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Construction machinery manufacturer achieves reliable, energy-efficient leveling with new machine

SITUATION

Liebherr-Hydraulikbagger GmbH is a manufacturer of construction machinery, with 46,000 employees at more than 130 locations around the world. At the company’s first site, in Kirchdorf an der Iller, Germany, Liebherr-Hydraulikbagger manufactures a variety of hydraulic excavators, articulated dump trucks, and material handlers. This is where steel construction takes on a strategically important role.

Each month the steel construction department levels 300 tons of laser-, plasma-, and flame-cut steel, with thicknesses from 8 to 40 mm, for constructing the upper- and undercarriages of hydraulic excavators and material handlers. “We need to make sure that our steel blanks, some of which are large and solid, are exactly level and low stress to maintain the high quality standards of our products,” explained Stefan Richter, head of steel construction.

Working with Project Manager Torben Handeck, who is in charge of programming and welding technology in the steel construction department, Richter set about finding a powerful, reliable, and economical part leveling machine that could stand up to permanently high operation over two shifts each day.

Resolution

Liebherr management was joined by machine operators and technicians from the steel construction and maintenance departments to make the final decision on a machine purchase: the Peak Performer from Kohler.

“They really grilled us,” said Dr. Hans-Peter Laubscher, managing director of sales at Kohler. “We discussed every single detail of the machine and gave a demonstration in our leveling center by carrying out different leveling trials.”

They chose a 120P Peak Performer with an advanced cleaning system. To clean the machine’s rollers, the machine operator moves the motor-driven top roller frame upwards. The operator then can slide either the top or the bottom guide plate with the supporting rollers and leveling rollers out of the machine, powered by an electric motor, to remove dirt.

Three other features of the system were key to their decision. First, it operates without any hydraulics. The servo-electronic leveling gap control helps reduce energy consumption and minimize maintenance, and it enables the machine to handle temperature fluctuations.

The direct drive for the leveling rollers was the second decisive feature. It employs distribution gears and cardan shafts to minimize electricity consumption. It also increases the direct input of power into the leveling rollers, which increases the material cross section that can be leveled and enlarges the working range, particularly in the case of wider sheets. The directly driven rollers also reduce slip on the material.

“The reversible leveling rollers were the third key factor for us,” said Handeck. Their service life can be extended by up to 50%, particularly when leveling comparatively narrow parts.

The uncluttered interior and the ease of access and clear arrangement of the machine driveline for the maintenance staff also were attractive features, as was the very small overall footprint.

The machine has delivered the reliable, precision leveling results required for producing construction machinery and material handlers while reducing energy consumption and maintenance costs.

Kohler Maschinenbau GmbH www.kohler-leveling.com