding arm of separate internal grinding unit

Table rotation

Space requirement
Internal grinding

Various internal cylindrical grinding arms available *

* available at additional cost

** at grinding wheel diameter of 350 mm

Subject to change

Standard accessories

Error diagnostic system and service modem

Software targeted preset of apex point

Electrical equipment as per VDE specifications

Operating manual, circuit diagrams, manufacturers

Software topological grinding

Multiprocessor continuous-path control with integrated PC

Software grinding reference collars and alignment

Swivelling control panel with color monitor

Hydraulic unit with cooler

certificate

Manual control panel for working in the machine

journals

Software grinding worms and spindles

Software for job preparation at the PC

Optional accessories

Grinding wheels, diamond dressing rolls, filter material

Automatic grinding wheel dresser

Counter support with pinion shaft driver system

Vacuum grinding oil filtering system

Acoustic centering and touch grinding sensor operation

Internal grinding unit for internal spur and helical gears

Wireless grinding wheel balancing unit

Integrated gear inspection system

Work area safety cover

Software special profiles

Switch cabinet cooling

Software grinding from solid stock

Software

Adding value through knowledge:

HFLER GearPro Software

HFLER has been able to maintain its position as a

document wear in the grinding wheel and, if necessary,

of almost all involute profiles. Profile modifications are

grinding wheel profile is calculated accordingly. The RAPID

technological leader with large investments in research

adjustments are made to the process. Dressing cycles

displayed graphically on the monitor. A free program

uses this algorithm to grind topologically modified

and development. One of the payoffs: GearPro, the

can be optimized for stock removal and stroke movements

enables point-by-point input of special profiles into an

tooth profiles in single- or double-flank grinding with

versatile software for HFLER profile grinding machines.

depending on the stock per flank. Sensors and automatic

x/y coordinate system.

deviations approaching zero.

GearPro gives users access to 50 years of experience

touch grinding analyze the stock per flank before grind

with grinding strategies and processes.

ing in this way stock removal can be automatically dis-

Greater dependability: lead modifications

Easier to use: operator functions

tributed over all tooth gaps. This saves unnecessary

GearPro makes it easy to program any kind of lead

Setting up jobs, changing workpieces, configuring the

Greater competitiveness: stock distribution

dressing cycles, prevents stroke movements into the air

modification for both single- and double-flank grin-

machine, monitoring processes GearPro can do all

The RAPID competitive edge: grinding processes can be

[air grinding], accelerates the process and improves

ding. The form and correction values are simply entered

this in just a few steps. GearPro displays the machine

controlled directly with the power input and major

the security of the results.

at the monitor and are displayed graphically.

status and processes graphically, making machine

Greater versatility: profile modifications

Greater perfection: topological grinding

even possible collisions during workpiece clamping are

Only the GearPro software awakens the dressing unit

The ever-increasing pace of industrial progress is placing

displayed before they become actual and very expen-

and the RAPIDs highly flexible grinding head. Multiple

great demands on the machine-building industry for

sive problems in the machine itself. No other machine

profiles can be dressed quickly and accurately coarse

ever more flexible solutions. One example would be

software offers so much transparency and ease of use

and open for high stock removal rates, fine for superior

gear profile grinding machines capable of producing

for planning and organizing processes.

surface quality. The standard software enables dressing

multiple tooth-profile topologies with minimum devia-

control more intuitive, easier and safer. Problems and

machining parameters. Comparative measurements

tions. HFLER has developed an algorithm for the RAPID

that can calculate optimum axial paths depending on
the desired topology of the tooth profile. The optimum

10

Service from HFLER:

Experts on demand

HFLER employees have been with the company for

speak both German and English. Experience shows that

together with customers, HFLER can get to know their

16 years on average, a level of dedication unusual even

95% of all problems can be analyzed and corrected this

requirements better while adding to its own experience

in this industry. The reason for this is HFLERs belief

way. For those that cant, HFLER technicians can ge-

with grinding wheels, grinding lubricants, grinding

that continuous training is key to maintaining its com

nerally be on site very quickly upon notification of a pro-

strategies, clamping fixtures, etc. New insights are im-

petitive edge, and the company invests accordingly.

blem to take care of them regardless of where in the

mediately applied to improving machine technologies

Only those with the appropriate qualifications and

world the machine is installed.

so that customers may reap the benefits as quickly as

experience ever come into contact with customers

whether as consultants, trainers, or as assembly and

possible.
Process control

Better customer care: the technology center

commissioning engineers. On the other hand, customers

Customers use the HFLER technology center to grind

will hardly ever see an emergency team from HFLER:

special designs quickly and economically. At the same

every HFLER RAPID is so well designed and so solidly

time, HFLER believes that, For better results, train

built that it will operate perfectly for many years.

with the customer. By working on grinding projects

Quicker fixes: remote maintenance

However, if serious problems do occur, professional
help is just a mouseclick away. At present, there is an

On-site service

RAPID 600 AI

HFLER is a member of AGMA and FVA and is DIN EN ISO 9001/2000

certified.

eight-member service team that can quickly analyze and

correct problems anywhere in the world by remote
diagnosis. They operate in virtually all time zones, and
RAPID 6000 AI

On-site customer advice

RAPID 6000

12

13

HFLER offices and service points

HFLER USA

HFLER India

HFLER Russia

Custumer Service Center HFLER

M/S Nemade Engineers

Marschala Timoschenko Str. 17

Great Lakes

#7, Patel Complex, Bhusari Colony

Geb. 1, 167

131 W. Layton Avenue, Suite 306

Paud Road, Kothrud

117359 Moskau, Russland

Milwaukee, WI 53207 / USA

Pune 411038, Indien

Phone: +7 / 495 416 60 14

Phone: +1 / 908 996 6922

Phone: +91 / 20 252 854 73

Fax:

Fax:

Fax:

E-Mail: russia@hofler.com

+1 / 908 996 6977

+91 / 20 252 854 74

E-Mail: usa@hofler.com

E-Mail: india@hofler.com

Custumer Service Center HFLER

HFLER China

New Jersey

HFLER Beijing

26 Sky Manor Road

Rm. 2412, Kuntai International Mansion

Pittstown, NJ 08867 / USA

Yi No. 12 Chao Wai Street

Phone: +1 / 908 996 6922

Chao Yang District

Fax:

Beijing 100020 / China

+1 / 908 996 6977

E-Mail: usa@hofler.com

Phone: +86 / 10 5879 7866

Fax:

Sales Department HFLER

+86 / 10 5879 7856

E-Mail: china@hofler.com

Great Lakes
12113 Hunters Creek Drive

HFLER Yantai Machine Service Ltd. Co.

Plymouth, Michigan 48170 / USA

Rm. 1212 HUAXIN INTL.

Phone: +1 / 734 416 5929

No. 28 Changjiang Rd.

Fax:

Yantai ETDZ.

+1 / 734 416 7088

E-Mail:

Yantai 264006 / China

rmackowsky@greatlakesgeartech.com

Phone: +86 / 535 610 3500

Fax:

+86 / 535 610 3502

E-Mail: china@hofler.com

HFLER Maschinenbau GmbH

Industriestrae 19
76275 Ettlingen / Germany
Phone: +49 / 7243 599 - 0
Fax:

+49 / 7243 599 - 165

E-mail: info@hofler.com
www.hofler.com

+7 / 495 416 60 14