Zoerkler Turns to New Machine to Improve Production of High-Performance Transmissions
Zoerkler Gears GmbH & Co KG, a renowned manufacturer of high-precision drive systems for the aerospace and automotive industries, recently switched to EMAG's VL 6 vertical pick-up turning machine to manufacture high-precision transmission components. This strategic investment underlines Zoerkler's commitment to innovation and top quality in the production of complex drive components.
Zoerkler's high-quality standards are reflected in the design of the company's production hall in Jois, Austria.
Over the past 120 years, Zoerkler has developed from a mechanical engineers' workshop into an innovation leader in the manufacture of high-performance gearboxes. Today, the company employs around 100 people, including eight trainees and 15 highly qualified design engineers, and it specializes in the design, manufacture and testing of drive systems for high-performance automobiles, helicopters and airplanes.
The company handles almost all process steps in gearbox production in-house. Its production chain begins with the purchase of raw materials and includes all essential processing steps.
"We use state-of-the-art turning and milling machines for basic machining. Our high-precision grinding processes, both cylindrical grinding and coordinate grinding, are then used to achieve the tight tolerances required," said Bernhard Wagner, Managing Partner of Zoerkler Gears.
Bernhard Wagner, Managing Partner of Zoerkler Gears GmbH & Co KG
"One of our specialties is bevel gears for helicopters, especially those with angles other than 90 degrees. We have established ourselves as absolute specialists in this field."
Zoerkler has also developed special expertise in the automotive industry, particularly in the optimization of vibration behavior and microgeometry. "This variety of technologies and our in-depth understanding of each individual process step enable us to manufacture even the most complex drive systems to the highest quality," added Wagner.
The company's recent decision to switch production to an EMAG VL 6 was based on the need for automated machining of heavier components with the highest precision and reliability. Wagner explains: "The VL 6 enables us to produce complex components with excellent dimensional accuracy, even with frequent changes of workpieces for our small series. This is crucial for our production flexibility and for meeting the high-quality requirements of our customers in the aviation and automotive industries."
Modern production hall with the VL 6 vertical pick-up turning machine from EMAG at Zoerkler.
The machine's integrated hard turning and milling functions are particularly noteworthy.
This multifunctionality enables Zoerkler to perform demanding machining steps in a single setup, which contributes significantly to increasing precision and shortening cycle times.
The vertical design of the EMAG VL 6 offered decisive advantages.
"Despite frequent retooling -- we change the workpieces to be produced several times a week -- we are very satisfied with the consistently high dimensional accuracy. This is particularly important for our precision parts," added Wagner.
High-precision machining of a gearbox housing on an EMAG VL 6.
Another advantage of the VL 6 is its highly developed automation system. "We can often run the machine autonomously in the second and third shifts, which significantly increases our productivity," said Wagner. The combination of reliable automation and constant precision enables efficient production around the clock without compromising on quality.
The integration of the VL 6 complements Zoerkler's impressive machine park with production technologies such as turning, milling, grinding, gear cutting, tooth cutting, bevel gear grinding and eroding as well as testing facilities. The company has a high-performance test stand for helicopter gearboxes with an output of up to 2 x 4 megawatts as well as special test stands for e-mobility applications. This equipment underlines Zoerkler's ability not only to manufacture complex drive systems, but also to test and optimize them under realistic conditions.
The impressive helicopter gearbox test stand from Zoerkler
Zoerkler's expertise covers a wide range of gearing technologies, including the manufacture of internal gears, gear rims and bevel gears for helicopters. The company is particularly proud of its expertise in producing bevel gear ratios not equal to 90 degrees -- a specialty that is highly valued in the aviation industry.
The successful integration of the VL 6 into Zoerkler's production processes underlines the company's commitment to continuous innovation and quality improvement. This investment consolidates Zoerkler's position as a technology leader in the manufacture of precision drives and prepares the company for future challenges in the rapidly evolving mobility industry.
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