PRODUCT DIVISIONS

divisions occupying important positions

in the fields of drive systems, castings,

machine components, plain bearings

and steel profiles. Today, the ZOLLERN

Group is internationally successful as

a supplier of high-tech parts and

systems for aerospace, shipbuilding

and engine manufacturing applications,

energy and information technologies,

vehicle and machine manufacture and

offshore conveying and handling

operations. ZOLLERN is in demand as

a supplier wherever reliability is at a

premium and breakdowns are out of

the question.

The ‘ZOLLERN’ brandname is synon y -

mous in the industrial world with

qua lity and reliability. In the course

of its history, going back 300 years,

ZOLLERN GmbH & Co. KG has

developed from a simple ironworks

into an ultra-modern company with

Drive systems embrace gearboxes and winches and linear modules andsystems for automated operations.

In the field of plain bearing technologyZOLLERN designs and manufacturesthin-walled bearing shells, bushings, tilting pad and thick-walled plain bear -ings, housing and pedestal bearings, sliding components and hydrostaticbearing systems.

Our range is completed by machinedcomponents comprising high-precisionsteel shafts and flat and round guides.These are tailor made to customers’drawings in lengths up to eight metres.

All our products can be processed to afinish in-house as well as heat and sur-face treated. Complete subassembliescan also be supplied.

Innovation and tradition

A company in changing times – theiron works of 1708 has developed into a modern group of companies,with over 3000 employees worldwide. To day, it offers purpose-made pro ducts to its customers in the form of cas t -ings, steel profiles, drive systems, plain bearings and mechanical engi-neering components.

From the very outset, ZOLLERN hasalways stood for quality, customer careand engineering know-how. And westill place a high value on comprehen-sive advice and customer accessibility– whether the requirement is for theoptimum design for e.g. a gearbox, precision casting or friction bearing, orhelp in selecting the best material forthe intended purpose.

Thus, we can supply drawn steel profiles to your precise needs, from a simple DIN profile to complicatedspecial profiles in ready-to-install condition.

In our foundry, we produce castings inan extensive range of alloys, from cop-per and steel to aluminium.

In this division, a variety of wroughtcopper products and castings are madein the form of forgings and investment,vacuum, sand, shell moulding and cen-trifugal castings. If required, we canalso supply rapid prototyping models,cast in the material you propose to use.

STEEL PROFILES

FOUNDRY TECHNOLOGY

DRIVE SYSTEMS

MECHANICAL ENGINEERING COMPONENTS

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PLAIN BEARING TECHNOLOGY 12 13

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General machine manufactureSteel profiles are used in generalmachine manufacture not only becauseof their precision but also by reason ofthe demand for complex shapes andwear-resistant finishes. Typical exam-ples include toothed profiles, clampingjaws, machining chip deflectors, guidesof every type and a great deal more.

ZOLLERN ISOPROFILThis name stands for special steel profiles produced by no fewer than 168 workers in the Laucherthal factory.

Optimised profiles for customersAt ZOLLERN ISOPROFIL, steel profiles are produced in close cooperation withcustomers from a wide diversity of industries. Our solutions enable them toundertake specialised design and manufacturing operations.

Quality and precisionThe processes used by ZOLLERN ISOPROFIL in the production of profiles in -crease the strength of the material through selective cold forming and heattreatment as well as improving their machining characteristics. Every stage of production is subject to quality assurance tests and inspections.

Cost effectiveness and the environmentThanks to small oversize allowances, the use of steel profiles is of financialbenefit to the customer. Through reducing further machining operations to an absolute minimum, the use of personnel, machines, tools and even ma -terials is minimised in turn. In comparison with conventional manufacturingmethods, the material content can be reduced by up to 60%. Successesachieved within the framework of a policy of continuous improvement havepermitted the use of environmentally harmful substances in the productionand post-processing of steel profiles to be considerably reduced.

Vehicle safety systemsSpecial profiles used by the automo-tive industry are subject to exactingrequirements in respect of surfacefinish, dimensions, shape and instal-lation tolerances. To produce thesehigh-quality profiles, ZOLLERNemploys the latest production, tes ting and measuring equipment.

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Surface hardened steel profilesInduction hardened profiles are used whereverthere is a need for hard, wear-resistant surfaces or special physical characteristics.Typical applications include linear guides, drivesystem components, splined shafts, chain gui-des, cutting blades, spring mechanisms, etc.

ZOLLERN steel profiles are used in countless industrial fields, e.g. plant construction,building and construction machines, power and electrical engineering, safety com-ponents for vehicle manufacturers, wood processing machines, medical technology,hunting and sports weapons, tool making and process engineering.

STEEL PROFILES

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Textile machines and printing pressesIn these industries, the emphasis is onhigh quality surface finishes, very closetolerances and components of widelyvarying shapes. Applications in textilemachines include e.g. thread guides,take-off rollers, needle bars and guiderails. Typical products for printing pres-ses include rollers for conveyer sys tems,tensioning rails and clamping bars.

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Hot rolling process

Precision castings To achieve the required quality offinish and complex internal shapes of this housing for a fitting for a do -mes tic water system, it was made as a precision casting by the lost waxprocess. Made of stainless steel, it ispressure tight and corrosion resistant.

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Precision castings Complex turbine wheels for carturbochargers are cast undervacuum from high heat resistantmaterials. Since no air resistanceis present during process, it ispossible to obtain vanes of lessthan 1 mm thickness.

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Circular furnace for firing moulds

Precision casting at the highest levelDeveloped from the lost wax method known in ancient times,invest ment casting is one of the oldest casting techniques of all. In those days, patterns were shaped from beeswax, packed in mud and clay and fired in an open fire, whereupon the wax patternmelted and ran out. The resulting mould could then be filled withliquid metal. Today, the original process has been industrialised with modern waxes and ceramic mould-forming materials and has acquired considerable importance in the mass production of standard parts.

Today, components weighing from one gram to about 150 kilo-grams and of increasing sizes are made by the investment castingmethod from super-alloys which are increasingly difficult to melt.The economic advantages of investment casting are revealed invalue analyses, particularly in the case of geometrically complica-ted parts or materials which are difficult to machine. Like no othermethod investment casting allows almost unlimited freedom ofdesign and achieves high standards of dimensional accuracy andsurface quality. Parts can often be cast to the finished dimensionsor with minimal allowances for machining.

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PRECISION CASTINGS

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Forgings Copper alloys are frequently used for dies in injection moul-ding machines. Their higher heatconductivity, in comparison withsteel, results in shorter cycletimes and improved cooling properties in critical areas.

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ForgingsVacuum-tight, highly conductive cop-per, meeting the highest standardsof purity and machining quality, isused in transmitting tubes for radio,TV, communications and other highfrequency equipment. Rail tractionmotors are fitted with ZOLLERN copper and copper alloy rings.

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FOUNDRY WORK

Ring rolling system

Forging at the highest levelForgings made of copper and copper alloys are made by ‘shaping’without machining. As a result, they exhibit a uniformly fine grainstructure with a favourable fibre flow, endowing them with highstrength and outstanding tenacity.

As a rule, the raw material is produced by us in-house in form ofcontinuous or chilled castings. The hot shaping of units weighing up to approximately 3000 kg or bar lengths up to 10 m is carriedout with forging hammers, an electronically controlled 1600-tonforging press and a ring rolling system. Semi-finished productssuch as bars, profiles and tubes are first extruded, after which they undergo cold forming.

Forgings are pre-machined or machined to a finish in a workshopequipped with highly efficient CNC lathes and machining centres.The properties of the materials are established by workshopinspections and by destructive and non-destructive tests in thelaboratory. In this way, the forgings fulfil the demanding require-ments of e.g. the electrical engineering industry, high frequencyand vacuum engineering industries and the aviation, shipbuildingand machine manufacturing industries.

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FORGINGS

Sand castings The housing for a piston pumpweighs around 580 kg and ismade of a copper-aluminiumalloy. With the addition of alu -minium, copper becomes stron-ger and more corrosion resistant.

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Sand castings Francis turbine wheels, machined toa finish and statically balanced, gen -e rate environmentally friendly electri-city. A long service life is assured bythe use of G-X5CrNi13-4 steel, highquality casting and precise, geome-trically accurate machining.

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Sand casting at the highest levelZOLLERN was making castings nearly 300 years ago. At that time, iron wassmelted from bog iron ore in our own blast furnace. Today, copper and copperalloys are used for castings in addition to non-alloyed and high-alloy steels.

Individual components and parts in short runs are made by the hand moul -ding method on the basis of wooden models. Castings can be made in unitsweigh ing up to approximately 4000 kg in copper alloys or 1200 kg in steel. A moulding machine capable of making shell mouldings is available formedium runs. Ceramic cores or parts of moulds can be used to satisfy moreexacting de mands for dimensional accuracy and surface quality. Centrifugaland transfusion casting methods permit the economical production of dynami-cally bal anced components such as bearing bushes and worm gear bodies.

A wide range of materials, starting with highly conductive pure copper for e.g. electrical leads, is available. Red brass, tin bronze, various types of brassand (including high-strength brass) and high-strength, corrosion resistant aluminium bronzes cover virtually all the material needs of the electrical engi-neering, machine and pump manufacturing and shipbuilding industries. High-alloy steels are used in the chemical industry and in the construction of waterturbines for the environmentally friendly generation of renewable energy. Byusing our services, which include model making, the production of castingsand preliminary or finish machining in our own machining shop, you canobtain all your needs from a single source.

SAND CASTINGS

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Steel castings Valve cores in the control fittings of steam turbines made of water resistant casting steel 1.7706 =G17CrMoV5-10, in unit weights from 3.5 kg to 400 kg.

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Steel castings Impellers for chemical and food pumpsmade of G-X5CrNiMoNb18 10, 1.4581.The cores of the impellers are made of a ceramic material to ensure a highquality finish in the area in contact withthe medium.

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Steel casting at the highest levelZOLLERN has considerable experience in the smelting of iron andsteel for investment castings and the production of sand castingmoulds for copper alloys. It was only natural to use experience andknow-how for the production of sand castings from steel, too.Today, steel castings can be made in unit weights up to 1200 kg.

We concentrate on components made of high quality materials andconforming to exacting standards of geometry and quality. Castingsare made from unalloyed, low-alloyed and corrosion- and acid-resi-stant steels. They are used in e.g. general machine manufacture,chemical and food industries and the construction of water tur binesfor hydroelectric power stations. Typical materials include heat treatable steels, ferritic and austenitic steels, duplex steels and non-magnetic steels. Special materials based on nickel or cobalt arealso used for castings. Thus, we are able to offer a comprehensiveselection of materials.

We also make available our experience in the production of steelsand castings already at the design and planning stage. In this way,components can be optimised in terms of the casting method usedand cost effectiveness. Pattern can also be procured by us, ensuringthat everything is supplied from a single source.

Pelton turbine wheel machined to a finish and ready to install; buk-kets ground as per templates and statically balanced; unit weight1200 kg; material G-X5CrNi13 4, 1.4313. The wheel generates environ-mentally friendly electric power in a water turbine.

Crossmember made of duplex steelX2CrNiMoN22 5 3, 1.4462; this mate-rial is used for components combi-ning high strength with high resi-stance to stress crack corrosion inmedia containing chlorides.

STEEL CASTINGS

Epicilic/spur gearbox for Sugar Cane Crusher

Gear systemsWith two sites manufacturing gears: HERBERTINGEN and DORSTEN, ZOLLERNis an important supplier of gear systems for mobile cranes, harbour, ship -board and offshore cranes, construction machines and wind turbines, indus -trial uses and special applications. Gearboxes are designed with turbines,industrial uses and special applications. Gearboxes are designed with modulestages which ‘plug’ together in the selected configuration with user definedoutput and input options.

The multifunctional nature of our gearbox designs permits individual gearcomponents to be mass produced. With the addition of fewer bespoken com-ponents, specific to the customer´s needs, a tailor made gearbox assembledprecisely meeting the application´s requirements.

Tested and proven designs are offered across the entire range with the benefits of: cost savings from higher volume production of standard parts,reduced lead times and readily available spares for units in service ZOLLERNgear systems are used throughout the world and in diverse applications.There can not be a single division of industry or materials handling which isnot equipped with ZOLLERN gearboxes.

ZOLLERN manufactures gearboxes using high-strength, hardened and heattreated materials. All externally toothed gearwheels are case hardened, withteeth ground to 4–7 quality, depending on size. This gives them a high con-tact area ratio and ensures low noise under load. ZOLLERN’S gearboxes fromboth HERBERTINGEN and DORSTEN can be fitted and supplied with additionalcomponents and features or as ready-to-install modules. Contact us for fur -ther details.

ZOLLERN always offer the best engineering and most cost-effective solutionsto your transmission. Let ZOLLERN advise you and we will supply you with agearbox optimized to your needs.

Wind Turbine Gearbox

Pitch and Azimuth Gear -boxes for Wind Turbines

GEARS AND WINCHES

DRIVE SYSTEMS

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AutomationWe offer systems for your specific automation and rationalisation programmes, from individual linear modules to turnkey plants complete with controls, conveying systems and protective enclosures.

Dynamic, high-capacity machines can be realised with our standard elements(with the assistance of our project engineers) or delivered as full-scale plants in various stages of completion.

Take advantage of the support offered by our project management departmentand its comprehensive advisory services as early as the initial planning stage.

Traversing gantry

Transfer system in a car body plant

Traversing axis

Press feeder

AUTOMATION

ZOLLERN plain bearings – keeping everything in motionWith over eighty years of experience in the development and manufacturing of metallic plain bearings and in highly developed production methods for composite plain bearing materials and a policy of consistent quality, ZOLLERN is one of the world's leading manufacturers of large plain bearings withsites in Braunschweig, Osterode and Herbertingen (in Germany), Brazil and France. Our success isbased on innovation, on-time deliveries, product quality, efficient customer services and reliability.

A glance at our product range reveals that ZOLLERN produces suitable plain bearings for every application, whether for the purpose of generating, converting and conveying energy in diesel and gas engines, gearboxes, turbines and turbo-machines, or in other industrial machines.

The requirement profiles of the plain bearings in modern machine designs are as many as they arevaried. It is not only the design principle of a machine but also its size and anticipated operating condi-tions which have a decisive effect on the design of the plain bearings used and their combinations ofmaterials. A technically efficient, economically viable plain bearing system must therefore be speciallyadapted to the requirement profile of the machine. A consequence of the development of engines andmachines to produce higher and higher outputs is that the plain bearings must accommodate increasin-gly high static and dynamic loadings while, at the same time, still achieving prolonged durability in service. That is why the world’s leading manufacturers of engines and machines place their trust in our products and their quality.

MAN B&W 12K98ME-CTwo-stroke diesel engine with ZOLLERN BHW main, conrod and crosshead bearings

Bearing shellsThin-walled plain bearings for internal combustionengines and other piston-type machines, configured as bimetal plain bearings or trimetal bearings withadditional electroplated overlay

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Sliding componentsValve plates and holding down devices for axial pis -ton pumps and motors subject to high loadings, withhigh precision geometry and plane parallelism, asready-to-install elements of semi-finished products

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BushingsBushings for general use in engines and industrialapplications, available in the largest possible sizesand wide combinations of materials, with or withoutelectroplated overlay

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Hydrostatic bearing systemsRadial, thrust and combined hydrostatic bearings forspindle units, guides and worm drives as bearings for test rigs and special purposes, with a variety ofregulating systems; composite bearing materials forapplications in special purpose machines

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Quality and environmental protection are our hallmarksHighly trained, conscientious employ-ees are as much a requirement forthe quality of our workmanship andthe constant, successful striving for progress as an efficient qualitymanagement system (QMS). Qualityimplies for us to be a reliable all-round supplier who can be dependedon unreservedly, whether for advice,for developing applications or forproviding prompt help in the event of emergencies. Precise, fully docu-mented procedures, from the sub-mission of quotations to the deliveryof the products, accompanied bytests and inspections using high precision measuring and analyticalmethods are the most important criteria for ensuring the consistentlyhigh quality of ZOLLERN products.

Advisory and other servicesZOLLERN provides each of its customers withindividually tailored technical services:

· Application-related advice on designs and materials

· Design and calculation of the plain bearings required

· Installation measurement of prototypes

· Trials of prototype bearings

· Assessments of plain bearings in service

· Customer staff training

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ZM Centre flange bearing on a generator

Steam turbine with radial tilting pad plain bearingsand hydrostatic starting-up aid

PLAIN BEARING TECHNOLOGY

Research and DevelopmentTest rig trials serve to confirm the proposed solution.At ZOLLERN BHW, we have at our disposal one of the world’s largest and most modern plain bearingtest rigs, enabling us to program and simulate alltypes of collective loadings. We can even undertakespecific, preliminary development work for ourcustomers, using the actual bearing housing itself.

Tilting pad and thick-walled bearingsRadial/thrust plain bearings or combined radial/thrust bearings as tilting pad bearings for applica-tions entailing very high rotary speeds or axial loadings, or as thick-walled plain bearings with highstability and special bore profiles. Principal applica-tions are turbines, gearboxes, turbo- compressors,fans, vertical generators, electrical machines, turbochargers.

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Housing and pedestal bearingsZ-bearings are high performance plain bearings complying with the appropriate DIN standard, designed in accordance with the modular principle.The broad spectrum of uses for the different types of bearings (pedestal, flange-mounted and centreflange bearings) embraces electrical machines, fans,turbines and test rigs.

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Test rig for engine bearings

Induction Hardening To deal with the large variety of com -po nent designs and sizes that requirehardening we have installed powerfrom 80 to 225 kW utilising frequen-cies in the range 10 to 400 kHz foroptimised control of depth of hardness.The continuous hardening lines are fitted with CPC – continuous processcontrol – for consistent performance.

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Processing/MachiningWe have facilities to manufactureand finish columns and bars to dia-meter 250 mm with rolled threads.

For many years now ZOLLERN has been investing in its ‘Long Shaft’philosophy; a facility unique in manufacturing today, has developed as a consequence. We are now able to manufacture precision bar in diameters 2 to 250 mm in lengths to 8 meters.

A multi-tiered computer controlled warehouse stores semi-finished prod -ucts delivering standard lengths of up to 8 meters on individual orderentry. All available are: PISTON RODS, SPARS, STRAIGHTENING ROLLERS,AXLES, PINS, PRECISION BEARING BARS, GUIDE SHAFTS, FLAT BARS.These are induction hardened, ground and polished to provide extra finesurfaces. Hard chrome plate is available for extreme applications in coat -ing thicknesses to suit specific requirements. Our production organisa-tion enables us to offer material, design and machining under one roof.The scope of our supply expertise ranges from the acquisition of rawmaterial to the surface finishing.

ZOLLERN is TÜV certified to ISO/TS 16949: 2002. We place a high valueon environmentally concerned production.

You may test out our claims! Please send us your enquiries with draw ingsand specifications. Our highly qualified and experienced staff will gladlywork with you and turn around to prepare competitive solutions quickly.

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Chrome Plating Linear bearing shafts and piston rods6 to 30 mm are plated in our preciselycontrolled continuous plating plant.Guides, Linear Profiles and Slides inlengths to 4 m can also be plated withZOLLERN Duro 3.

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Surface GrindingGuides and Bars are manu facturedin lengths to 8000 mm – there arefewer joints for in longer gantry orslideway systems.

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MECHANICAL ENGINEERING COMPONENTS

ZOLLERN has its own electro-plating facility meeting themost stringent quality andreliability standards.

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ZOLLERN plants

Foundry TechnologyHitzkofer Straße 1D-72517 SigmaringendorfTel. +49 75 71 70 44 0Fax +49 75 71 70 60 1eMail zgt@zollern.de

Steel ProfilesHitzkofer Straße 1D-72517 SigmaringendorfTel. +49 75 71 70 24 6Fax +49 75 71 70 27 5eMail zst@zollern.de

Laucherthal plant

ZOLLERN GmbH & Co. KG

Drive TechnologyGearsHüttenstraße 1D-46284 DorstenTel. +49 23 62 67 0Fax +49 23 62 67 40 3eMail zgd@zollern.de

Dorsten plant

ZOLLERN Getriebetechnik Dorsten GmbH

Drive TechnologyGears and WinchesHeustraße 1D-88518 HerbertingenTel. +49 75 86 95 95 47Fax +49 75 86 95 95 75eMail zat@zollern.de

AutomationHeustraße 1D-88518 HerbertingenTel. +49 75 86 95 95 86Fax +49 75 86 95 95 85eMail zht@zollern.de

HydrstaticHeustraße 1D-88518 HerbertingenTel. +49 75 86 95 95 38Fax +49 75 86 95 97 15eMail zha@zollern.de

Herbertingen plant

ZOLLERN GmbH & Co. KG

Mechanical Engineering ComponentsSandweg 60D-88326 AulendorfTel. +49 75 25 94 81 30Fax +49 75 25 94 81 00eMail zmb@zollern.de

Aulendorf plant

ZOLLERN Maschinenbauelemente GmbH & Co. KG

Plain Bearing TechnologyAlte Leipziger Straße 117D-38124 BraunschweigTel. +49 53 12 60 50Fax +49 53 12 60 53 00eMail bhw@zollern.de

Braunschweig plant

ZOLLERN BHW Gleitlager GmbH & Co. KG

Plain Bearing TechnologyRolandsweg 16 – 20D-37520 Osterode am Harz Tel. +49 55 22 31 27 0Fax +49 55 22 31 27 99eMail bhw@zollern.de

Osterode plant

ZOLLERN BHW Gleitlager GmbH & Co. KG

Plain Bearing TechnologyAv. Manoel Inácio Peixoto, 2147BR-36771 Cataguases MGTel. +55 32 34 29 53 02Fax +55 32 34 29 53 26eMail zollern@zollern.com.br

Brazil plant

ZOLLERN Transmissoes Mecanicas LTDA

Plain Bearing Technology62, Rue Pierre CurieF-78131 Les Mureaux CEDEXTel. +33 1 34 74 39 00Fax +33 1 34 74 28 52eMail infoTLC@zollern.com

France plant

ZOLLERN TLC SAS

Foundry TechnologyOverweg 15 D-59494 SoestTel. +49 29 21 78 96 0Fax +49 29 21 78 96 17eMail info@zollern-afs.dewww.zollern.de

Soest plant

ZOLLERN Aluminium-Feinguss SoestGmbH & Co. KG

Sales offices

Drive TechnologyNo. 79, 11th Avenue 300 457 TianjinPeoples Republic of CHINATel. +86 22 25 32 38 60Fax +86 22 25 32 38 10eMail sales@zollern.sina.net

Foundry Technology Rua Jorge Ferreirinha, 1095, Ap. 1027P-4470-314 Vermoim MAIATel. +351 22 94 14 68 1Fax +351 22 94 14 69 5eMail zcp@zollern.com

283 Lockhaven Drive Suite 204USA - 77073 Houston, TexasTel. +1 71 36 73 79 02Fax +1 71 36 73 79 50eMail zollernna@aol.com

0317235 Pecica FNFerma 20

China plant

ZOLLERN (Tianjin) Machinery Co., LTD.

Portugal plant

ZOLLERN & Comandita

USA plant

ZOLLERN North America L.P.

Romania plant

S.C. ZOLLERN S.R.L.

ZOLLERN S.à.r.l6A rue GutenbergF-57200 SarregueminesTel. +33 3 87 28 45 02Fax +33 3 87 28 45 03eMail france@zollern.com

France

ZOLLERN Italiana S.r.L.Via della Ciocca, 9 I-21026 Gavirate (VA)Tel. +39 03 32 46 20 59Fax +39 03 32 46 20 67eMail info@zollern.it

Italy

Zollern UK LimitedCastle Hill, 1, The StablesGB-CV8 1NB KenilworthTel. +44 19 26 51 54 20 Fax +44 19 26 85 34 11eMail sales@zollern.co.uk

Great Britain

ZOLLERN Nederland B.V.Kerkstraat 37 5253 NieuwkuijkTel. +31 73 51 11 009Fax +31 73 51 15 100eMail zol-lern.nl@zollern.com

Netherlands

ZOLLERN RussiaDerbenevskaja nab 11, Korpus „A” 6. Floor, Office 66115114 MoscowTel. +7 49 59 13 68 50

Russia

www.zollern.com

ZOLLERN Norden ABSvetsarvägen 15, 2tr.SE-171 41 SolnaTel. +46 8 578 772 72Fax +46 769 43 45 47Sven.Edvardsson@zollern.comwww.zollern.com

Sweden

ZOLLERN GmbH & Co. KG

Postfach 12 20D-72481 Sigmaringen/GermanyTel. +49 75 71/70-0 Fax +49 75 71/70-602 info@zollern.dewww.zollern.com Z5

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