WITH REGULAR MAINTENANCE BY KERN

Reduce production downtime by half and ensure a long service life for your spindle

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Increase the service life of your spindle by a factor of 5 and save high repair costs.

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Benefit from ongoing maintenance to ensure the high quality of your work at all times.

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As a Kern partner, you will receive a replacement spindle within 12 hours in an emergency.

The world market leaders choose KERN

A small selection of our customers:

Customer logo Spindle repair and spindle service Bosch
Customer logo Spindle repair and spindle service BMW
Customer logo Spindle repair and spindle service Daimler
AMAG Austria Metal
Customer logo Spindle repair and spindle service Schaeffler
Customer logo Spindle repair and spindle service ZF
Airbus logo
Customer logo Kiefer Werkzeugbau
Liebherr customer logo
Premium Aerotec
Customer logo Leiber Group
Studer customer logo
SCANIA logo
MAN logo
Volvo logo

Why industrial companies around the world rely on KERN

Over the last 23 years, we have repaired over 16,000 spindles - 80% of which were large motor spindles. Many customers come to us with problems that even the manufacturer itself is unable to cope with. The main reason we can help them is that we can work with more than 2,900 brands and are familiar with over 500 failure patterns.

So we have seen every challenge before - and found the cause of every spindle failure.

Our case studies

DESPITE TOTAL LOSS

50 % cost saving compared to a new spindle

Company: Schaeffler Technologies AG & Co. KG
Industry: Movement and mobility
Schaeffler
Initial situation:
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One of the company's large 1,100 kg turning spindles was a total loss and could no longer be used. The cost of a new one was well over €120,000, which is why Schaeffler Technologies AG & Co. KG decided to repair it.
Procedure:
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After analyzing the cause, we began by rewinding the stator and completely refurbishing the motor.
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After all parts had been cleaned and replaced if necessary, we tested the machine on our state-of-the-art test site. Under real conditions, we were able to check the spindle and verify that it would function perfectly in use at our customers.
Result:
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Ultimately, the repair saved the company 50% of the costs that would have been incurred with a new purchase. At the same time, they received a spindle from us that was of the same quality as new and has now been in use for 7 years without any failures.
AFTER CONSTANT FAILURES

Spindle service life of over 30,000 hours guaranteed

Company: BMW
Industry: Automotive
BMW
Initial situation:
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The company constantly had to deal with spindle failures, which caused high costs and tied up a lot of human resources.
Procedure:
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We extensively modified and optimized the company's Weiss motor spindles. However, we quickly realized that the repairs did not really last long and breakdowns were still frequent.
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We then identified the actual problem in the spindle environment. Among other things, the hydraulics were preventing the spindles from working as desired.
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We advised the company to repair the machines, which led to a massive reduction in spindle failures.
Result:
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Costs and spindle failures were reduced by ⅓, which more than doubled the service life. Many spindles have now been running for over 30,000 hours and their precision has also improved significantly. In general, the company has become more flexible and is now less dependent on the manufacturer.
PRODUCTION WITHOUT DISRUPTIONS

Downtime reduced by over 70

Company: Airbus
Industry: Aerospace industry
Airbus
Initial situation:
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The company worked with large Kessler motor spindles, which showed recurring failure patterns. In the past, repairs were only carried out sparingly by other market players.
Procedure:
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The failure analysis showed that some of the spindles were leaking and had major vibration problems. We carried out extensive modifications and managed to bring the concentricity to below 1 µ - sometimes even 0.5 µ.
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We also refurbished the HSK holder so that the spindles now have a 340 mm arbor that runs with an accuracy of 1 µ.
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Finally, we applied a new coating to ensure a longer service life.
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But that wasn't all: during the course of the repair, we discovered that the problem was not only with the spindles themselves, but also with the floor on which the machines were standing. Following our advice, the floor was completely prepared and leveled.
Result:
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Failures have been reduced by 70% - as has the noise level of the spindles, which has been greatly reduced thanks to the minimal vibrations of less than 0.3 mm/s. Thanks to the improvements, the spindles can now work much longer and much more precisely. At the same time, there are hardly any more problems, which saves the company large sums of money every year.
WITH HIGH QUALITY STANDARDS

30 % cost saving compared to a new spindle

Company: Liebherr-International Germany GmbH
Industry: Mechanical engineering, vehicle construction, household appliances, building construction, civil engineering, hotels, mining, earthmoving, aerospace and transportation technology
Liebherr
Initial situation:
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Liebherr-International Deutschland GmbH used a Kessler motor spindle type SMS 090.32.4.FOS/F to manufacture their wide range of products. They had high demands on the quality of their products, which they were unable to meet as their spindle was constantly breaking down and not working precisely enough.
Procedure:
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After dismantling, we discovered that the clamping system was defective and the drawtube was bent. Among other things, we completely refurbished the shaft with HSK 63 mounting and installed a special hybrid bearing with Kronidur steel to make the spindle less sensitive to heat and ensure a longer service life.
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At the same time, we replaced all electronic parts as a preventive measure and renewed the rotary union with a Deublin system with a ceramic sliding disk seal.
Result:
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Thanks to our repair, the company paid 30% less than for a new spindle from the manufacturer - without having to compromise on quality. In the meantime, we have repaired several spindles for Liebherr-International Deutschland GmbH and brought them up to date, which has led to a massive reduction in breakdowns and a high level of cost savings.
DOWNTIMES GREATLY REDUCED

Express repair in 4 days

Company: ZF Friedrichshafen AG
Industry: Mobility
ZF Group
Initial situation:
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ZF Friedrichshafen AG is the largest transmission manufacturer in the world. Due to constant spindle failures, the company had high opportunity costs and regular delays in the entire production process.
Procedure:
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After dismantling, we cleaned all the individual parts and repainted them. This meant that the premium quality was also visible from the outside.
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We then laser-welded and ground the HSK 100 tool holder and the facing system. In this way, we achieved perfect concentricity of less than 1 µ at the front of the 340 mm test mandrel.
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Once all the modifications had been completed, we checked the spindle in an extensive test run on our Siemens test stand.
Result:
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Thanks to the repair, the company saved 30% of the costs that would have been incurred with a new spindle. At the same time, we were able to reduce downtime by ⅔ and achieve first-class spindle quality.

What other managing directors say about KERN

We have already worked with over 10,000 companies worldwide. Find out here what results we usually achieve and what you can expect when working with us.

We have asked your company for an emergency repair of a Weisser electrospindle. (...). The repair actually allowed us to restart our systems on Saturday morning at 10:30 am. This allowed us to continue production over the weekend and prevented machine downtime. (...) We particularly appreciated the availability, responsiveness and professionalism that you demonstrated. We would therefore like to thank you and look forward to working with you in the future.

Eric Schwarz Responsable Fournitures Prestations Industrielles, PSA Group

Dear Mr. Steeb, We are pleased to inform you that the spindle you repaired for us (on our Fehlamm P95 machine) was installed without any problems and is working perfectly. In our opinion, the repair was carried out to a very high quality and within the agreed time frame. Thank you very much for your good work.

Robert Gačnikar, GALERO

Congratulations and 1000 thanks to all participants for this fabulous performance. Many greetings from Brandenburg.

 Klaus Jacob, Team Leader Plant Engineering Schlote Group

Your way to us

Book an appointment

Date

Register for a suitable appointment via our website and arrange a non-binding initial consultation.

Consulting

Consulting

You explain your current situation to us and we will tell you exactly how we can help you.

Forecast

Forecast

Based on your description, we will provide you with an approximate initial forecast. We then take a detailed look at the spindle and draw up a cost estimate.

Implementation

Implementation

We dismantle your spindle quickly to find out where the problems occur. You will receive an overview of the necessary measures and repair costs.