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  • Offer Profile
  • KAPP NILES is a globally operating group of companies with high-quality and economical solutions for finishing gears and profiles. More than 800 employees represent the innovative strength and expertise of the sustainably managed family company which has grown for over 120 years.

    With production sites in Germany as well as worldwide sales and service branches, we are responsive and reliable in all major markets.
    KAPP NILES is partner for companies from numerous industrial sectors in the segments mobility, automation and energy.

    The perfect interaction between machines, tools, and technologies enables the precise machining to a thousandth millimetre and up to a diameter of eight metres.
    Each system solution is individually optimised for customer requirements and serviced by us throughout its life cycle. Highly accurate measuring equipment complements the comprehensive product range to ensure the required quality.

    KAPP NILES supports efficient and stable processes with innovative services and digital solutions.

Product Portfolio
  • DIGITAL SOLUTIONS

  • Digital solutions from KAPP NILES are displayed in the software platform KN assist. Our digital products aim to generate the greatest possible added value for you. Quality, availability, efficiency, resources, user-friendliness and service play a major role here. We focus on the core areas of connectivity, production, machine and support in order to master all current and future challenges together with you. The digital solutions thus stand for a perfect interaction of efficient processes around our machines.
      • GEAR-DATA-EXCHANGE (GDE) IMPORT / EXPORT

      • Digital Solutions - Perfect interaction for efficient processes

        What does GDE Import / Export include?

        • Data transfer of order-related data between your higher-level system (master computer, USB stick, ...) and your processing machine

        What data does the GDE format include?

        • Tooth data
        • Tooth thickness dimensions
        • Profile and flank line modification
        • Grinding and dressing tool data
        • Measuring and evaluation ranges
      • KN CONNECT

      • Digital Solutions - Perfect interaction for efficient processes

        What does KN connect include?

        • Standardised connection to your network via a separate IPC
        • IPC with firewall and OPC UA server
        • Provision of data (umati data scope) via OPC UA

        What are the advantages of KN connect?

        • Standardised interface across machine manufacturers through OPC UA and umati → Also for existing machines
        • Machine becomes I4.0 ready → Basis of digital solutions and requirement for further products
        • Secured TÜV-certified interface
      • CLOSED LOOP

      • Digital Solutions - Perfect interaction for efficient processes

        What does Closed Loop by KAPP NILES include?

        • Standardised transmission (GDE format) of correction values via network or USB
        • Automatic or manual execution of corrections
        • Correction values for profile angle deviation fhα, flank line angle deviation fhβ and tooth width, sphere dimension, two-ball dimension Wk

        What are the advantages of Closed Loop by KAPP NILES?

        • Automatic correction of series parts during production according to defined rules, if necessary with spindle reference
        • Reduction of the rejection rate
        • Compatibility with machines from other manufacturers (both machining and measuring machine)
      • PRODUCTION MONITORING

      • Digital Solutions - Perfect interaction for efficient processes

        What does Production Monitoring include?

        • Production behaviour of your machine (availability, running times, non-productive times, downtimes)
        • Production key figures such as OEE (pressures, temperatures, speeds, outputs, ...)
        • Job history and displays on HMI, web application (PC and tablet) and as an app on smartphones

        What are the advantages of Production Monitoring?

        • Easily accessible OEE key figures
        • Detection of defined threshold value overruns (KPI‘s)
        • Device-independent access to all relevant production data
      • TOOL MANAGEMENT

      • Digital Solutions - Perfect interaction for efficient processes

        What does Tool Management include?

        • Guided change sequences (step by step)
        • Avoidance of incorrect installation of a component with simultaneous flexibility
        • Display of all relevant component information (ID, geometry data, process data, ...)

        What are the advantages of Tool Management?

        • Reduction of the risk of crashes due to the set-up of an incorrect component
        • Reduction of preparation times for grinding project
        • Support in planning and analysing the condition of a component
      • CONDITION MONITORING

      • Digital Solutions - Perfect interaction for efficient processes

        What does Condition Monitoring include?

        • Monitoring of the linear and rotatory axes by reference runs
        • Evaluation of the wear condition through indices from 0-100 and prognosis regarding durability
        • Interface to other (digital) products in your production system, e.g. parts tracing

        What are the advantages of Condition Monitoring?

        • Reduction of unplanned machine downtime
        • No unnecessary or premature replacement of components → Reduction of inventory costs
        • Maintenance of production quality through monitoring of quality-relevant components
      • PROCESS MONITORING

      • Digital Solutions - Perfect interaction for efficient processes

        What does Process Monitoring include?

        Monitoring of the worm condition and analysis of ripples / orders
        Evaluation of the condition and indications based on the adjustable limits
        Interface to other products (such as parts tracing) and export function for analysis outside the machine

        What are the advantages of Process Monitoring?

        Reduction of rejection rates through 100 % inspection of all components
        Early detection of defects ? Timely rejection of conspicuous components
        Process monitoring can be adapted to your individual requirements

      • PART TRACING

      • Digital Solutions - Perfect interaction for efficient processes

        What does Part tracing include?

        • Recording of defined data during the grinding process for each workpiece
        • Creation of a data record for each workpiece with a defined identification (ID)
        • Interface to your systems for transmitting the data records

        What are the advantages of Part tracing?

        • Complete traceability and documentation of all manufactured components
        • Evaluation of data for process optimisation
        • Reduction of the rejection rate through rapid identification of anomalies and potential sources of error together with connected analytical systems
      • MAINTENANCE MANAGEMENT

      • Digital Solutions - Perfect interaction for efficient processes

         

        What does Maintenance Management include?

        • All maintenance plans and instructions in digital form
        • Reminder function through traffic light system of due dates and notifications
        • All done maintenance and servicing are stored in the system archive

        What are the advantages of Maintenance Management?

        • Predictable maintenance schedules through preventive maintenance suggestions
        • Latest maintenance documentation in digital form on your machine‘s HMI or mobile devices
        • Maintenance archive per machine (history of done maintenance)
    • Innovative Technology for Gears and Profiles

    • Continuous generating grinding
      For continuous generating grinding all tooth flanks of the workpiece are machined simultaneously during one stroke of the helical tool. This is realized with a synchronized constant rotation of the workpiece relative to the grinding tool. Due to the kinematics of this process indexing and positioning times are greatly reduced resulting in low cycle times. Therefore it is a highly productive and cost-effective process well suited for small and medium-sized gears. Both dressable ceramic tools and non-dressable CBN tools can be used (in cylindrical or globoid design).

      Discontinous profile grinding
      Profile grinding of gears describes a process for which the tooth flanks are machined gap after gap with single or multi-ribbed profiled tools. Regarding the possible work piece geometries this process offers highest flexibility while achieving highest quality. Profile grinding is mostly utilized for small batch series and prototype manufacturing. Dressable ceramic wheels as well as non-dressable CBN-tools can be used for this grinding process.
        • topological generating and profile grinding

        • the prevention or targeted manipulation of process-related bias presents a challenging requirement for a production process. Due to the user-friendly guidance and machine-internal calculation of dressing and grinding paths, this method has found its way into the field of serial production.
        • superfinishing

        • KAPP NILES machines provide the option to integrate precision grinding technology into both the profile and generating grinding process. The additional effort required for this is generally less than 50 % of the machining time of a conventional grinding process.
        • generating grinding with small tools

        • using high-speed grinding spindles on the KX 160 / 260 TWIN machines, gears with interfering edges which could previously only be machined with the profile grinding or honing process can now be machined with the generating grinding process. This new development offers high potential for optimisation.
        • cycloidal gearbox

        • cycloidal gearboxes distinguish themselves by high transmissible torques, better rigidity and low wear. For high precision profile machining of the two main components of a cycloidal gearbox - cam disk and needle ring gear - high performance technologies from KAPP NILES are available.
        • double helical gears

        • KAPP NILES offers a wide range of machine concepts for grinding double helical gears in all different sizes. Whether equipped with a horizontal or vertical workpiece axis, the hardware / software of all machines can be upgraded with innovative solutions for grinding helical gears.
        • tool management

        • KAPP NILES offers intelligent clamping equipment and tools providing all information relevant to the process via an integrated RFID data storage carrier of the machine control unit. The new components allow for time savings by forgoing manual data input and thus eliminating input errors.
      • Generating(Profile)-Grinding Machines

      • machines customised for your requirements

        Most of the following solutions combine continuous generating grinding and discontinuous profile grinding in one machine. For the grinding of your gears, shafts, rotors and special profiles KAPP NILES offers best suitable profile grinding machine and generating gear grinding machine. KAPP NILES generating gear grinding machines are best suitable for the medium and large batch production of gears with very high precision in conjunction with high productivity.

          • KNG EXPERT SERIES

          • gear center

            • max. tip diameter [mm]: 350
            • max. workpiece length [mm]: 700
            • module range [mm]: 0.5 - 5.0
            • max. face width [mm]: 400
            • max. helix angle [deg]: ± 45

            Machine concept

            The KNG 350 expert is based on a compact, set-up-optimised machine concept and is intended for use in medium and largescale series production of external geared components. The integrated workpiece handling ensures short non-productive times and can handle both bored parts and shafts. The new functional and ergonomic machine design paired with the innovative user-friendly interface KN grind supports the user during set-up and optimisation of grinding projects.

            High-performance technology options combined with application-specific aligning and measuring functions enable maximum precision and surface qualities on the workpiece. The NC-controlled aligning device adapts automatically to different workpieces

          • KNG FLEX SERIES

          • gear center

            • max. tip diameter [mm]: 350
            • max. workpiece length [mm]: 700
            • module range [mm]: 0.5 - 6 / 0.5 - 8
            • max. face width [mm]: 400
            • max. helix angle [deg]: ± 45

            Machine concept

            The KNG 350 flex HS is based on a compact, set-optimised machine concept and is intended for use in small, medium and large series production of externally toothed components up to 350 mm diameter. The machine is characterised in particular by the highest grinding quality and productivity, even when using small tools. Using a high-speed grinding spindle (HS) with a speed of 25,000 rpm, even gear teeth with interfering contours can be ground, requiring tool diameters of 55 mm (generating grinding) or 20 mm (profile grinding).

            The concept also offers full flexibility in the selection of loading and automation solutions. From manual loading to downsize automation to robotic loading. The optionally integrated ring loader ensures the shortest non-productive times and can handle both bore parts and shaft-shaped workpieces. The new functional and ergonomic machine design paired with the innovative user-friendly interface KN grind supports the user during set-up and optimisation of grinding projects.

          • KX TWIN SERIES

          • gear center

            • max. tip diameter [mm]: 170 / 260
            • module range [mm]: 0.5 - 5.0
            • batch size: medium and large series
            • processing method: generating grinding

            Machine concept

            Machines of the KX TWIN series have been designed for continuous generating grinding with dressable and non-dressable tools. They are particularly suitable for the high production volumes in the medium and large batch production of gears and shafts.

            The concept includes two identical workpiece spindles arranged at opposing sides of an rotary indexing table. While machining one part, the second workpiece spindle simultaneously loads / unloads and aligns another part.

            The machines are optimised for automatic loading with a standardised, cost-effective combination of pallet conveyor and gantry loader. By using an optional high-speed grinding spindle (HS), it is even possible to grind gears with interfering edges which require a tool diameter of 55 mm (generating grinding) or 20 mm (profile grinding).

          • KX DYNAMIC SERIES

          • gear center

            • max. tip diameter [mm]: 125 / 260
            • module range [mm]: 0.5 - 5.0
            • batch size: medium and large series
            • processing method: generating grinding

            Machine concept

            Intended to be used within the automotive industry, the DYNAMIC series convinces with minimal set-up and non-operational times. The concept is based on the integrated loading function and the optionally available automatic changeover of the workpiece fixtures.

            Parallel to grinding operation, the second pick-up axis can unload the finished workpiece and pick up an unmachined part. The workpiece is aligned outside the working area. To reduce non-productive times, the workpiece spindle can be swivelled into the working area in an already accelerated state.

            Continuous generating grinding with dressable grinding tools is used as machining process. For application-specific purposes, dressing tools with integrated tip dresser as well as flexible tools with separate tip dressers can be used on the dressing unit. The integrated automation reduces the space requirement to a minimum. Topological generating grinding is available as an option..

          • KX 300 P

          • gear center

            • max. tip diameter [mm]: 300
            • module range [mm]: 0.5 - 5.0
            • batch size: medium and large series
            • processing method: generating and profile grinding

            Machine concept

            Based on different tool and process technologies, user-specific, optimal production solutions can be configured.

            The tool spindle with counterbearing can hold dressable and non-dressable grinding worms or profile grinding wheels. Due to the use of auxiliary spindles small grinding wheels up to a minimum diameter of 25 mm can be used.

            Machines can be loaded either manually or automatically. The use of an integrated ring loader allows short loading times for both bore and shaft parts.

          • KX 500 FLEX

          • gear center

            • max. tip diameter [mm]: 500
            • module range [mm]: 0.5 - 10.0
            • batch size: medium and large series
            • processing method: generating and profile grinding

            Machine concept

            The patented KX 500 FLEX is designed for the flexible use of a wide range of tooling and machining technologies. Thus, application-specific production solutions can be configured to perform diverse processing jobs and a wide range of batch sizes efficiently and economically.

            Dressable tools for versatile machining processes and non-dressable CBN tools can be used for highly productive manufacturing as well as grinding of gear geometry with interfering edges.

            The machine concept is based on a rotary indexing table which incorporates the tailstock and dresser offset against the workpiece spindle. The dressing unit can accommodate a single or twin spindle dresser.

          • ZX 630, ZX 800, ZX 1000

          • gear center

            • max. tip diameter [mm]: 650 | 800 | 1000
            • module range [mm]: 0.5 - 15.0
            • batch size: prototype to large series production
            • processing method: generating and profile grinding

            Machine concept

            The ZX series provides high-end productivity, even for bigger gears and larger modules. The requirements for outstanding flexibility can easily be met, too.

            The inherently rigid machine base enables easy installation without anchoring in the hall floor. The rotary table is generously dimensioned and can bear heavy loads.  It is driven by an electrical high-accuracy direct drive, providing a high level of positioning accuracy even for the profile grinding process.

            The compact design enables all operations from the hall floor and allows for easy set-up for machining individual parts, low and medium serial production volumes. The changeover between profile and generating grinding processes only lasts a few minutes. The tool spindle has a counter support for better rigidity and optimal surface finish.

            A wide range of dressing processes are available, e.g. double flank dressing with simultaneous tip dressing, single flank dressing and topological dressing.

          • RX 120

          • rotor grinding

            • max. profile OD [mm]: 120
            • max. profile length [mm]: 220
            • batch size: series production
            • processing method: generating and profile grinding

            machine concept

            The machines of the RX series are used for pre-finish and finish grinding of pre-profiled steel and cast iron screw rotors.

            Due to the innovative drive concept on the tool side, a maximum drive power of 46 kW is reached. Especially for roughing, this high performance results in extremely high stock removal rates and shortens machining times considerably. In combination with an optimally adapted tool technology, a highly productive and efficient working process will be guaranteed.

            With regard to pre-grinding, the patented rotor grinding machine RX 120 provides the option to use the advantages of continuous generating grinding instead of profile grinding in manufacturing rotor profiles. For the finishing operation, only profile grinding is used. By applying the generating grinding process as the pre-grinding process, a reduction of up to 40 % in grinding times can be realised compared to conventional machines and processes.

        • Profile Grinding Machine

        • machines customised for your requirements

          KAPP NILES is one of the market leading manufacturers of profile grinding machines. We offer worldwide service and sales of machines for high-precision profile grinding of gears and profiles. Using KAPP NILES profile grinding machines, you are able to grind such workpieces as gears, shafts and profiles with the highest accuracy.

            • Gear profile grinding machines of the KNG ready series

            • gear profile grinding machine

              • max. tip diameter [mm]: 320
              • module range [mm]: 0.5 - 10.0
              • batch size: prototype to series
              • processing method: profile grinding

              machine concept

              The profile grinding machine KNG 3P ready offers an inexpensive entry into precision machining. It has been designed as a solution for flexible production of small and medium lot sizes. The machine is characterised by a grinding spindle with high drive power for components up to module 10 mm. The directly driven rotary table is generously dimensioned for a table load of up to 350 kg. The dresser sits stationary against the tool axis and even allows the use of small dressing wheels with a minimum diameter of 65 mm. The working area can be used without any restrictions at large helix angles. Alternatively, the swivel range of the machine allows the grinding of worms. Thanks to the low height of the machine bed and the short distance to the machine elements all operations can be carried out without requiring means.

              The innovative, operator-friendly user interface KN grind allows a machine-oriented and an intuitive parameterisation of the machining task.

               

            • Gear centres of the KX series: KX 300 P

            • gear center

              • max. tip diameter [mm]: 300
              • module range [mm]: 0.5 - 10.0
              • batch size:prototype to large series production
              • processing method: generating and profile grinding

              machine concept

              Based on different tool and process technologies, user-specific, optimal production solutions can be configured.

              The tool spindle with counterbearing can hold dressable and non-dressable grinding worms or profile grinding wheels. Due to the use of auxiliary spindles small grinding wheels up to a minimum diameter of 25 mm can be used.

              Machines can be loaded either manually or automatically. The use of an integrated ring loader allows short loading times for both bore and shaft parts.

            • Gear centres of the KX series: KX 500 FLEX

            • gear center

              • max. tip diameter [mm]: 500
              • module range [mm]: 0.5 - 10.0
              • batch size: prototype to large series production
              • processing method: generating and profile grinding

              machine concept

              The patented KX 500 FLEX is designed for the flexible use of a wide range of tooling and machining technologies. Thus, application-specific production solutions can be configured to perform diverse processing jobs and a wide range of batch sizes efficiently and economically.

              Dressable tools for versatile machining processes and non-dressable CBN tools can be used for highly productive manufacturing as well as grinding of gear geometry with interfering edges.

              The machine concept is based on a rotary indexing table which incorporates the tailstock and dresser offset against the workpiece spindle. The dressing unit can accommodate a single or twin spindle dresser.

            • Gear centres of the ZX series: ZX 630 | 800 | 1000

            • gear center

              • max. tip diameter [mm]: 650 / 800 / 1000
              • module range [mm]: 0.5 - 15.0
              • batch size: prototype to large series production
              • processing method: generating and profile grinding

              Machine concept

              The ZX series provides high-end productivity, even for bigger gears and larger modules. The requirements for outstanding flexibility can easily be met, too.

              The inherently rigid machine base enables easy installation without anchoring in the hall floor. The rotary table is generously dimensioned and can bear heavy loads.  It is driven by an electrical high-accuracy direct drive, providing a high level of positioning accuracy even for the profile grinding process.

              The compact design enables all operations from the hall floor and allows for easy set-up for machining individual parts, low and medium serial production volumes. The changeover between profile and generating grinding processes only lasts a few minutes. The tool spindle has a counter support for better rigidity and optimal surface finish.

              A wide range of dressing processes are available, e.g. double flank dressing with simultaneous tip dressing, single flank dressing and topological dressing.

            • Gear Profile Grinding Machines ZE Series: ZE 400 | 650 | 800 | 1200

            • gear center

              • max. tip diameter [mm]: 650 / 800 / 1000
              • module range [mm]: 0.5 - 15.0
              • batch size: prototype to large series production
              • processing method: generating and profile grinding

              Machine concept

              The gear profile grinding machines in the ZE series are used for high-precision machining of external and internal gears. The machine concept stands for maximum quality, very straight forward handling and compact design.

              The basic machines are equipped with a dresser, counter support, integrated measuring device, balancing unit and comprehensive software for grinding and measuring of involute profiles.

              Easy accessibility provided by doors that open wide, and operation from the hall floor allow for easy set-up for machining individual parts and small-scale serial production. The machines feature generously dimensioned rotary tables with electrical direct drive and deep rotary table bores.

              All machines of the ZE series can be equipped with internal grinding attachments.

            • Gear centres of the KNG master series: KNG MASTER

            • gear profile grinding machines

              • max. tip diameter [mm]: 1000 / 1250
              • max. workpiece length [mm]: 1500
              • module [mm]: 0.5 - 35.0
              • max. stroke lengh [mm]: 1000
              • max. helix angle [deg]: + 45 / - 120

              Machine concept

              The machines in the master series are perfect for high-precision machining of external and internal gears as well as special profiles.

              The machine concept stands for maximum workpiece quality. High thermal stability and rigidity are achieved through an optimised design and matching components. The inherently rigid machine base enables easy installation without anchoring in the hall floor.

              The new functional and ergonomic machine design paired with a innovative user-friendly interface KN grind supports the user during set-up and optimisation of grinding projects. High-performance technology options and application-specific alignment and measuring devices mean that

            • Gear Profile Grinding Machines: ZP 16 - 28 | ZP 30 - 80

            • gear profile grinding machines

              • max. tip diameter [mm]: 1,600 / 2,000 / 2,400 / 2,800 | 3,200 / 4,000 / 5,000 / 6,000 / 8,000
              • max. module [mm]: 40 | 50
              • batch size: prototype to large series | prototype to medium series
              • processing method: profile grinding

              Machine concept

              The gear profile grinding machines of the ZP series is well known worldwide for profile grinding of external and internal gears. The ZP machine represents quality, durability and outstanding flexibility.

              Even the basic gear profile grinding machines are equipped with coolant filtration unit, dresser, in process measuring system, balancing unit, acoustic emission sensor, and comprehensive software for grinding and measuring of involute profiles. Further outstanding features are, amongst others, a well dimensioned rotary table with electrical direct drive and large table bores; optional hydrostatic bearing and guideways for highly accurate positioning, excellent load capacity and almost unlimited lifetime. The latest drive and control technology enables grinding of even very complex gear geometries using a five machine axes interpolation. The machine perfectly fits to customer-specific requirements, no matter if it is prototype grinding, small batches or series production.

              All gear profile grinding machines of the ZP series can be equipped with internal gear grinding attachment. From standard applications to customer-specific grinding tasks either with dressable wheels or CBN grinding wheels; KAPP NILES will provide the right solution for your requirements.

              Multiple spindle configurations are available. The gear profile grinding machine can be equipped with stronger motor and grinding spindle and optimised axes with increased stroking speed for productive grinding of large module workpieces.

              Gears with short run-out or workpieces with interfering shoulders can be ground with a spindle and wheel adaptor for smallest grinding wheels. Some machines even allow the use of two grinding spindles for even more flexibility.

            • Universal Gear Grinding Machines VX Series: Universal Gear Grinding Machines VX 55 | VX 59

            • gear profile grinding machines

              • max. tip diameter [mm]: 500 | 630
              • module range [mm]: 0.5 - 16.0
              • batch size: prototype to small series
              • processing method: profile grinding

              Machine concept

              The profile grinding machines of the VX series are extremely suitable for meeting the highest requirements concerning the final quality of the produced gears. Both dressable tools and non-dressable CBN tools may be used in the process.

              As the grinding adapter can be fitted with two exchangeable grinding spindles, the cutting passes can be realised with the sequential use of roughing and finishing tools in one workpiece set-up. As an alternative, multiple gears can be machined in one set-up.

              VX machines configured for the use of dressable tools feature integrated dressing equipment producing any type of grinding wheel profile. The combination of measuring system and profile dressing equipment also allows for automated machining according to the so-called GMG-strategy (grinding - measuring - grinding). The dressing and grinding programme is generated automatically based on the gear data.

            • Rotor Grinding Machines RX Series: Rotor Grinding Machines RX 55 / 59

            • rotor grinding

              • max. profile OD [mm]: 320
              • max. profile length [mm]: 550 | 850
              • batch size: medium series
              • processing method: profile grinding

              Machine concept

              The machines of the RX series are used for pre-finish and finish grinding of pre-profiled steel and cast iron screw rotors.

              Due to the innovative drive concept on the tool side, a maximum drive power of 46 kW is reached. Especially for roughing, this high performance results in extremely high stock removal rates and shortens machining times considerably. In combination with an optimally adapted tool technology, a highly productive and efficient working process will be guaranteed.

            • Rotor Grinding Machines RX Series: Rotor Grinding Machine RX 120

            • rotor grinding

              • max. profile OD [mm]: 120
              • max. profile length [mm]: 220
              • batch size: medium series
              • processing method: generating and profile grinding

              Machine concept

              The machines of the RX series are used for pre-finish and finish grinding of pre-profiled steel and cast iron screw rotors.

              Due to the innovative drive concept on the tool side, a maximum drive power of 46 kW is reached. Especially for roughing, this high performance results in extremely high stock removal rates and shortens machining times considerably. In combination with an optimally adapted tool technology, a highly productive and efficient working process will be guaranteed.

              With regard to pre-grinding, the patented rotor grinding machine RX 120 provides the option to use the advantages of continuous generating grinding instead of profile grinding in manufacturing rotor profiles. For the finishing operation, only profile grinding is used. By applying the generating grinding process as the pre-grinding process, a reduction of up to 40 % in grinding times can be realised compared to conventional machines and processes.

          • Special Solutions

              • GAS / GIS / HGS

              • GAS

                Machines from the GAS model range are used for processing external threads and similar profiles. Typical components for these machines are external ball screws for automotive steering systems, as well as drive worms and small pumps and metering components. In line with the shaft-type geometry of the components, these machines are designed with a horizontal workpiece axis and have correspondingly long travelling paths. Parts are machined by discontinuous profile grinding only; the tool concept is adapted to the corresponding component requirements:

                • non-dressable CBN profile grinding wheels
                • dressable ceramic grinding wheels

                For specific applications, various tools can also be combined.

                GIS

                Machines of this type are used for the hard and soft finishing of internal threads in ball screw tracks or similar profiles. Typical applications besides vehicle steering are recirculating ball screws in the field of automotive.

                Parts are machined by discontinuous profile grinding.

                Non-dressable CBN profile grinding wheels are exclusively used, typically in a combination of roughing and finishing tools.

                HGS

                The high-speed grinding machine HGS is mainly used for grinding slots in pump rotors into the solid, through-hardened material. Slot widths of 0.5 to 2.0 mm can be produced with high efficiency due to package clamping and automatic unloading and loading. The in process measuring control ensures maintaining slot width tolerances.

                The HGS uses non-dressable CBN profile grinding wheels only.

              • Gear Grinding Centres ZP B

                • max. tip diameter [mm]: 1250 | 3000
                • max. module [mm]: 40
                • batch size: prototype to medium series
                • processing method: gear profile, bore and face grinding

                Machine concept

                Based on the well-known ZP series, application-specific solutions have been developed. The machines of the ZP B model have been designed for complete hard finishing (gearing and reference surfaces) of external planetary and bull gears with a tip diameter of up to 3,000 mm.

                The combination of the machining processes achieves a high potential of cost-saving opportunities based on the following effects:

                • Reduction of set-up, alignment and idle times
                • Reduction of cycle times
                • Realisation of smaller dimensions
                • Reduction of scrap and reworking percentage
                • No machining of auxiliary surfaces
                • Reduction of space requirements
              • Gear Profile Grinding Machines ZP I/E and ZP E/I

              • profile grinding of gears

                • max. tip diameter [mm]: 2000 | 2500 | 2900 |on request
                • max. module [mm]: 40
                • batch size: prototype to medium series
                • processing method: profile grinding

                Machine concept

                The ZP I/E type is developed for high-precision profile grinding of internal gears with large modules and gear widths. The ZP I/E type now offers remarkably high efficiency and optimised solutions for such grinding tasks and at the same time the flexibility our customers need, to grind external gears by merely swiveling the grinding arm by 180°.

                The internal grinding attachment is mounted directly on a large machine column and carries the complete grinding arm including a dressing and measuring unit. The grinding wheel will be dressed by a patented method using the tangential axis of the grinding head and a dressing axis. The CNC dressing device is located directly above the grinding wheel, which allows the wheel to be dressed in its grinding position. This eliminates long dressing paths and at the end, reduces the process times significantly. The grinding spindle is driven by a timing belt. This concept increases the torque on the grinding wheel, allows the grinding spindle to be thermally separated from the motor, and provides a compact design. The strong drive delivers enough power for high material removal also when using large and wide grinding wheels.

                Even the basic machines are equipped with coolant filtration unit, dresser, in process measuring system, balancing unit, acoustic emission sensor and comprehensive software for grinding and measuring of involute profiles.

                The use of high-strength, vibration-absorbing and durable spheroidal cast iron is one of the key features for the machine accuracy. Further outstanding features are, amongst others, a well dimensioned rotary table with electrical direct drive and hydrostatic bearing for highly accurate positioning, excellent load capacity and almost unlimited lifetime.

              • Universal Profile Grinding Machine VG

              • Profile grinding up to 250 mm tip diameter

                The universal gear grinding machine VG was developed for the grinding of external and internal profiles with highest quality demands. In this series the tool concept, non-dressable CBN tools, is used. It is possible as appropriate after testing to enlarge the working area.
            • Tools

            • As a manufacturer of gear and profile grinding machines KAPP NILES offers sophisticated/highly developed technologies with different, the particular task customised tooling concepts.
                • Dressing tools

                • For profile dressing of vitrified bonded grinding tools. In addition to CBN and diamond tools for hard and soft finishing of gears and profiles there are dressing tools for profiling of vitrified bonded grinding tools in the product line.
                • Grinding tools

                • Discontinuous profile grinding is usually used for smaller lot size production and also for bigger gears. Therefore KAPP delivers sintered diamond form rolls which can be in an economic version with natural diamond or in a long life version with handset CVD diamond sticks.

                  These rolls can be reground several times and exhibit a high tool life.
              • Metrology

              • with KAPP NILES you are well cared for your measuring tasks

                KAPP NILES Metrology GmbH will draw from long-standing wealth of experience from employees of both, former R&P Metrology GmbH from Aschaffenburg, Germany and Penta Gear Metrology residing in Dayton, OH in the USA. The complete measuring technology portfolio includes stationary and mobile measuring machines, measuring instruments, as well as special measuring devices.
                  • Measuring machines

                  • machines customised for your requirements
                      • KNM 2X / 5X | 9X series

                      • Measuring machines for small and medium-sized workpieces up to 1,250 mm

                        The KNM 2X / 5X / 9X analytical measuring machines are designed for high-precision measurements of gears, gear tools and rotationally symmetric workpieces.

                        All guides and base plates made of granite are extremely stable in the long-term and have identically low expansion coefficients. Air bearings with emergency operation properties ensure perfect and wearfree guides without short-term errors. Air spring elements underneath the base plates safely shield from jolts and vibrations.

                        Special bases are not required. Non-ferrous linear and torque motors of the rotary tables ensure ultimate position precisions and path accuracy. Despite the compact design, spacious travel ranges ensure a tangential generating motion towards the base circle for any profile. Based on the requirements, different scanning touch probe systems can be used. The control cabinet can be arranged freely.

                        features

                        • ultra-compact design
                        • machine structure with outstanding intrinsic accuracy and thermal stability
                        • large bearing distances of guides
                        • inherently stable granite machine base on air springs to absorb vibrations
                        • no need for a separate foundation
                        • drive system close to centre of gravity
                        • linear motors in x-, y- and z-axes
                        • highly precise air bearing rotary table with direct drive
                        • “smart” tailstock 2X / 5X / 9X
                        • “smart” quick change clamping system (option)
                        • flexible positioning of electronic cabinet
                        • state-of-the-art KNM C5 controller
                        • temperature compensation
                        • CAA technology for all linear axes including tailstock
                        • easy to use operator-friendly software (clear user interface, plausibility check)
                      • KNM X series

                      • Measuring machines for large workpieces up to 6,000 mm

                        According to customer-specific requirements, the KNM X series can be either designed as a stationary machine for medium and larger sized gears, or as a docking station. For this purpose, any size of the machine base can be combined with a rotary table and a transportable 3-axes measuring device. The KNM X machines boast high-precision mechanics with optimal accessibility, laser-based safety equipment, large bearing clearances and generously dimensioned guiding cross-sections. Linear motors are used in all linear axes. High-precision rotary tables with air or hydrostatic bearing (diameter of 500 to 1,800 mm) feature direct drives / through-holes. Controlled air spring elements underneath the base plates safely shield from jolts and vibrations. No special foundations are required. The use of drives close to the centre of gravity ensures a low level of dynamic distortions.

                        features

                        • machine structure with outstanding intrinsic accuracy
                        • large bearing distances of guides
                        • inherently stable granite machine base on active dampers to absorb vibrations → no foundation required
                        • drive system close to center of gravity
                        • linear motors in X-, Y-, Z- measuring axes
                        • high precision air- or hydrostatic bearing rotary tables (diameters from 500 to 1,800 mm) with direct drive and through hole
                        • motorized positioning of measuring column (V-axis) to the actual workpiece diameter
                        • laser based system for safe operation
                      • KNM P series

                      • Portable measuring machines for gears and diverse components

                        The equipment of the KNM P series has been optimally adapted directly to the production machine according to the specific customer requirements regarding the autonomous measurement of gears, ring-shaped workpieces such as bearing rings, housings etc.

                        The combination of base plate and rotary table in a customised design (docking station) forms a full-featured 4-axis measuring device. Measurements can even be carried out without rotary table directly in the workshop area. In the KNM P machines, specially designed high-precision mechanics add to optimal accessibility with state-of-the-art drive technology (linear motors). The CNC-controlled 3-axis structure allows for checking all gear parameters or general workpiece profiles.

                        Arbitrary workpiece diameters and easy transport are especially worth emphasising. The measuring equipment is placed on a sturdy base connected directly to the production machine or foundation.

                        features

                        • parts sizes: diameter unlimited
                        • no influence by operator
                        • highly accurate mechanics in special design with perfect accessibility
                        • base plate, side parts and X-axis in special designed steel structure
                        • Y and Z axes of granite with air bearing guide elements for wear-free and smooth operation
                        • use of state-of-the-art drive technology (linear motors)
                        • easy to move from one operation position to the next
                        • combined with a base plate and a rotary table in customised design (docking station), the KNM P series can also run as a stand alone 4-axes measuring system
                      • KNM C series

                      • Measuring machines for complex workpieces

                        The machine has been optimally adapted for the determination of geometrical errors at bearing rings, slewing rings and cylinder-shaped workpieces. The CNC-controlled 4-axis structure allows for the expansion to a significantly larger component range, such as gears or 3D-measurement tasks on prismatic workpieces. All machines of the KNM C series are equipped with state-of-the-art drive technology (linear motors), and feature generously dimensioned guiding cross-sections and large bearing clearances.

                        The base plate, vertical columns and axes are made of granite. This ensures stable thermal behaviour. Air spring elements underneath the base plate safely shield from jolts and vibrations. The raised Y-guide and a drive close to the centre of gravity reducethe dynamic distortions to a minimum. Measurement uncertainties are at MPEE≥ 0.6 μm + L/400 | MPETHP≥ 0.8 μm. Reliable software is available for fully automated measurement cycles.

                        features

                        • highly accurate mechanics in special design with perfect accessibility
                        • base plate, side parts and axes of dark granite lead to consistent thermal conduct
                        • base plate supported on controlled air springs for vibration insulation
                        • air bearing guide elements in all axes for wearfree and smooth operation
                        • generously sized guide cross-sections
                        • large distances between bearing positions
                        • Y-guide risen, drive close to the center of gravity, low dynamic distortions
                        • use of state-of-the-art drive technology (linear motors)
                        • rotary table with air bearing and direct drive
                        • integrated tailstock (optional)
                        • perfect combination between the metrological features of a form measuring device with the strengths of a gear measuring machine respectively coordinate measuring equipment
                        • measuring uncertainty (DIN EN ISO10360):
                          MPEE ≥ 0.6 µm + L/400
                          MPETHP ≥ 0.8 µm
                    • Measuring equipment

                    • features for your inspection needs
                        • DOB G series

                        • production environment friendly in-process gauges

                          This workshop-ready series is developed to comply with the requirements of the production. By using linear actuators, the probe moves into position into the gear teeth. A load cell controlls the actual pressure of the measurement. The control of the system is available with two control components. EDRO (Enhanced Digital Read Out) is a web based digital display that can be accessed using a standard web browser or a PC based software system.

                          features

                          • available in internal and external gauges
                          • fast exchange of probes
                          • linear powered to ensure proper speed and pressure during testing
                          • dimension over pins
                          • odd tooth calculations
                          • shop hardened design (2 year warranty standard)
                          • optional PC control software
                            • absolute measurements
                            • remember calibration values for each ball
                            • turret probe assembly (*3 positions)
                            • interface with robot (pass / fail)
                            • machine feed back generation for size changes
                          • output options
                            • CSV (Comma Separated Variables)
                            • Q-DAS output (certfied)
                        • DFT series

                        • production environment friendly functional equipment

                          The double flank rolling system is designed even for the use on the shop floor. The specifically designed base of the machine ensures stability and longevity in operation. The dual slide rails provide a very robust base for the physical control of the machine components. The spindle meets perfectly the requirements of manufacturing conditions on the modern shop floor.

                          features

                          • measure total composite error
                          • measure tooth to tooth error
                          • measure total runout
                          • measure circular tooth thickness
                          • optional journal references
                          • automated cycle information
                          • dimension over pins
                          • document centre distance
                          • document testing pressure during test
                          • interface with robot for loading / unloading
                          • save data in CSV and PDF formats
                          • internal and external DFT are available
                        • spline gauges

                        • functional hand held gauges for in-process measuring

                          We offer a wide range of spur and helical gears as well as worms for the rolling test and as machine calibration patterns. More-over, we produce functional Go and No-Go composite and variable indicating spline gauges to support your inspection needs. To verify our inspection system accuracy, we maintain gear prototypes which have direct traceability with the NIST–Y1 US standards laboratory.

                          features

                          • Plug Gauges (Involute, Parallel & Serration)
                          • Ring Gauges (Involute, Parallel & Serration)
                          • Taper Master Plug Gauges
                          • Spur Master Gears
                          • Helical Master Gear
                          • Helical Master Component Replica
                          • Variable Spline Indicator Ring Type
                          • Variable Spline Indicator Plug Type
                          • Indicating Ring Type Gauges
                          • Taper Spline Mandrels
                          • Rotalock Mandrels
                          • Lead and Involute Artefacts