KettenWulf GmbH Division Ferlacher Förderketten A-9163 Unterbergen 25 Austria T + 43.(0) 4227.25 27 F + 43.(0) 4227.35 94 [email protected] www.kettenwulf.com KettenWulf NV Division Dyna Chains Venecoweg 20A - De Prijkels E17 B-9810 Nazareth Belgium T + 32.(0) 9.243 73 73 F + 32.(0) 9.221 56 03 [email protected] www.kettenwulf.com Hangzhou Wulf Chain Co. Ltd. 40 Tangning Road, Yunhe Town Yuhang District 311102 Hangzhou P.R. China T + 86.(0) 571.861 899 00 F + 86.(0) 571.861 899 50 [email protected] www.kettenwulf.com 02 04 06 08 10 12 14 16 18 22 Wulf Chain USA, LP The Woodlands at Riverside 8110 Troon Circle SW, Suite 170 Austell, GA 30168-7852 USA T +1.678.433 0210 F +1.678.433 0215 [email protected] www.wulfchain.com KettenWulf Representative Office Czech Republic Dukelských hrdinu˚ 2780/26 CZ-690 02 Brˇeclav Czech Republic T + 42.(0) 519.32 50 95 F + 42.(0) 519.32 50 96 [email protected] www.kettenwulf.com KettenWulf Representative Office Poland ul. Ogrodowa 34 B\ 4 PL-65-001 Zielona Góra Poland T + 48.(0) 68.325 43 37 F + 48.(0) 68.325 43 37 [email protected] www.kettenwulf.com KettenWulf Representative Office Japan Monoh 4-chome, 14-13 Minoh-shi Osaka 562-0001 Japan T + 81.72.796 24 24 F + 81.72.722 20 99 [email protected] www.kettenwulf.com Focus on the KettenWulf Group From left to right: Ansgar Wulf, Julia Wulf, Tobias Wulf KettenWulf Betriebs GmbH Export Division Industriestraße 41 D-28876 Oyten Germany T + 49.(0) 4207.608-0 F + 49.(0) 4207.608-149 [email protected] www.kettenwulf.com GB Photos: Erik Hinz, Münster; KettenWulf, Kückelheim; Michael Gehrig, Lennestadt Due to steady technological progress, all of the product information and technical specifications in this catalogue are subject to change. The use and applicability of these technical specifications is incumbent on your own responsibility. Also, we disclaim any errors due to misprints or other causes. Reprints, in whole or in part, require the written approval by KettenWulf. KettenWulf Betriebs GmbH Zum Hohenstein 15 D-59889 Eslohe-Kückelheim Germany T + 49.(0) 2973.801-0 F + 49.(0) 2973.801-228 [email protected] www.kettenwulf.com Contents Contacts worldwide About our company KettenWulf world-wide Partners to industry KettenWulf conveyor chains KettenWulf roller chains KettenWulf sprockets What we can do to assist you Industrial applications Special industry solutions Our production at a glance Research and development Contents From left to right: Ansgar Wulf, Julia Wulf, Tobias Wulf 02 04 06 08 10 12 14 16 18 22 KettenWulf world-wide Partners to industry KettenWulf conveyor chains KettenWulf roller chains KettenWulf sprockets What we can do to assist you Industrial applications Special industry solutions Our production at a glance Research and development KettenWulf – trustworthy and reliable KettenWulf: A name which has been synonymous with superior product quality in the manufacturing of chains and sprockets for more than 80 years. A name also signifying customer focus, reliable product quality, service and improved customer profitability. With this in mind, we concentrate our attention on those factors which are relevant for both current and potential customers – and it is these factors that form the basis for all our activities. Trust in technology: In our world-wide production and quality management, we have always placed great importance on the use of leading-edge technology. Providing the best possible quality to our customers is an integral part of our company’s commitment, and we employ state-of-the-art machine tools and production methods to achieve this goal. Quality by intelligence: Our staff is our capital, representing our company in all phases of our cooperation with you, the customer. Our sales engineers are flexible and are always ready to give their very best to meet your needs. We put our creativity and our staff’s dedication at your disposal in developing tailor-made solutions for your company. We are only satisfied with our work if you are fully satisfied, too. Clients first: Anyone who has had business with our company will know how seriously we take this phrase. We do not see your questions and requests as problems, but as a challenge. We are there for you whenever you need us – always and at any time. We will convince you of the efficiency and reliability of our products over and over again by meeting your requirements. We review our service and product range permanently to ensure that our customers’ demands are met fully. Our aim is to always give our best for you. Profitability and result oriented: Each investment you make in cooperating with our company should always be an appreciable investment in improvement. This gives you security of investment and costs – another good reason for placing your trust in a business relationship with our company – a relationship intended to last. Günter Wulf President 02|03 KettenWulf was founded in Kückelheim, Germany, in 1925. Thanks to powerful economic growth in the second half of the 20th century, the company developed from a small sized factory into a leading brand producer of chains and sprockets. Today, the KettenWulf Group, with six production facilities in Europe and Asia, is a market leader and one of Europe’s largest producers of conveyor chains, roller chains and sprockets. More than 900 employees develop, produce and market tailor-made conveyor and drive engineering solutions all around the globe. KettenWulf world-wide The main factory in Kückelheim not only houses the company headquarters, but also the ›KettenWulf Competence Center‹. This provides world-wide support for customers in all technical issues. Kückelheim, with a production area of 25,000 square metres and a staff of roughly 500, is the largest production facility of the worldwide KettenWulf Group. KettenWulf in Ferlach, Austria: where high-quality chains for various applications and industrial sectors are produced here. From the heart of Germany to Europe and Asia With its production facilities in Europe and Asia and global sales network, KettenWulf is one of Europe’s leading and largest manufacturers of conveyor chains, drive chains and sprockets. We are where our markets are. Our expansion strategy serves the needs of our customers worldwide. We are always available wherever we and our high-quality developments and products are needed. This is why KettenWulf has succeeded in establishing a strong global focus. Our production and sales activities are organized across many countries all around the world. You can find us in Germany, Belgium, France, Austria, the Czech Republic, Poland, the USA, Japan and China – and we aim to expand even further... Illustration top left: Our central European storage facility in Ghent, Belgium. This modern warehouse and administration complex provides space for more than 7,000 pallets and has more than 9,000 square metres of storage area. The highly modern, fully-automated highbay ware-house has improved KettenWulf’s supply capabilities and gives us even greater flexibility. Illustration top right: Production and sales facility in Hangzhou, China, just two hours drive from Shanghai. The green areas show the countries to which KettenWulf exports its products. Production/ branch office Sales agency 04|05 KettenWulf as a developer and manufacturer of chains and sprockets provides tailor-made solutions in the conveyor and drive engineering sector. Since the individual requirements of every customer are different, KettenWulf provides customized product solutions for all industrial sectors. Our engineers and technicians develop special chain systems, adapted to suit specific environmental conditions. Partners to industry We are partners to all sectors of industry. For example, in the steel production sector: our conveyor chains move multi-ton sheet-steel coils at a temperature of 1,000° C precisely and reliably through the various production stages. Production and management processes certified in accordance with DIN EN ISO 9001:2000, together with the ›KettenWulf Competence Center‹ in Kückelheim, ensure that KettenWulf’s high quality standards are adhered to all around the world. Specialist engineers at the Competence Center offer their expert knowledge for our top-class product developments world-wide. Conveyor chains, roller chains and sprockets Almost every industrial sector benefits from our know-how. Wherever things need to be moved, conveyor or transmission engineering is involved. We commit our know-how and more than 80 years of experience to the development of high-quality products in order to sustainably enhance product performance and service life. From the experience we have gained over decades, we know what chains and sprockets need to accomplish under the most extreme conditions. We also apply our know-how to professional motorcycle racing – with success. Today, many motorcycle professionals prefer to use our products and are rewarded by success, too. And so, due to the steadily growing demand for our products in this sector, we have continuously extended our product range. Our Belgian subsidiary “DC AFAM NV” now sells ›DC‹ and ›AFAM‹ roller chains, sprockets and accessories for the motorcycle industry all over the world. 06|07 KettenWulf is a leading manufacturer of high-quality conveyor and transport chains. Our chains are used in a broad range of applications in a wide variety of industries – from automobile production, through bulk material handling conveyors, right down to woodworking. Since the individual requirements of our customers are different, KettenWulf mainly provides customized product solutions in this sector. We develop special conveyor and transport chains, adapted and optimized to suit your specific requirements. KettenWulf conveyor chains Low-maintenance and lubrication-free chains provide economical and ecological advantages as well as cost reduction in the service and maintenance sector. This illustration shows an example of lubrication-free technology for the escalator industry. Tailor-made precision for all industrial sectors KettenWulf develops and manufactures special conveyor and transport chains of all types and sizes, for applications in all industrial sectors. We also manufacture standard chains to DIN, ISO and ANSI specifications. Our product range includes galle chains, draw-bench chains, block chains, lantern pinion, lifting chains and hinged gear racks for waterway locks and weirs. Figure 1: chain for the cement industry 1 2 3 4 5 6 7 8 Figure 2: conveyor chain for pretreatment and electrocoating equipment Figure 3: Lifting chain for weir installations Figure 4: Double-strand chain for paper roll transport Figure 5: Forming section chain for insulating material industry Figure 6: Step chain for escalators Figure 7: conveyor chain for final assembly in the automotive industry Figure 8: Steel mill chain for transporting coils 08|09 From the use in industrial production plants right through to the use in agricultural machinery – KettenWulf offers the ideal roller chain for your particular requirements. Whether you want to use a chain subjected to continuous stresses or with a high resistibility against temperature changes and corrosion – KettenWulf always has the perfect solution. We offer an extensive range of roller chains in all sizes for a wide variety of applications. We offer you roller chains according to DIN and international standards. KettenWulf roller chains KettenWulf – your partner for high quality roller chains. Quality ensuring maximum service life High performance roller chains and bush chains for drive and conveyor systems are available from stock. Every day new items are developed and applied for special applications successfully. We produce roller chains up to size 400 with 127 mm pitch, oilfield roller chains and marine-diesel roller chains. Figure 1: Hollow-pin chain 1 2 3 4 5 6 7 8 Figure 2: Sharp-top roller chain Figure 3: Glass-oven chain Figure 4: Accumulation chain Figure 5: Polymer Block chain Figure 6: Oilfield roller chain Figure 7: QX-ring roller chain Figure 8: Gripper chain 10|11 Sprockets are a crucial factor in the efficiency and service life of any chain system. For this reason, we at KettenWulf focus on manufacturing our own sprockets since chain and sprockets from one source ensure a maximum of operational hours. Besides sprockets in all DIN/ISO/ANSI standard pitches and tooth forms, our product range includes tailored solutions with optimum tooth shapes and sprocket sizes, of course. Whether you need sprockets of high-grade materials, with special heat treatment, and additionally indiction-hardened teeth – KettenWulf always has the right solution for you. KettenWulf sprockets KettenWulf produces sprockets in various dimensions and designs according to customer requirements. Optimum tooth designs for all chain types We provide matching sprockets for all types of chain. Besides producing sprockets with DIN standard tooth forms, our CNC machines can also be used to produce sprockets with optimized tooth shapes. Products made of high-grade materials, heat treated and with additionally induction-hardened teeth are the standard in our company. Figure 1: Sprocket with detachable root segments Our production spectrum includes all sprocket designs, including sprockets with one-sided hubs and sprockets with two-sided hubs, split-type sprockets, sprockets with detachable tooth shells or tooth segments, shear-pin sprockets, pinion sprockets, as well as sprockets with patented noise-reduction features and wheel systems. 1 2 3 4 5 6 7 8 Figure 2: Duplex-sprocket Figure 3: Triple strand sprocket Figure 4: Sprocket with intermediate gaps and lightening holes Figure 5: Sprocket with saw toothing Figure 6: Pinion sprocket Figure 7: Sprocket with segmented rim and intermediate gaps Figure 8: Sprocket with patented noise reduction 12|13 Our work is characterized by competence, experience, efficiency and a high degree of commitment. Our products ensure your long-term, sustainable success. And for this reason, we offer you the use of our services from the very start, making us a reliable partner for your conveyor and drive engineering needs. Both our advisory services and the product grades we offer are adapted to meet your individual wishes and requirements. What we can do to assist you Do you have any questions regarding state-of-the-art conveyor and drive technology and are you looking for a partner with a worldwide organization network to assist and support your projects? Then do not hesitate to contact us – we consider technical advice and related services to be an essential part of our work. Our experienced engineers and technical staff are always available to answer your questions. Development, production, installation, after-sales KettenWulf combines a whole range of highly-specialized fields of expertise to support your projects. We have effectively networked individual services to achieve the very best solutions for your products: » Development: we develop and design the best possible conveyor and drive engineering solutions correspondent to your wishes and requirements. » Production: we use state-of-the-art technology to manufacture special conveyor chains, drive chains and sprockets for you. » Installation: if you wish, our reliable and trust worthy partners can handle your on-site installa tion work. » After-sales: upon request, we can inspect and check the condition of your chains and sprockets with respect to their functional capability and remaining service life. KettenWulf networks four fields of competence to provide its customers with the best service possible – from product development, through hightech manufacturing using laser cutting machine tools and stand-alone robot workplaces, right up to on-site inspection of the installed chains and sprockets. Teamwork – not just a word at KettenWulf. Complex problems often require complex solutions. Working in highly-qualified teams ensures reliability and efficiency on the road to finding the most suitable solution. 14|15 Our conveyor chains, roller chains and sprockets are in use all over the world. Innovative developments, high quality materials and manufacturing precision are what make the difference. That is why many well-known manufacturers from all sectors put their trust in KettenWulf’s products and services. These include manufacturers of: » escalators » bulk material handling equipment » automobiles and parts » steelworks equipment » weir and floodgate equipment » timber handling and woodworking equipment » papermaking and handling equipment » insulating material equipment Industrial applications Chains for the escalator sector: London, Madrid, Lisbon, Prague, Buda-pest, New York and St. Petersburg – our escalator and moving walk-way chains move billions of passengers. Products for all industrial sectors – world-wide Chains for the steel industry: from slat conveyor for transporting ore and scrap metal right up to wire cooling chains for wire production processes, our chains are used in virtually all steel and iron industry processes. Chains for the paper industry: in this industry, chains are used in conveyors for recycled paper, for mechanical shredding of logs and for the transport of paper rolls. Chains for the timber and woodworking industry: from the transportation and debarking of logs, through sawing, right up to palletizing boards and plates, it is impossible to imagine wood processing without conveyor and roller chains. Chains for the insulating material industry: our special chains reach highest lifetime facing extreme conditions. Chains for bulk material handling industry: whether it is coarse or fine grained bulk material which has to be moved, and whether the material has corrosive or abrasive characteristics – KettenWulf always has the right solution, even for transporting hot materials. Chains for the packaging industry: precision and speed count in packaging lines – KettenWulf provides chains specially designed to meet these extreme requirements. Chains for weirs and floodgates: KettenWulf also offers maintenance-free technology solutions for use in the worst conceivable conditions, thus reducing maintenance and operating costs and ensuring compliance with strict environmental protection regulations. Chains for the car industry: high production standards call for reliable and powerful means of production. KettenWulf supplies special chains, tailormade to suit individual production stages. 16|17 We are always in touch with current developments. As a result, we are keen to invest our experience and knowledge in promising industrial developments and offer our customers the know-how we have gained from our core industries. This enables us to venture into new fields and offer our products and services to the renewable energy industry, for instance. Special industry solutions Renewable energy generation is an expanding market. KettenWulf manufactures planetary shafts for modern wind turbines. Products for complete transmission systems Assembling a deviating shaft for the bulk material handling industry. As a leader in conveyor and drive technology, KettenWulf has established itself on the market as a supplier of special components. Apart from manufacturing drive and deviating shafts, we design and produce complete drive shaft systems, comprising shaft, sprockets and bearings. KettenWulf assembles complete drive shaft systems and delivers these to customers in a ready-to-install package. Completely assembled drive shaft system for the wood industry. Completely assembled drive shaft system for the escalator industry. 18|19 We deliver only the best quality products. To ensure this, we use only the most modern machines and manufacturing methods. Furthermore, our quality management and R&D department are engaged in constant enhancement of our product quality. To assure continuous high quality of our products at all levels, practically all the individual parts of our chain products are made in-house by our own staff. Apart from this, all KettenWulf products – irrespective of whether they are manufactured in Kückelheim, Ferlach, Hangzhou or any other production facility – are subject to the same quality requirements. Our production at a glance CNC lathes are used to produce parts of our chains with utmost precision. Quality certified in accordance with DIN EN ISO 9001:2000 Customer satisfaction and confidence are the corner stones of KettenWulf’s policy. To ensure constant high product quality, KettenWulf has obtained certification to prove the compliance of its quality management system with the strict requirements of DIN EN ISO 9001:2000. In order to meet our customers’ quality demands and ensure long product service life, we have implemented quality management procedures in all production and management processes. From incoming goods inspection to final tests and inspection, we do our very utmost to supply only the very best quality products to our customers. Laser cutting: KettenWulf relies on laser-cutting technology for the production of link plates, which require utmost precision. It also makes the production of plate components with complex contours possible. Heat treatment: We use two different heat treatment processes for the components of our chains and sprockets – case-hardening and induction hardening. With these processes, we achieve chain links of great friction resistance. Induction hardened sprockets reduce the wear in the tooth gaps, thus ensuring optimum interaction of chains and sprockets over longer periods. 20|21 Quality in all production processes Mechanical processing: KettenWulf uses only the latest CNC technology in the mechanical processing sector. This makes it possible not only to turn bushings, pins and rollers, but also mill link plates, sprocket teeth and pitch borings. Variable designs are no problem at all, thus enabling us to meet special customer requirements. Aside, precision grinding machines can be used to grind all bushes, pins and rollers for our chains to within very tight tolerances, thus ensuring an absolute fit. Welding technology: All welding is carried out by our own company welding division. State-of-the-art MIG and MAG processes are used here for production. In order to ensure constantly high quality, we use partially automated and fully-automated welding equipment to manufacture our products. Punching: Modern punching technology allows serial production of link plates and attachments. At KettenWulf, we produce our own punching tools. Using special production methods we can ensure a very high pitch accuracy of our chains. Shot peening of link plates and attachments ensures further quality improvement. Metal-forming: To bend attachment link plates or attachment angles, the bending zones of the work piece are initially inductively heated up. This prevents bending cracks and considerably increases the service life of the link plates. Final assembly: During the last production step the divers components of the chain are assembled by hydraulically operated presses. After the final inspection, the products are shipped to the customers. 22|23 Our large and well-equipped testing laboratory carries out the following basic examinations and tests on a regular basis: » Service life testing of chain components » Ability to withstand aggressive media » Roller wear tests » High-temperature tests » Fatigue strength testing of chain components Research and development With the aid of extensive tests on our own test benches, our R&D department has been able to develop two major technologies for producing low-maintenance and lubrication-free chains. We can provide lubrication-free chains of either sealed or non-sealed designs to suit various ambient conditions and environmental influences. Innovation in chain and sprocket technology Over the past years, there has been a strong increase in the demand for low-maintenance and lubrication-free chains. More and more customers are choosing chains of this type, mainly out of economic and ecological considerations. The advantages are obvious, as the use of low-main-tenance and lubrication-free chains greatly reduces maintenance and service costs. Since post-installation lubrication is no longer necessary in many applications, the possibility of subsequent lubrication and maintenance faults is thus eliminated. KettenWulf has developed a variety of seals for chains for use in special environmental conditions. These seals prevent the entering of dirt and fluids, thus ensuring good lubrication of the parts over longer periods. This can not only increase the service life considerably, it also extends the frequency of re-lubrication in comparison to earlier designs. KettenWulf also offers special chain designs which need no re-lubrication at all. Depending on the requirements, either lubrication-free chains with sealed or non-sealed bearing designs are used. Often, the sound of a chain running over sprockets when a machine is in operation can be annoying. In order to substantially reduce chain-sprocket contact noise, KettenWulf has developed a special noisereduction feature. This patented design ensures that the chain does not strike the gaps between the sprocket teeth, but are guided into each tooth gap in a controlled manner. This reduces the operational chain noise to such an extent that it can usually no longer be heard above normal ambient noise levels. Innovations in the conveyor chain sector: for example lubrication-free chains with sealed or non-sealed bearing designs. Innovations in the sprocket sector: for example, sprockets with patented noise reduction. 24| Our quality management is based on the guidelines of DIN EN ISO 9001:2000. Fatigue strength of a material or component is being determined by high frequency pulsation. As we only process flawless material, all raw material is carefully checked when it enters the factory. Along with material testing, all prefabricated parts and finished products are subject to on-going quality control. For example, hardness tests are carried out on hardened components. Quality management An actual breaking load test confirms the calculated breaking load values. By means of spectral analysis the alloying additions of the steel are defined. KettenWulf GmbH Division Ferlacher Förderketten A-9163 Unterbergen 25 Austria T + 43.(0) 4227.25 27 F + 43.(0) 4227.35 94 [email protected] www.kettenwulf.com KettenWulf NV Division Dyna Chains Venecoweg 20A - De Prijkels E17 B-9810 Nazareth Belgium T + 32.(0) 9.243 73 73 F + 32.(0) 9.221 56 03 [email protected] www.kettenwulf.com Hangzhou Wulf Chain Co. Ltd. 40 Tangning Road, Yunhe Town Yuhang District 311102 Hangzhou P.R. China T + 86.(0) 571.861 899 00 F + 86.(0) 571.861 899 50 [email protected] www.kettenwulf.com 02 04 06 08 10 12 14 16 18 22 Wulf Chain USA, LP The Woodlands at Riverside 8110 Troon Circle SW, Suite 170 Austell, GA 30168-7852 USA T +1.678.433 0210 F +1.678.433 0215 [email protected] www.wulfchain.com KettenWulf Representative Office Czech Republic Dukelských hrdinu˚ 2780/26 CZ-690 02 Brˇeclav Czech Republic T + 42.(0) 519.32 50 95 F + 42.(0) 519.32 50 96 [email protected] www.kettenwulf.com KettenWulf Representative Office Poland ul. Ogrodowa 34 B\ 4 PL-65-001 Zielona Góra Poland T + 48.(0) 68.325 43 37 F + 48.(0) 68.325 43 37 [email protected] www.kettenwulf.com KettenWulf Representative Office Japan Monoh 4-chome, 14-13 Minoh-shi Osaka 562-0001 Japan T + 81.72.796 24 24 F + 81.72.722 20 99 [email protected] www.kettenwulf.com Focus on the KettenWulf Group From left to right: Ansgar Wulf, Julia Wulf, Tobias Wulf KettenWulf Betriebs GmbH Export Division Industriestraße 41 D-28876 Oyten Germany T + 49.(0) 4207.608-0 F + 49.(0) 4207.608-149 [email protected] www.kettenwulf.com GB Photos: Erik Hinz, Münster; KettenWulf, Kückelheim; Michael Gehrig, Lennestadt Due to steady technological progress, all of the product information and technical specifications in this catalogue are subject to change. The use and applicability of these technical specifications is incumbent on your own responsibility. Also, we disclaim any errors due to misprints or other causes. Reprints, in whole or in part, require the written approval by KettenWulf. KettenWulf Betriebs GmbH Zum Hohenstein 15 D-59889 Eslohe-Kückelheim Germany T + 49.(0) 2973.801-0 F + 49.(0) 2973.801-228 [email protected] www.kettenwulf.com Contents Contacts worldwide About our company KettenWulf world-wide Partners to industry KettenWulf conveyor chains KettenWulf roller chains KettenWulf sprockets What we can do to assist you Industrial applications Special industry solutions Our production at a glance Research and development
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