YILMAZ REDÜKTÖR VR Serisi

YILMAZ REDÜKTÖR
Yilmaz Workflow and
Gearbox Manufacturing
R & D Department
Murat Cem Ünal
21.06.2011
Monthly
Annual Target
IFS/ERP
(Planning Department)
Weekly
Monthly
Reports
Material
Requirements
Plan (MRP)
Orders of
customers
Processing
Commands
Buying
Demands
Manufacturing
Purchasing
M, D, T, K, H, Y Series
K, P, R, B Series
P, R Series (compact)
E Series (irreversibility)
Helix angle:
8 - 25 ̊
Profile angle
Normal module
Reference circle diameter
Reference pitch
Helix angle
Transverse module
Reference circle diameter
Number of teeth
Reference pitch
Generation of an involute profile:
Involute
Involute
Base circle
Root circle
Base circle
Reference circle
Outside circle
Base cylinder
Involute
Raw material
input
Saw
Turning
machine
Hobbing
Keyway
Heat
treatment
Grinding
Sub Storage
Hobbing
Shaper
Internal Gear
External Gear
Gear milling
Continuous Gear Grinding
Gear Grinding with Disc
AGMA 390.03
DIN 3961
ISO 1328
Japan JIS
AQ10
Q7
7
3
AQ11
Q6
6
2
AQ12
Q5
5
1
AQ13
Q4
4
-
AQ14
Q3
3
0
Manufacturing process
Quality in accordance with ISO
Grinding
2–7
Shaving
5–7
Hobbing
6–9
Milling
6–9
Sintering
8 – 12
Shaping
6–9
Better
Raw material
input
Saw
Centering
drill
Keyway
Grinding
Storage
Turning
machine
Casting
Sandblasting
Cleaning
Storage
Priming
Milling
Storage
Collecting of
all parts
Assembly of
Gearbox
Red Box
Assembly
Department
Assembly of
Gearbox with
Motor
Quality
Control
Oil Filling
Painting
Transport
Special Order
Special order means minor changes like diameter
change of flange or shaft and not a completely new
gearbox design
Research &
Development
Planning
Department
Manufacturing
Rearranging
Manufacturing
Rearranging
Workflow
Machine Setup
Adjustments
Machine setup after failed part:
Machine
Setup
Manufacturing
Process
Approving
Red Box
No machine setup after approved part:
Machine
Setup
Manufacturing
Process
Approving
Production interrupt after failed
part:
Machine
Setup
Manufacturing
Process
Continuous production without any
failed product:
Manufacturing
Process
Controlling
according to
sample
procedure
Controlling
according to
sample
procedure
100 % control of
manufactured
parts
Red Box
Dimension and topology measuring
After Hobbing
After Hobbing
Runout of middle axis of gear will
be calculated from the values
above.
After Grinding
Required Quality
Actual Quality
After Grinding
Runout will be calculated from the
values above.