High Precision Grinding - English

by KMT

High Precision

Take a flight with KMT’s M.D. in Germany

KMT’s environmental work win SKF prize

Centreless history in international research journalLong lifespan withservice contract

World leaderin precision grinding

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Publisher: Ann-Christin Sandin Almén Project leader: Daniel Svensson Editor: Henrik Ekberg, Håkan Hellström Photo: Stefan Svensson Cover photo: Stefan Svensson Layout: Therese Adolfsen Original: Malin Svensson Media sales: Maud Svensson, Maria Sveed Production: Roxx Communication Group, www.roxx.se Printing: Strokirk-Landströms, 2013

KMT LIDKÖPING Tel: 0510-88 000, E-mail: [email protected] UVA Tel: 08-634 75 00, E-mail: [email protected] USA Tel: +1 508 634 4301, E-mail: [email protected] China Tel: +86 10 652 20 515, E-mail: [email protected] Germany Tel: +49 7152 35 9390, E-mail: [email protected] India Tel: +91 981 082 4106, E-mail: [email protected]

www.kmtgrinding.com

We at KMT Precision Grinding continue our journey by offering our customers new products within high precision grinding. Both in the form of new machine generations, through products and services that lengthen the life of older machines, or new functions for customers’ existing KMT machines. In this customer newspaper you can read about our customer's appreciation of renovated ma-chines and about a new control panel for older machines. During the EMO exhibition in September we will introduce a new generation of machines that are aimed at high volume production. This generation has, of course, the KMT machine's well known and appreciated characteristics, such as high precision and consistency in production during long periods of time. You can also read in this newspaper about our involvement and work to protect the environment. A task that has resulted in a prestige-filled prize from one of our customers.

Pleasant reading! Thomas Karlsson,President & CEO

contentsA world leader in high precision grinding ........ 5

Machine development - a time consuming

process ........................................................... 6

New UGC makes old machines younger .......... 7

Ovako Hällefors appreciate problem solutions . 9

KMT in Germany ........................................... 11

Portrait: Immanuel Grau ................................ 12

KMT in China ................................................ 14

Chinese customer reference 1 ....................... 16

Chinese customer reference 2 ....................... 17

A green priority ............................................. 18

Blue Competence

“for excellent environmental work” .............. 19

The wind has changed for the wind turbine

industry ........................................................ 20

Prestige filled prize to KMT ........................... 21

Centreless principle in respected

research journal ............................................ 22

Service contract extends lifespan ................... 25

KMT's model range ....................................... 26

20

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19

16

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Dear reader,

www.kmtgrinding.com High Precision Grinding | 3

With grinding quills in tungsten carbide from Håmex you are able to come up to your great expectations on grinding with the highest attainable precision and effi ciency.

Box 1117, SE-581 11 Linköping, SwedenTel +46 13 357650, Fax +46 13 357660

[email protected], www.hamex.se

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KMT Precision Grinding is now a company with presence across the whole world. From plants in Boston, Leonberg, Lid köping, Bromma, Gurgaon and Beijing, we cover all the world's time zones and can offer 24 hour support.

In the USA, China and Germany, KMT's companies work with sales and aftermarket. In Sweden we have factories for manufacture of new machines, refurbishment and repair. In India, Gurgaon, we have a plant for refurbishment.

KMT Precision Grinding, which is now the world leader in precision grinding, is one of the oldest machine manufacturers in Sweden. The company is the result of the merger of the two companies UVA International AB and KMT Lidköping, which were founded in

1928 and 1875 respectively, then as Nomy AB and Lidköpings Mekaniska Verkstads AB.

From the start, the factory in Lidköping manufactured outdoor lighting, park benches and other products for agriculture. Machine manufacture started in 1902, and in 1908 we were one of the first suppliers to SKF, who started business in the previous year.

From the start, UVA manufactured hydro -dynamic bearings and gearboxes for locomotives. n

WorLD LeADer in precision grinding

PivoTal years in KMT's hisTory

1875 Lidköpings Mekaniska Verkstad AB (LMV) was founded

1928 In Stockholm, the company Nomy, later UVA was founded

1929 LMV becomes a part of SKF1979 LMV starts cooperation with a partner in

the USA1982 KMT Precision Grinding GmbH (current

name) was founded in Germany1986 Lidköpings Mekaniska Verkstad AB LMV

changes name to Lidköping Machine Tools AB (LMT)

1996 UVA becomes a part of Karolin Machine Tools (KMT)

2000 SKF sells LMT to KMT2000 KMT opens an office in China 2006 LMT changes name to KMT Lidköping2006 KMT Production Machinery India starts

up in Gurgaon, India2007 UVA merges with KMT Lidköping and the

company changes name to KMT Precision Grinding AB

2008 Nordstjernan buys all the shares in KMT2008 KMT Beijing starts in China2009 KMT Precision Grinding Inc starts in

Boston, USA


MacHine develoPMent “a time consuming but eventful process”KMT’s grinding machine development work is a continuous process performed in close coop-eration with our customers where the focus is on customer benefits. KMT’s development work is primarily carried out in two parallel phases. First, there is long term development work where the whole machine concept is examined and then adapted to new technology and/or customer requirements and second, short term development where modules in the machine concept are upgraded and refined.

Long term development work has a time horizon of about 10 – 15 years and more short term development has a horizon of one week to 6 months. UVA’s most recent large development project is the change from the U88 program to the current Nomyline program, with associated control system. The Nomyline program was launched in 2001 and has been continuously upgraded since then. The program comprises the UVAi for internal grinding, UVAe for external grinding and UVAie for combined internal and external grinding.Current development work is with KMT’s external grinding program, the Nomyline UVAe, which is used for

example to grind needles for diesel injection systems.

”Our ambition is to make our machines as efficient as possible for our customers” says Urban Myrefors, site manager at KMT’s Bromma plant.

Reduce carbon dioxide emissionsOur work in producing components that reduce the emission of e.g. carbon dioxide is today highly typical and a priority in the automotive industry. At KMT Bromma, we make machines that grind parts that control the fuel injection in diesel engines, where the tolerance is measure in thousandths of a millimeter. This is possible thanks to our long experience

with grinding and knowledge of our customers’ needs. KMT is now working on a completely new concept for needle grinding which doubles the output while at the same time improving the grinding results.

“This could even be a new patent”, discloses Urban Myrefors. “Our hopes are that we will be implementing this new concept on our machines as early as 2013.”

Wide conceptAt the same time, our ambition is to

widen the machine program in order to enter new markets outside the automotive industry. The hydraulic industry for example is an interesting

Urban Myrefors, Site Manager at the KMT plant in Bromma.

FACTS

KMT’s development workin Brommais performed graduallyduring a longperiod of time. It’s a caseof extremelyadvancedtechnology.

6 | High Precision Grinding www.kmtgrinding.com

MacHine develoPMent “a time consuming but eventful process”

Our new control panel, the UGC, has been developed from the older Uvatronic 2 machine. The existing panel has become difficult to source parts for. Since the new UGC panel is built on the Panel-PC standard, it can communicate via Ethernet with a small PLC that converts the format so that it matches the control system for the Uvatronic 2. The older machine is thereby equipped with modern technology allowing it to utilize several different new functions and also be easier for the operator to handle.

“The microprocessor provides functional improve-ments, for example it's easy for us to connect form Bromma to solve a problem and then download the program, or transfer it to the company's own central computing system. It also has a considerably larger screen with touch functions,” says Björn Almgren, aftermarket manager at KMT Bromma.

Satellite handle and larger screenThe appearance of the new control panel is similar to that of the latest control system, Uvatronic 3. The new panel is equipped with removable satellite handle which means that the operator can work away from the central unit. This means that the machine operator can perform actions inside the machine and still have full control of the system. The larger and clearer screen gives the operator a better working environment ergonomi-cally. The larger text and better contrast makes it easier to read when, for example, sun shines into the room.

Great interestLast spring, KMT Bromma installed the first new control panel on an older grinding machine at a Danish customer. During the summer, another 10 or so new UGC's has be installed.

“The level of interest is high, we have quite a lot to offer and expect that the new control panel will simplify and improve production at many companies with older grinding machines,” says Björn Almgren. n

A new control panel for older grinding ma-chines makes the difference. The newly devel-oped UGC improves the operator's ergonomic situation and the built-in PC makes it possible to connect up to KMT in order to solve prob-lems that may arise.

New UGC makes old machines younger

market. But it puts other demands on the machines.

“We want to widen our concept so that it suits other applications. This requires increased flexibility. For example, within the hydraulic industry you don’t get the same high produc-tion levels as the automotive industry.”

Close cooperation with customersGrinding machines come from a branch with long traditions. For this reason continuous improvement is extremely important for development of the machines. Customizing grinding machines for different markets requires an open dialogue and feedback from our customers, a pre-condition for satisfying our customer’s needs.

“A machine series can have a lifespan of 20 years and during that time, constant improvements are made. But when new technology arrives that gives added value, it is necessary to perform a larger overview of the basic modules; the bed, slides, controls, etc. “Development work on our products is a continuous process in very close coopera-tion with our custom-ers. This process provides the most cost-effective production

possible for our customers,” says Urban Myrefors.

Extremely advanced technologyAccording to Urban Myrefors, the process of developing a new machine can take between two and three years; it’s a case of extremely advanced technology in the modules that are used in the machines. The slides that perform the linear movement must have an exact straightness to ensure the best grinding. Other important points are the axial accuracy of chuck jaws and our own grinding spindles. Our own control system is updated continuously to provide ease of use for our customers, which is also an important part of development.

“And then of course it is all finally up to how one combines these modules to create a machine for a specific product. We always adapt the machine to the customer’s needs, but certain basic functions must be in harmony to ensure the optimum

grinding result.” n

Björn Almgren, Sales and Aftermarket Manager at KMT in Bromma


HYBRID Dressing Toolswith Cutting-edge Technology

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Ovako Hällefors is a loyal customer to KMT. The global steel maker has bought grinding machines from Lidköping for decades. During the last few years, cooperation has intensified. In the summer of 2012, a CL740 and a CL5B where taken out of operation at Hällefors and where replaced with two newly refurbished CL630 machines. Since then, an additional grinding machine has been refurbished and updated and the CL740 that was replaced last year in now up on blocks at Lidköping, ready to go through an extensive refurbishment in order to perform a spectacular comeback next year to the same company.

“All movable mechanical parts and all electronics are to be replaced, all that is left is the bed itself. From our part, these refurbishments feel like we are getting new machines back,” says

Thomas Andersson, production manager at Ovako Hällefors.

New control system halves time The new/old machines are, as apposed to the older, equipped with a control system that makes the operator's job considerably simpler. According to Jarkko Haikola it takes close to a year to learn how to handle a grinding machine with manual settings. That time is halved with the new control system.

“We get a better yield and fewer complaints since the machine is updated with the new control system,” adds Jarkko Haikola.

Weightlifting bars for theWC and OlympicsThe components that are ground by KMT's machines are used, amongst other things, within the roller and

bearing industry and in linear steering. In Hällefors even more specialised products are made, such as weightlift-ing bars which are supplied via Eleiko to both the World Championships and the Olympics.

Jarkko Haikola thinks that KMT's strength is the competence and knowledge of the personnel. He values the stability and robustness of the grinding machines, and also the problem-solving role that KMT have taken during recent years.

“I worked previously as a mainte-nance manager and within that area, KMT have become much better. They come to us with ideas and solutions that we can take up together for discussion. It could be a suggestion to introduce replacement spindles or spindle refurbishing. And that is something that is greatly valued.” n

INCreASeD ProDUCTIoNOvako Hällefors appreciates KMT's problem solutionsThree newly refurbished grinding machines from Lidköping improved availability and increased the production rate at Ovako Hällefors. Next year, yet another updated machine will be delivered to Hällefors.

“To us, they seem like new machines, despite the fact that the bed is old,” says Jarkko Haikola, project leader at Ovako Hällefors.

Jarkko Haikola, project leader at Ovako Hällefors.

Thomas Anders-son, responsible for production at Ovako Hällefors.

Machine before refurbishing

Machine after refurbishing

FACTS

After refurbishing older grinding machines, where all the moving mechanical parts and electronics have been replaced, the machine will be as new again. Since Lidköpings machines are built with hydrostatics, they do not wear out the basis structure.


ZIWAMEKANISK TILLVERKNING

Postal addressBox 55, 386 21 FärjestadenSWEDEN

phone+46 485-345 65

[email protected]

We have a long tradition as a proudsupplier to the KMT Precision GrindingAB of precision machined parts.We produce everything from singleprototype parts to parts for massproduction.

Most of our customers are machinebuilders to food and engineeringindustries. We know what quality ourcustomers demand and delivers this at acompetitive price.

We have en extensive network ofpartners both within Sweden and theBalkans.

www.lmv.se • +46 (0) 510-78 76 00

Precision is our specialityWe manufacture high precision components for KMT and other machine manufacturers.

E-mail: [email protected] • Phone: +46 (0) 8-80 01 13

Grinding parts toengineering�•��We�work�with�small�series�

and�problem�solutions

We are pleased to be in a cooperation with KMT

•��Over�40�years�experience�in�grinding

Proactivity, loyalty and dedication

The products are used in solutions, and the solutions are used in the products Our business is to make your business better

08 - 555 921 00 www.tubehydraulik.se

Passion for hydraulic

Manifold

System

Pumps

Engines

Measuring instrument

Filter

Accumulators

Valves

Immanuel Grau is the General Manager of KMT Precision Grinding Germany since 2008. But he has been working within the company, or its predecessor UVA, for more than 16 years.

“I have worked here since January of 1997, so I have been a part of this company for a long time. I actually feel at home here,” he says.

The “home” of KMT Precision Grinding Germany is the south German town of Leonberg. Immanuel Grau grew up not far from here, and is now living in Leonberg with his girlfriend.

Deep knowledgeImmanuel Grau first started his training to become a car mechanic in trade school, but he never really felt comfortable with that career.

“I chose to attend technical college and studied to be a technical engineer before I started my job as an service engineer at UVA GmbH in Stuttgart,” says Immanuel Grau.

He has since then made a career at UVA and KMT. After three years as a service engineer, he became service manager, sales engineer, key account (for Siemens among others), and manager of the entire German team of KMT. During these years he also studied business administration and management to become a Master of Science in 2006.

“I saw the potential to grow with KMT, which is a company that really

gives you the opportunity to grow, both as an employee and as a person,” says Immanuel Grau. “My years of working as a service and sales engineer have provided me with a deep knowledge about grinding machines and their special market.”

Office and warehouseThe office of KMT in Germany is strategically placed in Leonberg, less than 20 km from Stuttgart, in Baden-Wuerttemberg.

“We are also about 20 km from the main production plant of one of our biggest customers, Bosch, as well as about 2 km from their headquarters,” says Immanuel Grau, General Manager at KMT Precision Grinding Germany.

“KMT Germany has been situated in Leonberg since 2005, and besides our office we also have access to a warehouse facility in the same building complex, at the centre of town.”

Broad customer baseAmong the office’s seven employees are service technicians, sales staff and aftermarket staff.

“We have a great mix in our customer base,” says Immanuel Grau. “Our location in southern Germany means that we are close to many smaller machining businesses, which are very frequent here. But we have also close relationship to companies like Bosch and Continental. I would say a typical customer has around 100-300 employees.”

A strong after market offer

gives KMT the edge over competition“KMT are known for its high precision grinding machines and our flexible model system,” says Immanuel Grau, General Manager of KMT Precision Grinding Germany.

“This combined with a superior aftermarket offer makes KMT an attractive partner on the German market.”

The distribution between KMT’s two brands, UVA and Lidköping, on the German market is about 50/50, according to Immanuel Grau.

“UVA is mainly used in the automotives industry, for machining of injector parts, and Lidköping for manufacturing of ball bearings,” he says.

Proactive serviceA strong aftermarket offer is what separates KMT from other competitors on the competitive German market.

“We have been successful in match-ing our customer’s demands with our service offer and service programs,” says Immanuel Grau. “Our approach is to be proactive and guide our customers towards well maintained grinding machines, which leads to better productivity.”

Service technicians perform field service support for mechanical, electrical and applications, as well as machine rebuilding and refurbish-ments, either on or off-site, depending on our clients’ needs and wishes.

“Especially rebuilding and refurbish-ments have been more common in the past three years, which probably can be related to the economical situation. Customers are also much more cautious and thorough today than they were 20 years ago before they put down an order for a new machine.” n

Immanuel Grau,General Managerat KMT PrecisionGrinding Germany.


Work is not everything for Immanuel Grau. Both paraglid-ing (where you use a parachute-like non-engine glider to soar through the air) and glider planes (airplanes that only uses upwind to travel through the air) are two of his biggest hobbies. Another big hobby is race boarding, a combination of snowboarding and carving skiing.

“My hobbies have taken me all over the world, I have paraglided in the Himalayas in Nepal for instance,” says Immanuel Grau. “For me, this

is a way to travel in all three dimensions, both height, length and width, that provides you with unique and fantastic experiences.”

High-performance wingWhen Immanuel Grau first started taking to the air, he used the safest possible version of the 12-metre wide paraglider wing.

“This was a really slow and rigid wing, which isn’t as flexible as the one I am using now,” says Immanuel Grau. “The present category 2 wing is more high-performance and more responsive, but at the same time more demanding and more risky for an un-skilled pilot.”

The wing weighs about 6 kilos, and the whole paraglider weighs up to 18 kilos in total. The harness and the lines that attach the wing to the

TRAvEl iN three dimensions“One of my greatest experiences is paragliding over the Blue lagoon in Turkey, it was an amazing feeling to fly over a beautiful landscape for hours, with nothing but the wind to elevate you,” says Immanuel Grau, General Manager of KMT Precision Grinding Germany.

Paragliding is one of Immanuel Grau’s biggest hobbies. A paragliding flight can last up to 3 hours and take you up to 3500 meters altitude.


TRAvEl iN three dimensionsharness are made of a strong synthetic material.

“As with parachutes, you have to learn have to pack and carry your wing in a safe way,” says Immanuel Grau. “Although the consequences are not nearly as serious if you should make a mistake, since the worst thing that can happen if the wing gets tangled at take-off is that you wont get off the ground.”

The paraglider is equipped with a reserve parachute; for a safe return to ground level if anything should happen during the flight.

in controlThe paraglider also has a number of instruments to pay attention to while in the air, such as a GPS and a rudimentary radio communications device, which allows the pilot to communicate with other pilots.

“We also use a variometer, that helps us find the correct thermal winds. It indicates when the glider is sinking or rising by audio signals, so we don’t have to actually look at the variometer. The higher the glider rises through the air, the faster and more high pitch the signal gets.”

The paraglider is controlled by both hand and foot controls. The hand controls are connected to the left and right rear edge of the wing and are used for manoeuvring and braking.

“The foot control is used for acceleration,”

says Immanuel Grau. “By decreasing the wing’s front angle of attack, the speed increases.”

The maximum speed of a series paraglider is about 55 km/h, for a high performance glider up to 70 km/h.

Faster and higherThe paraglider can be launched from a flat surface by motor towing, but Immanuel Grau prefers to start from higher ground, running into the wind and inflating the wing by the air pressure that is created.

“It is important both to start and land into the wind,” says Immanuel Grau. “When landing this decreases the speed and improves the control of the wing.”

If you need to make a fast descent for some reason, the pilot could get the paraglider into a fast spiral movement downwards.

“But you really have to be careful, since the G-forces can get so strong that causes you to blackout while hurtling towards the ground,” he says.

Immanuel Grau has travelled the world with his paraglider,but this summer he stayed in Germany. n

FACTS

Paragliding first appeared in the early 19650’s, when new kinds of parachute designs allowed for better control of the wing and made it possible to soar through the air. Paragliding has become very popular in Europe, with France alone having over 25,000 active pilots.There are several ways to compete in paragliding, such as racing in distance and accuracy, as well as aero-acrobatics.

You can find more facts about paragliding on www.fai.org (The World Air Sports Federation).



KMT Precision Grinding in China has its head office in Beijing with a network of service technicians across the whole country. KMT has a total of 16 employees in China.

“We have service technicians in eight towns strategically positioned over the whole of China, to offer as effective service as possible to our customers”, says Jan Li Yang, division manager at KMT Precision Grinding Technology (Beijing) Co., Ltd.

KMT place great importance on customer communication and sharing operating experience with customer, which allows us to focus on our production reliability, and even a complete customer service solution, including training, advice, technical guidance on site, and spare parts supply, etc.

“On the Chinese market, we offer the Chinese users a European experience of advance grinding machines, this is part of our company philosophy”, says Jan Li Yang.

“KMT's grinding machines are designed with consideration to machine lifespan and process efficiency. We can offer good customer service since we regularly commu-nicate with customers on any problems they may have, so that we can top up our spare parts stock. We will also arrange different types of training on site according to the customer's requirement, such as mechanical programming, electrical programming and NC programming, as well as maintenance training, etc. It is necessary to have high technology customer service for these types of professional machines, so that we are always customer orientated.” n

“One of our strongest sales arguments is of course our understanding of the entire production process, something that sepa-rates us from many of our competitors,” says divisional manager Jan Li Yang, to explain KMT's success on the Chinese market. “Our aftermarket and our service offer are also an important part of our success.”

KMT China


Following Chinese railway’s rapid develop-ment, new demands for heavy loading and high-speed train and urban rail transit construction are followed by demands for higher precision in railway bearing precision. Nowadays, Chinese high-speed train bearings mainly reply on import. Though this kind of bearing is beginning to be produced domestically, it is still difficult for railway bearing manufacturers to select proper equipment based on the standards of train purchasers; price, precision, productivity, service life, reliability and delivery time.

Key processThe KMT LIDKÖPING grinding

machine has been running at Beijing Nankou SKF Railway

Bearing Co.,Ltd. for 7

years. The two sets of LIDKÖPING grinding machines SUU240A and SUU240B play an important role in the key process of inner ring raceway grinding for wheel bearings. Continuing running in three shifts makes operators trust the LIDKÖPING grinding machines deeply. Three years later, further production capacity expansion is needed, There fore Nankou SKF is considering to purchase two sets of LIDKÖPING grinding machines as a part of another product line, ensuring the operation of its two shifts. Model SUU240A/B/C is a flexible, fast adjusting and high production grinding machine. It can grind internal, external or rib face just in a single operation. Model SUUC240 combination grinding machine can simultaneously grind internal, external and rib face. It is equipped with Siemens 840DSL control system that provides user-friendly control and safe operation.

100 % guarantee“Our company has passed the

Association of American Railroads (AAR) certificate, and our

product quality is unique, with an annual production of 200,000 new bearings and more than 100,000 repaired bearings. It gets 50% of the domestic market of new lorry bearing and above 20% of the domestic

aftermarket of repairs of

bearing. Moreover, there are other parts exported to Southeast Asia, South America and Eastern European etc.” Plant Manager Mr. Cheng Gang said, “To keep such high production, it requires the 100% guarantee of the high efficiency in the product process. Especially with railway speed increase and heavy loading required, and the customer’s demand in bearing safety and shorter lead time, further improvement is required for the bearing quality reliability and high efficiency.”

Precision and stabilityMr. Cheng further introduces that: “Our application with domestic grinding machine is presently unsuccessful, even if it can be repaired conveniently and cheap, the usage result is not good. Therefore, we are very cautious to select the core equipment for the key process. At first, we select LIDKÖPING grinding machine according to SKF Group’s recommendation because it is originally designed to process bearing by SKF Group itself, and then LIDKÖPING plant is independ-ent from SKF Group because of being sold to KMT Group. After using a LIDKÖPING grinding machine, it is obvious that the grinding precision and stability under mass production is unmatched with domestic machine and similar other imported machine, therefore we would like to place an order again to purchase two sets of LIDKÖPING grinding machines as there are plans for an expansion of our second product line.”n

Wheel bearings play an important role to ensure safe and long-term traffic for passenger and freight trains. Even a tiny flaw can cause an accident. Therefore, there is a great demand for higher output quality on grinding operations.

Communication between Mr. Jan Li Yang, GM of KMT Beijing and Mr. Cheng Gang, Plant Manager of SKF Nankou.

The bearing inner ring processed by LIDKÖPING grinding machine.

LIDKÖPING grinding machine in the SKF Nankou plant.

High precision and efficiency grinding for wheel bearings


At Yantai Fuer Precision Machinery Co.,Ltd. the precision grinding machine UVA Nomyline, which is the latest deve-loped new generation of KMT Precision Grinding AB, is playing a very important part in the processing workshop.

Exhaust fumes from automobiles and engineering vehicles are attracting attention with increased environment awareness. The series S of fuel injection nozzle of diesel engine is beginning to be replaced by the new generation P nozzle, because of the S series disadvantage in incomplete combus-tion, high fuel consumption and substandard exhaust fume etc.

Yantai Fuer Precision Machinery Co.,Ltd., part of Shandong Kangda Group, was established in 2003 by conforming to this trend of development, building on many years of experience in technology of Shandong Kangda Fuel Injection Co.,Ltd., which is a domestic backbone enterprises to produce injection nozzle.

First user in AsiaIn 1984, Shandong Kangda Fuel Injection Co.,Ltd. imported two sets of KMT inter nal grinding machine UVA U80 from Sweden. In

2005, when Yantai Fuer began to set up its first production line, the further cooperation of both sides became natural.

Good tools are prerequisite to the success-ful execution of a job. With the worldwide reputation of KMT UVA in high precision grinding of small size and the confidence in each other, Yantai Fuer finally decided to purchase 2 sets of ID machine UVAi Nomyline and 3 sets of OD machine UVAe Nomyline as their core equipment in their first line.

Nozzle and needleThe GM of Yantai Fuer, Mr. Liu Yongjiang knows very well the P nozzle production process. Nozzle and needle are couple parts; they are not interchangeable.

Mr. Liu Yongjiang said: “We imported this line from Sweden UVA for nozzle and needle match grinding, which achieve automatic loading/unloading, in-process measuring and keep good fit clearance for match grinding.”

Measuring systemMost of the domestic companies still use manually matching at present, which is not only a long process and low efficiency, but also many substandard products. Yantai Fuer has resolved the problems depending on KMT UVA match grinding machines.

“As a match grinding machine unit, integrated with Marposs in-process measuring system, it is an ingenious design.” Mr. Liu Yongjiang introduced, “ The needle size can be calculated automatically after getting the data from the nozzle measuring station, so the nozzle and the needle can match each other extremely well.”

On the road to success5 years later, as the market demand for fuel injection nozzle is growing, Yantai Fuer set up a second production line. They also have plans to set up a third production line and a new assembly line.

“In the fuel injection industry, the KMT grinding machine is world leading because of its unique hydrostatic slide, chuck and quill, which are its core competence.” The chief engineer of Yantai Fuer, Mr. Sun Yongzhi comment the features and unique advantage of KMT grinding machine as: “The biggest value of KMT is that they are not satisfied with the achievement they have already made, but to constantly innovate. They have new products and technology in each generation, for instance, the hydrostatic slide changed to linear slide and the linear motor replaced the servomotors. By combining modern technology, KMT grinding machines are always at the top level all over the world. Meanwhile, the KMT self-developed control system UVATRONIC is the programming software integrated with yearly accumulated grinding experience, such as grinding know-how, parameter setting and grinding wheel dressing, all features can be controlled with the software, with friendly interface and parameters easily changed, it shows that KMT is a professional grinding machine supplier.”n

Mr. Jan Li Yang, GM of KMT Beijing and Mr. Liu Yongjiang, GM of Yantai Fuer.

At the centre of HigH Precision Production


Systemlösningar för framtiden

Rullningslager och linjärstyrningar är centrala transmissions-komponenter. De arbetar ”i centrum av rörelsen”, vilket gör dem till en naturlig startposition för andra funktioner som mätning, reglering och kontroll.

Att integrera ett mekatroniskt system är så mycket mer än att kombinera de bästa komponenterna till en enhetslösning. Att uppnå en perfekt fungerande helhetsfunktion är en fråga om perfekt matchning av individuella komponenter till varandra. I över hundra år har vi arbetat med lagerlösningar för rörliga maskindelar så vi känner väl till de avgörande kriterierna som påverkar elektroniska komponenter i meka-niska system.

Vår erfarenhet betyder din säkerhet!

Schaeffler Sverige AB Tel. +46 8 595 10 900 ⋅ [email protected] www.schaeffler.se

907027_186x134_S1.indd 1 07.08.2013 16:48:54

System solutions for the futureRolling bearings and linear guidance systems are central power transmission components. They work “in the center of motion”, which makes them the natural starting point for integrating other functions for measuring, regulating and controlling.

But mechatronic system integration is much more than just combining the best components to form a single unit. Achieving the overall functionality is a matter of correctly matching the individual parts to each other. We have spent decades working in the field of bearing supports for moving machine parts, so we know the critical influences that affect electronic components in mechatronic systems.

Our experience means security for you!

Schaeffler Sverige AB+46 8 595 10 900 • [email protected]

Box 730, 531 17 LIDKÖPING, Besöksadress: Plastgatan 6 A, Tel. 0510-270 85, Fax. 0510-293 65, www.vanermek.se, e-mail. [email protected]

Serviceföretaget för induStri, handel och Sjöfart

KMT:s trademarks

KMT’S ENviRONMENTAl WORK can be described as a comprehensive and constantly evolving process that includes our own business, that of our customers, and the final product. The unique precision bearings that are produced for wind power turbines make KMT an important

player in the alternative energy market. Our energy-efficient solutions for older grinding machines reduce our customers’ energy needs. Blue Competence certification certainly feels very relevant to a company that prioritizes its sustainability work very highly.

a green Priority to be proud of


KMT's sustainability work is wide and ongoing. KMT has previously focused on it's own opera-tions, such as premises, environment and equipment, but now we place greater interest in

making KMT's grinding machines more energy efficient to reduce their influence on the

climate. Amongst the energy saving measures the company is working with, we can name reduced air consumption on grinding machines - compressed air uses a lot of energy and leakage can occur on older machines.

Energy monitoring of grinding machinesWe have produced an instrument that

allows the machine operator to monitor the energy consumption of the grinding machine.

In this way the operator has full control over the energy consumption when the machine is in full production. A week-end program is another example of energy saving measures for the production side. It means in short that one can

program the machine so that it starts up earlier, before the operator is in place.

“Our goal is to hold a high environmental profile and we also note that our customers also demand this. Amongst these are SKF, who have even awarded us a prize for our environmental work,” explains Stefan Frid.

Fulfilling the parametersIn the summer of 2012 we took a decision to fulfil the criteria demanded for receiving the newly established environmental certificate Blue Competence, which the VDMA (German Engineering Federation) have founded. Certifica-tion is performed by CECIMO which is a European association of machine manufacturers. A company that wished to be certified according to Blue Competence must fulfil different predefined sustainability criteria in both their own operations and in their products.

“We now fulfil the parameters required, which is not the least important for the environment and in marketing for the company,” says Stefan Frid. n

KMT's environmental and sustainability work can be seen in not just our own operations. Equally large demands apply to the grind-ing machines we deliver to our customers. This environmental work has resulted in a Blue Competence certificate.

“If one thinks about the lifespan of our machines, the question of energy efficiency becomes extra important,” says Stefan Frid, technical manager at KMT in Lidköping.

Blue coMPetence “proof of our exceptional environmental work”

FACTS “BlUE COMPETENCE”

Since the start in February 2012, eight of CECIMOS National Associations and 58 machine manufacturers and development organisations in Europe have been certified in accordance with Blue Competence. A company the wishes to be certified must fulfil the predefined sustainability criteria in their production/products and business methods. The companies that have fulfilled these conditions can then communicate to their customers and the general public that they are Blue Competence-certified.


Ocean-based wind power turbines are expected to be the fastest growing segment within wind power. During the period 2017 – 2020, more than twice as many MW will be installed compared to 2013 – 2016. The primary countries that are investing are Great Britain, Germany and China.

“If a generator is located in a wind farm in an ocean, it just can’t be allowed to break down. It costs too much to send out a few people in a boat to change a bearing, for example. The demand for precision prevails for the whole range of bearings used in wind turbines which Is why KMT has incorporated much of the same technology used to achieve high accuracy in its full range of machines, from 20 mm to 4000 mm. It is also very popular for Swedish municipalities to invest in their own wind power systems. There are currently more than 50 municipalities with their own wind power. Even the Swedish business sector is investing. An example is IKEA, which already has 46 turbines to supply sustainable energy to their own stores.”

First in the world With all their experience from bearing grinding, KMT chose to invest in machine that both grind and turn components of larger diameters. We believe we are the first grinding machine company to take this approach. The VTG 1500 can handle bearings with an outside diameter of between 500 and 1,500 millimeters which amongst other things, is suitable for the aircraft, arine, offshore, and paper indus-tries. The larger machine, VTG 4000, can handle bearings between 1,300 and 4,000 millimeters, primarily for the wind power industry.

“We have the same resolution for positioning in all LIDKÖPING machines, independent of the area of use. “The linear motor technology used in our small range precision bearing grinders is the same as that used in our largest machines, except that the linjarmotor is longer,” says Otto.

Every component used in the manufac-ture of KMT machines is important to its performance. For example, the linear motors used in our vertical grinding machine slide are used to accurately position grinding wheels and turning tools for grinding, but they also accelerate rapidly to very high speeds when changing tools.

The high-speed motors combined with such features as hydrostatic work head bear-ings and friction-free slide way systems uniquely qualify KMT as a leader in wind turbine bearing grinding. In a wind power turbine, there are bearings in several places, for example in the rotor blade fixture, on the turbine shaft, and in the gearbox.

“The better the precision a bearing has, the easier the turbine will rotate and the less energy will be lost,” explains Otto Jern-ström, who emphasizes the importance of every component in the wind mill. n

“The better the bearing works, the easier the turbine rotates and therefore the less energy is lost, explains Otto Jernström,” sales manager at KMT Precision Grinding.

After a few years of stagnation, the need for wind power turbines is growing again, but now the industry is putting very stringent demands on the components its uses.

“KMT is perfectly positioned to meet these demands as it has developed a large range of grinding machines for the manufacture of bearings with extremely high precision” says Otto Jernström, Sales Manager for KMT Precision Grinding.

THE WiND HAS CHANGED


KMT Precision Grinding have reconstructed a grinding machine at SKF that resulted in a 75 percent reduction in air consumption. This corresponds to an estimated reduction in carbon dioxide emissions of about 13 tons, per machine. For a large company like SKF with many grinding machines that run both two and three shifts, this means a dramatic reduction in environmental influence, which is also in line with SKF's environmental strategy.

As can be seen in the motivation, the strength of KMT’s upgrade for a reduction in air consumption is that it can be applied on both old and new machines in the production environ-ment, without influencing the performance or final product.

“It doesn't affect the program, the control system or the electrical system. And it's sufficient to close down a line for a couple of says for the upgrade. The investment pays for itself in less than a year. At the same time it brings a considerable environmental benefit,” says Otto Jernström.

What KMT have actually done is to change the air seals in the slide system. By using the new mechanically designed air seals, they can be run at a pressure of four bars instead of six bars. A whole 60 percent of the savings in air consumption are due to this feature.In addition, older valves with rubber seals are changed to a new generation of valves with steel seals that reduce leakage. These can be retrofitted or provided as standard equipment during machine refurbishment. The procedure is performed on KMT's inner and outer grinding machines.

“We have around a thousand machines around the world where we can perform this procedure. But it can also be implemented on other machines,” says Otto Jernström and continues:

“This investment is part of our quest to improve the total ownership cost (TCO), that is how much it costs to run our machines in the long term.” n

Prestige filled prize to KMTin a fight with ten of thousand of other suppliers, KMT Precision Grinding was awarded SKF's prestigious special prize for innovative work this spring by reducing air consumption.

“This award is extremely important to us and is probably the finest award we have ever received. it is also completely in line with our environ-mental work,” says Otto Jern ström, sales manager at KMT Precision Grinding in lidköping.

WiNNER FOR SPECiAl ACHiEvEMENTKMT PRECiSiON GRiNDiNG AB

KMT Precision Grinding AB, a supplier grinding machines, services, spare parts and tooling, is a partner to all SKF bearing manufacturing units globally.

KMT is awarded for their innovation to dramatically reduce compressed air consumption without compromising machine performance and output quality. The innovation can be implemented not only on new machines, but above all, as an upgrade package to already installed machines at SKF. This innovation is supporting the SKF climate strategy and participation in the WWF Climate Savers Programme.

Thanks to their acceptance of the SKF challenge to find solutions to bring innovation regarding less energy consumption, KMT has confirmed its role as a long-term partner, participating in improving the total cost of ownership of the installed machine base in SKF. n

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Centerless history reaches far back in time. The first machine for grinding using the centerless principle was supplied by Lidköpings Mekaniska Verkstad in 1922. The basic design itself, incorporating hydrostatic technology that reduces friction and eliminates wear, is the main reason that KMT have, during the past years, delivered over 4,000 of these high precision machines. Millions of rods, pistons, shafts and various bearings have been produced from centerless machines around the world. It’s not strange then that there is a demand to hear about the history, which KMT in Lidköping had an important part to do with.

”Doctor Fukuo Hashimoto, who is the chairman of the CIRP grinding committee has always been interested in Centerless grinding and asked me and a few others to help write an article about the machine. It turned out to be about 25 pages that concerned the Lidköping part, which I have

been responsible for and partly written myself,” says Hans-Olof Stålfelt.

lead the developmentIn the article you can read about how KMT led development during the 1920s with their Centerless machine in Europe, at the same time as competitor Cincinnati dominated in the USA. It speaks about the design and construction of the machine and how it has changed through the years until today. The article also describes the importance of the machine’s development to industry, and the products that have been centerless ground and how the future for the centerless principle appears. As a result of this honorable mission, KMT decided to apply for membership in this world-leading organization within technical production research. Today, KMT is one of about ten Swedish companies in CIRP amongst the others are Volvo, SKF and Sandvik. Even KTH, the Royal Institute of

In 1922 the first Centerless machine was delivered from Lidköpings Mekaniska Verkstad. Its history and development can now be found in an annual publica-tion issued by the international organization CIRP. KMT’s Hans-Olof Stålfelt is one of the co-authors.

”It’s an honor participating in this publication; CIRP consists of the ultimate research elite within production technology.”

THe CeNTerLeSS PrINCIPAL’S HISTorY in an international research journal

For the last two years KMT have been a member of CIRP

FACTS

Centerless grinding is a round grinding method invented at the end of the 1800’s to mass produce components with very tight diameter tolerances.www.cirp.net


THe CeNTerLeSS PrINCIPAL’S HISTorY in an international research journal

Technology, is represented in the organiza-tion, which is on the leading edge in the world as far as design, optimization, controls, grinding and handling of processes, machines and systems are concerned The whole CIRP organization has about 600 members comprised of both universities and companies within the branch. Their purpose is to encourage research and development within produc-tion technology and contribute to global economic growth and welfare in society. The members meet twice a year with the main meeting held annually in Paris, and the other meeting at various locations which change from year to year. This autumn, Copenhagen will be responsible.

”The meetings are an exchange between researchers and industry. Researchers look at new ideas that can be implemented in industry and we explain which problems we encounter. ”This is an important forum to be involved in since the leading spearheads of the research world are involved,” says Hans-Olof Stålfelt.

Can influence researchFor KMT, this gives us the possibility to

influence which new research project will be taken up by CIRP. It also gives input for new development possibilities, for example, the energy effectivisation of production. At

each meeting, ten universities hold seminars about different projects, which the attending companies can then vote for to see who will be chosen.

”Today, everything circles around TCO, Total Cost of Ownership; how much a product costs to own from when you buy it until you get rid of it, and how it influences the environment,” explains Hans-Olof Stålfelt.

Energy-efficient machinesA direct consequence of KMT’s involvement with CIRP is the work with energy-efficient machines and TCO. The wide knowledge within the organization has ensured that KMT are on the leading edge in the world when it comes to environmental and sustainable work for grinding machines.

”A development that we are currently working on in Lidköping is to add cooling water to grinding machines using a special method which reduces energy consump-tion. ”We believe this development will help reduce energy consumption by as much as 20%, which is a very high number,” says Hans-Olof Stålfelt. n


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SMC has extensive experience creating competitive advantages for its customers through excellence in

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KMT's grinding machines in Lidköping have a recognised long lifespan. The hydrostatically constructed machine has vital parts that do not wear out, since friction has almost been eliminated. Production can therefore continue year after year with retained performance. The only part that actually needs to be updated are the electronics in the control system.

“We receive machines for renova-tion that are 20, 30 years old. After mechanical and electrical refurbish-ment they are in principle as new and can be operated for a further 30 years. What the customers gain from a refurbishment is partly that they are cheaper to buy and partly that lead time is halved,” says Urban Larsson.

Reliability is securedBy investing in a service contract, our customers can count on securing the reliability and lifespan of their grinding machines for a long time into the future. With a service contract, KMT take a greater responsibility for the machine and the customer can rely on the right service and maintenance being performed.

“There are many players on this market, but not that many can guarantee qualified service and the right spare parts. The greater the number of players that establish themselves on the market, the more important it is with this type of service contract,” says Urban Larsson.

inspection on siteA first step toward a service contract can be to order a Health Assessment on the machine by KMT, where service personnel travel to the customers and perform an inspection of the grinding machine. In this process, the entire machine is examined, everything is documented and a recommendation is given to the customer. It is often the case that something needs to be repaired or updated.

“A machine Health Assessment with changes made, subsequently leads to increased reliability, which ultimately makes the total cost of ownership lower,” explains Urban Larsson.

Quarterly maintenance kitKMT's spare parts market covers

Qualitative grinding machine with a long lifespan auto-matically create a large aftermarket. But there is another way of increasing the lifespan and reliability.

“A service contract definitely improves reliability,” says Urban Larsson, sales manager at KMT in Lidköping.

Dag Aronsson travels round inspecting older machines.

“We receive machines that are 20, 30 years old. After mechani-cal and electrical refur-bishment they are in principle as new and can be operated for a further 30 years,” says Urban Larsson, Sales Manager at KMT in Lidköping.

“We have a number of upgrade packages but we also have more service-orientated im-provement packages where we send out an engineer who checks out the program and how the machine could work better,” says Björn Almgren, Sales Aftermarket Manager at our Bromma office.

service contract lengthens the grinding machine's lifespan

everything from standard components such as valves, filters, hoses and belts, to the company's own manufactured spare parts. To make the whole thing as simple as possible for the customer and to heighten reliability, we are now offering our customers a complete spare part or maintenance kit.

“Instead of ordering just one part, the customer can now order a quarterly maintenance kit that includes a number of items. In this way the customer does not need to invest time in finding out exactly what needs to be changed. It's a more preventive way of working,” says Urban Larsson.

Upgrading with new technologyThe aftermarket is a large and important part of KMT's operations and our ambition is to increase it. At our factory in Bromma we are always trying to find new improvement products for our customer's machines. The new control panel, UGC, is an example of how an older machine can be upgraded with new technology. For a better measurement result on the product that the grinding machine produces, KMT now offer a so-called scanning service. Vacuum loading is another example that makes produc-tion itself more stable and secure.

“We have a number of upgrade packages but we also have more service-oriented improvement packages where our engineers, together with the customer, try to find methods to improve and make machines and production more efficient,” says Björn Almgren, aftermarket manager at our Bromma site. n

service conTracT

By signing a service contract, KMT take a greater responsibility for the grinding machine. As a customer, you can therefore depend on the right service being performed and the right parts being used. This give the machine a longer lifespan.


High Precision Grinding Machines

UVANomyliNe iNterNAl/FAce/exterNAl

liDKÖPiNGSUU240/320/600

liDKÖPiNGVtG1500/4000

liDKÖPiNGDG300/400/500/700/800

Valve Lifter

Nozzle Grinding Pump Body

Inner Ring SRBWindmill, radar Station Hard turning/grinding external or internal

Inner Ring Gearbox, large craneHard turning/grindingexternal or internal

Slewing BearingWindmillHard turning/grinding

Inner Ring DGBBBearing - Face

Inner RIng DGBBBearing - Face

Outer Ring DGBBBearing - Face

JointsBearing - Face

Gear PartAutomotive - internal

Inner Ring SpindleBearing - external

Outer Ring FlangeBearing - internal

Inner Ring Truck HUBBearing - external or internal or rib Face

machine type Workholding Principle Work Piece Dimension

VtG1500 internal /external /

Hard turning

magneticchucking

iD oD

min Ø 440max Ø 1 450

min Ø 500max Ø 1 500

VtG4000min Ø 1 000max Ø 3 800

min Ø 1 300max Ø 4 000

machine Grinding Wheel Principle Work Piece Dimension

DG300 300 mmiD oD

ø 5-160 max 80

DG400 500 mm ø 15-240 max 120

DG500 500 mm ø 20-250 max 80

DG700 700 mm ø 190-610 max 250

DG800 800 mm ø 300-820 max 250


UVAi internal chucking

Bore length

ø 0,5-100 max 200

UVAi twin

internal chucking ø 0,5-36 max 120

UVAe externalChucking/

between centersø 1,0-80 max 160

UVAieexternal/internal

chucking ø 1,0-36 max 160

Uva iindex

internal chucking ø 0,5-36 max 80

UVAie mc internal chucking ø 1,0 - 36 max 80


SUU240

internal/ external/ Flange

(rib Face)

Shoe centerless/

centric chucking

oD Width

ø 20-240 max 120

SUU320 ø 100- 320 max 140

SUU600 ø 150-600 max 200

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26 | High Precision Grinding www.kmtgrinding.com26 | High Precision Grinding www.kmtgrinding.com

High Precision Grinding Machines

liDKÖPiNGSSB 110/200

liDKÖPiNGSGP62B

liDKÖPiNG/UVANANo iD

liDKÖPiNGSUUc240/600/800

liDKÖPiNGcl630/660

Inner Ring DGBBBearing - internal

Outer Ring HUBBearing - internal

Inner Ring DGBBBearing - internal

Outer Ring DGBBBearing - external

Inner Ring DGBBBearing - external

Inner Ring DGBBBearing - external

Outer Ring Truck HUBBearing - external and internal

Outer Ring Railway Bearing - external and internal

Inner Ring SRBBearing - external and internal

CamshaftAutomotive - external

Outer RingBearing - external

JointsAutomotive - external

machine PrincipleWork Piece

oDWheel Width

Wheel Ø (WorN)

cl630 ≤125 300 (400) 610/630 (380)

cl660 ≤250 610 (700) 610/630 (380)


SUUc240

external/internal/Flange

(rib Face)

Shoe centerless

iD/oD Width

iD min ø 80oD max ø 250

max 130

SUUc600iD min ø 130

oD max ø 600 max 180

SUUc800iD min ø 370

oD max ø 820 max 250


Nano internalShoe center-less/centric

oD Width

min ø 8max ø 72

max 52


SSB110

internalShoe

centerless

oD width

Ø 19-150 max 65

SSB200 Ø 20-160 max 100


SGP628 externalShoe

centerless

oD Width

ø 7-62 max 40







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