press technology - ortlinghaus · multi-plate clutch-brake units. ortlinghaus is also the preferred...

Press Technology

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Otto Ortlinghaus established the Ortlinghaus Group in 1898. It

originally manufactured machine knives and tools. Since 1923

Ortlinghaus has been producing plates, which form the techno-

logical core of most of our products.

Today, we are a fourth-generation family-run company with more

than 550 employees and manufacturing sites in Germany, Swit-

zerland, and China. We are proud of our long history and have

structures and processes in place to ensure the long-term stability

of the Group. Our values and long-term targets, which comprise

stability, innovation, and growth, are aligned in this respect, too.

One of the most distinctive features of the Group is its collabor-

ative culture. Shareholders, management and employees alike

all have a firm commitment to this. In addition, we promise our

customers to always and unwaveringly protect the Ortlinghaus

brand, which is embodied in the quality of our products. Since

the foundation of our company, we have repeatedly left our mark

on technology history: As early as 1932, Ortlinghaus produced

multi-plate clutches as a complete machine element.

However, we achieved worldwide renown with the Sinus®

plate, which had a substantial impact on press technology. The

last decade has seen many breakthrough developments in the

field of mechatronic systems, especially in the press technology

and marine technology sectors. One recent example of this is the

Pa.go mechatronic closed-loop control system for clutch-brake

units in large automotive presses.

Next to the press technology sector, Ortlinghaus is active in the

following industries:

• Marine technology

• Agriculture & Forestry technology

• Construction technology

• Oil & Gas technology

• Materials handling technology

• Mining technology

Ortlinghaus Group.

Founded in: 1898

Employees: > 500

Subsidiaries: Ortlinghaus (U.K.) Ltd. / England Ortlinghaus France / France Ortlinghaus AG / Switzerland Ortlinghaus Drive Technology (Shanghai) Co., Ltd / China Ortlinghaus Drive Technology India Pvt.Ltd. / India OOO „Ortlinghaus RUS“ / Russia Manufacturing: Wermelskirchen / Germany Gams / Switzerland Shanghai / China

Sales: Worldwide via agencies

4 5

We have been active in the press technology industry for more

than 75 years. Today, we offer products across the entire spectrum

of mechanical presses and servo presses, from clutch-brake units

and brakes to compact drives and mechatronic control technology.

We are the only manufacturer to successfully combine building

clutches with producing plate linings and mechatronic systems.

Ortlinghaus has developed a reputation for quality throughout the

world – and we are highly motivated to meet and exceed our pre-

vious standards. We work with our customers to create custom

solutions that are characterized by innovation and superior engi-

neering.

Our worldwide network of more than 25 subsidiaries, sales part-

ners and service hubs ensures our high degree of customer service.

Industry Overview and Business Units.

Automotive presses

These large flywheel presses are mainly used for the production of

large and complex forming parts for automakers. The drivetrain

system usually consists of hydraulically actuated, wet-running,

multi-plate clutch-brake units. Ortlinghaus is also the preferred

supplier of most worldwide press manufacturers and European

automakers.

>> Page 6

Servo presses

Servo presses are used in the automotive industry as well. These

press types generate forming energy directly by large high-

torque electrical motors, without the need to install a flywheel

and clutch-brake unit. For safety reasons, it is necessary to install

a reliable safety brake. Ortlinghaus is the leading manufacturer of

these brakes used in the automotive industry and supplies several

press manufacturers with both standard and specially designed

safety brakes, too.

>> Page 9

C-frame presses

C-frame presses are normally available for capacities from 40 to

250 tons and equipped with flywheel drivetrain solutions. The

presses can be operated manually or automatically. In recent

years, Ortlinghaus has supplied many dry-running and wet-run-

ning clutch-brake units. Ortlinghaus has newly developed the

Cee.go System, which is a new and innovative clutch-brake unit

for these machines.

>> Page 8

Forging presses

Mechanical forging presses with flywheel drive are suitable for

the mass production of forging parts. Ortlinghaus provides a

wide range of products for mechanical forging presses, such as

clutch-brake units, complete press drives and separate wet-run-

ning clutches and brakes. Ortlinghaus is the only manufacturer

of plates who is able to deliver very large dimensional plates for

clutches with a torque range of up to 1.4 million Nm.

>> Page 10

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Applications.

Automotive presses

Pa.go

Features: · Preventive maintenance

· Wear measurement

· Electronic slip control

· Error diagnosis

· Interface

· Diagnosis of clutch-brake-unit data

· Closed-loop control of Pa.go

· Convenient touch display

· SD card slot for data recording

· Various sensor and bus interfaces

>> Page 21

Compact-drive Series 046

Torque: up to 100,000 Nm

Features: · Complete press drive with flywheel,

planetary gear and pneumatically

actuated clutch-brake unit

· Generation and transferral of

forming energy for the kinetic

energy of the rotating flywheel

>> Page 17

Main drive locking clutch Series 055

Torque: 11,000 - 100,000 Nm

Features: · Transferring press ram weight to press

frame at stationary press

· Formfit torque transmission, switchable

in each press ram position, switch position

monitored by sensors on two channels

>> Page 13



Features: · Complete press drive with flywheel, planetary gear and clutch-brake unit

· Hydraulically actuated

· Generation and transferral of forming energy for the kinetic energy of the rotating flywheel

>> Page 17

Clutch-brake unit Series 123

Torque: 3,000 - 630,000 Nm

Features: · Hydraulically actuated, wet-running,

high thermal load allowed

· Acceleration and deceleration

of press ram in single-stroke

mode

>> Page 16

Control units Series 0086 - 392

Features: · Fast filling and draining of the piston chamber of the clutch-brake unit

· Control of the clutching and

breaking function of the

clutch-brake unit

· Including safety valve

>> Page 20

Standard power pack

Features: · Power packs with oil tank

capacity of up to 630 liters

>> Page 20 - 21

Customized power pack

Features: · Power packs with oil tank capacity of

up to 2,000 liters

· Also power packs for machine

lubrication available with oil tank

capacity of 1,500 liters

>> Page 20 - 21

Diagnostic port

Features: · Interface for connection measurement equipment

· Transmits speed-signals,

pressure-signals and

PSW-signals

8 9

Applications.

C-frame presses



Features: · Wet-running, high thermal

load allowed


of press ram in single-stroke mode

>> Page 16

Clutch-brake unit Cee.go

Torque: 5,200 - 28,000 Nm

Features: · Acceleration and deceleration of

press ram in single stroke mode

· Wet-running, multi-plate,

pneumatically actuated

>> Page 19



Features: · Acceleration and deceleration of

press ram in single-stroke mode

· Single-disc, dry-running clutch-

brake unit, high own moment of

inertia, organ, subjected to wear

for each engagement process

>> Page 18



Features: · Acceleration and deceleration


· Single-disc dry-running clutch-brake

unit, high moment of inertia, organ,

subjected to wear for each engage-

ment process

>> Page 18

Servo presses

Brake Series 170

Torque: 1,875 - 60,000 Nm

Features: · Presses driven directly by high-torque

electrical motors

· Medium-sized presses from press force

250 tons up to large presses with press

force 2,500 tons

· Preferred in large servo presses of

automakers

>> Page 14

Prot.act brake

Torque: 10,000 Nm - 63,400 Nm

Features: · Hydraulically released dry-running

brake with friction pads

· Designed for mounting on front side

of torque motor, 2 flange surfaces

· Suitable for siemens-motor

· Similar design principle to

approved 170 series

>> Page 15

Hydraulic multi-plate brakeSeries 022

Torque: 1,000 - 30,000 Nm

Features: · Plates with sintered,

or organic lining

· Hydraulically released

multi-plate brakes

1110

Applications.

Forging presses


Torque: up to 1,400,000 Nm

Features: · Complete press drive with

flywheel, planetary gear,

and clutch-brake unit

· hydraulically actuated

· Generation and transferral of

forming energy for the kinetic

energy of the rotating flywheel

>> Page 17



Features: · Wet-running, hydraulically actuated,

high thermal load allowed



>> Page 16

Clutch Series 127

Torque: up to 1,400,000 Nm

Features: · Acceleration of press ram in

single-stroke mode

· Transferring forming energy from

flywheel to press ram

· Hydraulically actuated clutch and

brake with wet-running sintered linings

Brake Series 128


Features: · Deceleration of press ram

in single-stroke mode

· Transferring forming energy from

flywheel to press ram

· Hydraulically actuated clutch and

brake with wet-running sintered linings

Standard power pack

Features: · Power packs with oil

tank capacity of up to

630 liters

>> Page 20 - 21


Features: · Power packs with oil tank capacity of

up to 2,000 liters

· Also power packs for machine lubrication

available with oil tank capacity of 1,500 liters

>> Page 20 - 21


Features: · Fast filling and draining of the piston chamber of the clutch-brake unit

· Control of the clutching

and breaking function of

the clutch-brake unit


>> Page 20


Torque: 11,000 - 100,000 Nm

Features: · Transferring press ram weight to press

frame at stationary press

· Formfit torque transmission, switchable

in each press ram position, switch position

monitored by sensors on two channels

>> Page 13

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According to DIN EN 692, the relevant safety standards for press

engineering, a mechanical restraining device must be present in

mechanical presses for repair work and work between the two

halves of the tool. The Ortlinghaus linear motion lock from the

series 055 is an approved restraining device according to the

German employers’ liability insurance association. The linear

motion lock is used to positively lock a shaft to the fixed housing

of a clutch so that the shaft cannot rotate. This is particularly

desirable for presses to ensure that the press ram will not move

in an uncontrolled or unintended manner during servicing or

maintenance work between the two halves of the die.


The Ortlinghaus ram locking mechanism enables a variable

locking of the press ram in any position, with a short actuating

time of about three seconds. The linear motion lock is matched

to and integrated into the machine’s drivetrain. It is engaged or

disengaged hydraulically. The state of the ram locking mechanism

actuated by oil pressure, either locked or unlocked, is detected

using inductive travel sensors and transmitted to the machine

control unit.

Length: 195 - 325 mm

Bore diameter: 120 - 260 mm

Outside diameter: 480 - 900 mm

Torque: 11,000 - 100,000 NmT

For dry- and wet-running clutches and brakes, Ortlinghaus is able

to provide a very comprehensive range of plates. The plates and

the friction surface are important functional elements in every

clutch and brake, and have been developed in many different

ways since the early days of clutches and brakes. The choice

of friction system depends on the application: in general, one

plate with friction material works together with a counterplate of

steel or cast iron. The inner and outer plates are mounted with

Torque: 150 - 1,600,000 Nm

Plates

the other drive components by lugs and slots, and the spline

is in accordance with DIN 867 and DIN 5480 as well as other

standards. In addition, holes in the plate for studs and special

shapes in accordance with customer requirements are available.

Combined with a multi-plate clutch or brake, these plates come

in a multitude of different dimensions, friction combinations, and

surface patterns.

Lock

ing

torq

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5 m

odel

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its

dim

ensi

ons

10,000 100,0001,000

50

100

1,000

3,000

10

500

200,00050,0005,000

Outer Ø, bore Ø and length [mm]

Locking torque MÜV [Nm]

Outside diameter [mm]

Bore diameter [mm]

Length [mm]

T

Fric

tion

diam

eter

[ m

m ]

Torque [Nm]

Plates in press technology

100

10

10,000

1,000

C-frame presses

Servo presses

Forging presses

Automotive presses

50,000

1,000,000 10,000,000100,00010,0001,0001005,000500 500,000 5,000,000

50

500

5,000

14 15

With the 170 model series, Ortlinghaus has developed a

hydraulically released and spring-loaded brake with dry-running

friction elements specifically developed for servomotor-driven

presses. The brake is normally used as a holding brake for

stationary machines, but can also be used as a safety brake for

emergency stops.

The brake is characterized by its minimal space requirements,

low moment of inertia of the parts rotating with the drive motor,

and short switching times. Designed as a multi-disc brake, it can

Prot.act is a servo brake which has been developed specifically for

the dimensions of the Siemens torque motors 1FW3 and 1FW4.

They are hydraulically actuated, spring-loaded and dry-running

multi-block brakes.

We have based the Prot.act on the tried-and-tested engineering

foundations of our servo brake series 170, which has been

successfully used in servo presses for many years.

Servo brake Series 170

Servo brake

transfer high torque. Thanks to its enclosed design, the brake

also operates with low external pollution and minimal noise. It

conforms to the European safety standard DIN EN 692 and is

largely maintenance-free.

Due to the design format with friction pads, the axial mobility

of the friction elements when operating the brake is possible

without moving metallic contact points. Thanks to the dry-

running principle, no undesired residual torque develops during

normal operation of the press with the brake open.

The Prot.act has the function of a linear motion lock in stationary

presses. It has extremely fast reaction times due to the directly

flanged press safety valve.

Because of the multi-block design principle, which uses friction

pads, the axial mobility of the friction blocks when operating the

brake is possible without moving metallic elements.

Length: 94 - 284 mm Length: 161 - 172 mm

Bore diameter: 65 - 160 mm Bore diameter: 130 - 220 mm

Outside diameter: 284 - 762 mm Outside diameter: 680 - 1,125 mm

Torque: 1,875 - 60,000 NmT Torque: 10,000 - 63,400 NmTRotations per minute: 350 - 3,000 min-1n Rotations per minute: 0 - 1,500 min-1n

Brak

ing

torq

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0 m

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its

dim

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10,0001,000

50

100

1,000

3,000

10

500

100,00050,0005,000

Outside Ø, bore Ø, and length [mm]

Braking torque TB5 [Nm]

Brak

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torq

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to

dim

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ons

10,0001,000

50

100

1,000

3,000

10

500

100,00050,0005,000


Braking torque TB5 [Nm]


Length [mm]


Bore diameter [mm]

Length [mm]

16 17

The hydraulically actuated clutch-brake units from the series 123

work exclusively with wet-running, oil-cooled plates with fric-

tion pairing steel/sinter.

The advantages of having a multi-plate construction and oil-

cooled friction pairing steel/high-performance sinter in addition

to actuation with pressure oil at 60 bar are seen in the product’s

extraordinarily compact design and high operating efficiency. The

series offer high torque, low moment of inertia and high switch-

ing speeds with a minimal need for maintenance. Model series

123 represent a good alternative to dry-running combinations.

The Ortlinghaus compact drive from the series 045 and 046 is

a ready-to-install drive unit consisting of a clutch-brake unit, a

flywheel and a gearbox. This drive unit is used in metal-forming

machinery such as eccentric presses in which the work capacity

of the machine is derived from a flywheel. In comparison to

spur gearing, the planetary gears used in the compact drives

save installation space and have smaller rotating masses.

High rotational speeds make it possible to keep the size of

the flywheels to a minimum and, when used with Ortlinghaus

clutch-brake unit, results in compact drive units with a broad

power spectrum. The individual components (clutch-brake unit,

flywheel with bearings and planetary gearing with output hub)

are matched to each other in order to suit the characteristics

Series 123Series 045 & 046

They operate in sealed housings which prevent leakage and keep

switching noise to a minimum.

With these benefits, the clutch-brake units are suitable for a

broad range of applications in press, shear press, and large

press engineering as well as in embossing presses and drawing

presses.

The series was designed and constructed according to interna-

tional safety regulations and approved by the German employers’

liability insurance association.

of the machine in a space-saving assembly. These series have

proven themselves in thousands of metal-forming machines

over the years.

Two different compact drive designs can be used:

• Pneumatically actuated single-plate clutch-brake unit (dry-

running) for machines which mainly work in continuous

operation.

• Hydraulically actuated clutch-brake units (wet-

running). These virtually wear-free, low-maintenance units are

particularly well suited for medium and large presses which also

work in single-stroke mode.

Torque: 3,000 - 600,000 Nm

Rotations per minute: 350 - 1,700 min-1

Outside diameter: 199 - 1,180 mm



Tn

Clut

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023

and

123

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10,000 100,0001,000

50

100

1,000

3,000

10

500

1,000,000500,0005,000 50,000


Clutch torque MÜ [Nm]

Length: 663 - 1,450 mm


Torque: up to 700,000 Nm T

Out

put

torq

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100,00010,0001,0005,000

1,000,000500,00050,000

Pneumatic compact drive 046 model series

Hydraulic compact drive 045 model seriesOutside diameter [mm]

Bore diameter [mm]

Length [mm]

Torque [1000 Nm]

18 19

The pneumatically actuated clutch-brake units from the tried-

and-tested series 400, 406, and 420 have been further developed

to meet the increasing performance and safety requirements in

press engineering. The 406 series offers optimally high clutch

and brake torques in small dimensions – making it a high-

performance compact design. Today, the model series represent

the traditional drive unit for stamp and form press engineering

and offer excellent adaptability in the following areas:

• Twelve-point attachment of the friction plates or two-point

attachment with straps of equal or different lengths provides

flexibility for various applications.

Cee.go is an innovative clutch-brake unit for C-frame presses. The

system is wet-running and pneumatically actuated and increases

the Overall Equipment Effectiveness.

The product combines the advantages of wet-running steel /sinter

plates and the problem-free actuation through compressed air.

The friction lining consists of plates with the friction pairing steel/

Series 400 & 406 & 420

• Friction element selection depending on shape and material

to obtain the most effective service life with quiet switching

under all operating conditions. The friction pad version is

recommended for machines with high dynamic loading or load

reversals under continuous operation.

• Attachment to the shaft or crankshaft with the aid of either keys

and lateral attachment or a clamping set – these being fitted

on the clutch side for the 420 series and on the brake side for

the 406 series.

sinter for a wet-running operation. The plate stack is virtually

maintenance-free, thus reducing press downtime.

The Cee.go boasts a series of technical innovations and advantages

that make its operation more efficient and cost-effective.


Rotations per minute: 500 - 3,200 min-1



Length: 48 - 662 mm

Tn

Torque: 5,200 - 28,000 Nm

Rotations per minute: 215 - 400 min-1

Outside diameter: 360 - 510 mm



Tn

Clut

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400

, 406

, and

420

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1,000 10,000 100,000100

50

100

1,000

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500

300,000500 5,000 50,000



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10,0001,000

50

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10

100

100,00050,0005,000

1,000




Bore diameter [mm]

Length [mm]


Bore diameter [mm]

Length [mm]

20 21


Function· Fast filling and draining of the piston

chamber of the clutch-brake unit

· Control of the clutching and breaking

function of the clutch-brake unit


Hydraulically actuated, wet-running Control: Hydraulic open-loop progressive control


Torque: 3,000 - 630,000 Nm

Features: · Wet-running, hydraulically actuated clutch-brake unit. Constant cooling-oil supply enables a high thermal load. Ideal for single-engagement flywheel presses

· Technology standard in the

automotive press industry

Cooling oil

Oil return flow

Pressure oil

Systems comparison.Systems comparison.

Cooling oil

oil return flow

Pressure oil

Pa.go

Features: · The Pa.go System consists of a servo

pump, a closed-loop control unit and a

servo controller

· Pa.go enables the precise closed-loop con-

trol of clutch-brake units in large presses.

While such control brings considerable

benefits during normal operations, it also

helps to counter the impact of changes

in operating conditions like temperature,

wear, oil leakage etc.

Hydraulically actuated, wet-running Control: Pa.go, Mechatronic closed loop control


Torque: 3.000 - 630.000 Nm

Features: · Wet running, hydraulically actuated clutch-brake unit. Constant cooling-oil supply enables a high thermal load. Ideal for single-engagement flywheel presses

· Technology standard in the

automotive press industry

Option 1

Standard power pack



630 liters

Standard power pack



630 liters

Rotary inlet Hydraulic rotary inlet

Option 2



capacity of up to 2,000 liters

Pressure oil

Option 1

Standard power pack


capacity of up to 630 liters

Option 2


Features: · Power packs with

oil tank capacity of

up to 2,000 liters

22 23

We have been operating successfully for more than 100 years –

and we are proud of this achievement. Experience, structure, pro-

cesses, and systems are key words in explaining what makes us and

our products stand out. We like to call it the Ortlinghaus factor.

Experience

Practical experience and acquired knowledge form the basis of

our success – but we never rest on our laurels. We are ext-

remely well versed in press technology applications and their

requirements. That is why we are able to develop completely

new, innovative solutions for our customers or make intelligent

modifications to existing products and systems with the same

degree of success.

Industry management

Sales and order processing at Ortlinghaus are structured in a

unique way, with a focus on industry management. Our staff are

highly specialized in particular sectors and concentrate exclusively

on trends and requirements within their designated industry.

The industry management system is supported by technology

experts who are each dedicated to a relevant field of technology

and its technical challenges.

Press technology is one of our largest segments. We have out-

standing expertise in this field, comply with recognized industry

standards, and can boast worldwide references.

Processes

Systematic development processes are crucial for Ortlinghaus. We

constantly analyze our markets, the trends in key areas of tech-

nology, and our customers’ needs and requirements. The results

shape and optimize our new product developments and versions

of existing models.

Systems

Our systems for designing clutch and brake systems are one of a

kind within the industry. They enable us to calculate products pre-

cisely and align them with all the relevant application parameters.

Our new product developments are recorded, structured, and

documented in our own software systems. This speeds up the

design process for any additional versions which are developed

in the future.

The Ortlinghaus Factor.

24 25

Ortlinghaus innovations process.

Technology ExpertsPlates & Hydraulics

Operation & Series production

Industry Manager & Sales PartnerIndustry Manager & Sales Partner

Man

ufac

turin

g

Specif cation

Technical & Commercial

Industrial Engineering

& Sourcing

Engi

neer

ing

& S

imul

atio

n

Prototyping & Testi

ng

Quality Improvement

Thermal limits

| Test

bench

| O

il te

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Mec

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Mec

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Ortlinghaus M

anufacturing and Supply-Chain Management

Ortli

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s Res

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Client task &Market requirement

Prot

Sales Groups

Market launch with customer

26 27

Quality, Health, Safety and Environment.

An integrated management system (IMS) that takes into account

all processes is the basis for Ortlinghaus’ corporate policy. Quality,

occupational health and safety, and environmental protection

play crucial roles for our company.

We have analyzed and documented all relevant processes in the

value chain. Our IMS is based on the resulting summary of pro-

cess descriptions, plans, procedures and guidelines as well as the

Ortlinghaus Management Manual.

The management system is the basis for all business activities

in our company and for our relationship with our customers. It

ensures that all customer-oriented product and manufacturing

specifications are reflected in elaborate instructions regarding

quality assurance and quality control and that they comply with

the relevant operating instructions and quality standards of the

Ortlinghaus Management System.

Our quality management system is based on the ISO 9001 stan-

dard. In the area of environmental protection, we are certified at

the Wermelskirchen site according to ISO 14001.

Ortlinghaus assigns the highest priority to occupational health

and safety. We live up to our principles in this area in our daily

conduct. At Wermelskirchen, we are currently working toward

ISO 18001 certification.

Our goal is to minimize the impact of our activities on the envi-

ronment. For this reason, all employees of the Ortlinghaus Group

have committed themselves to complying with essential environ-

mental guidelines. In addition, all our processes in Wermelskirchen

are certified accordingly.

We are convinced that long-term success can be achieved only

through the right balance of economic, ecological and social

conduct.

Ortlinghaus-Werke GmbH

Kenkhauser Str. 125

42929 Wermelskirchen

Germany

Phone: +49 (0)2196 85 - 0

Fax: +49 (0)2196 855 - 444

[email protected]

www.ortlinghaus.com

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press technology - ortlinghaus · multi-plate clutch-brake units. ortlinghaus is also the preferred...

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