Navigation : EXPO21XX > METALWORKING 21XX > H01: CNC Machine Centres > KAPP NILES
Videos
Loading the player ...
  • 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
  • DIGITALISATION

      • KN assist software platform

        • optimisation of the set-up process with shorter preparation times
        • easy management of components in the warehouse system
        • KN extender with digital functionalities for tool management
        • condition monitoring informs about the state of the machine
        • maintenance and repair manager with maintenance schedule lists
        • remote service with complete remote service infrastructure
      • The innovative user interface KN grind

      • Allows intuitive parameter configuration of machining task. The operator is guided and supported during the input of workpiece and technology data. Subsequently, a flexible machining sequence is defined via process control. During process monitoring, the operator is able to observe and influence the machining status at any time.
      • Closed Loop

      • Data between machine tools, equipped with the KN grind, and measuring machines are transmitted quick and secure. The machine to machine communication is based on OPC UA specifications in the process. The measurement values are transmitted in gear data exchange format and edited to become user-friendly, which makes the decision process regarding corrections to be implemented significantly easier.
      • Universal machine tool interface „umati“

      • Upon request, accessibility to the OPC UA-based universal umati interface can be provided. This option will make it easy to integrate your machine tool to the already existing IT-infrastructure.
    • 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.

          • Generating gear grinding machines of the KNG ready series

          • max. tip diameter: 320 mm - prototype to medium series - external gears
                • KNG 320 READY

                • gear generating grinding machine

                  machine concept
                  With the gear generating grinding machine KNG 320 ready, KAPP NILES offers users in the field of gear grinding an inexpensive entry into precision machining. The KNG 320 ready is designed as a solution for the flexible production of small and medium lot sizes. ergonomics

                  The gear generating grinding machine KNG 320 ready has been optimised for manual ergonomic loading. 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 tools.

                  measuring system
                  The integrated measuring device allows for the measurement and evaluation of all relevant toothing features. This function is used both for the optimisation of the set-up process and for the alignment of the toothing with optimised measurement switch.

                  control and software KNgrind
                  The control system Sinumerik 840D sl is used on a 19” touch screen. The innovative, operator-friendly user interface KNgrind allows a machine-oriented and an intuitive parameterization of the machining task.

                  The operator is guided and supported during the input of workpiece and technology data. Via process control a flexible machining sequence is subsequently defined. In a process monitoring the operator is able to view and to influence the machining status at any time.

                  features
                  An outstanding feature of the KNG 320 ready grinding machine is the tool drive. It combines high speeds of up to 6,700 min-1 for a constant cutting speed, even with a slimmer worm, with high stability. Thanks to the absence of a counter-bearing and an integrated automatic HSK interface to the tool holder, the worm change can be carried out in the shortest possible time. The alignmentfree level indicator on the tool axis rounds up the optimised set-up design.

                  The retractable dresser offers all relevant dressing procedures from the form-bound roll for higher or recurring lots up to topological dressing for prototypes and small lot batches. The standardised interface allows the customer to easily connect automation systems it procures, such as robots, to the machine.

                   

            • Gear Centres KX Series

            • max. tip diameter: 500 mm - prototype to large series production - external gears and shafts - custom automation - horizontal or vertical workpiece axis
                • 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

                  The KX 100 DYNAMIC and the KX 260 DYNAMIC generating gear grinding machines represent a systematic further development of the technology already applied in the KX 160 TWIN multiple spindle design. The machine concept makes it possible to minimise the auxiliary process times and to reduce set-up times. The integrated loading function and the optionally available automatic changeover of the workpiece fixtures, make these machine concepts the perfect solution for medium and large batch production of external spur and helical gears.

                  The KX 100 DYNAMIC generating gear grinding machine includes two separate and pivoting columns, the KX 260 DYNAMIC includes one. A vertically moving pick-up axis is mounted on the column(s); each pick-up-axis is equipped with a workpiece spindle. While one workpiece is ground, the second spindle transfers the completely processed workpiece to the handling conveyor and picks up an unprocessed part. The workpiece is aligned outside the working space. Subsequently, the workpiece spindle accelerates to the processing speed in order to minimise the auxiliary process times. The optional multi-function axis allows discharging of measuring and test pieces. Aside of optimised set-up times machine concepts, KAPP NILES now offers intelligent clamping devices and grinding tools for this series, which provide all process relevant input data within an integrated RFID data storage.

                  Continuous generating grinding with dressable cylindrical tools is the grinding method. Dressing tools with integrated tip dresser as well as flexible tools with independent tip dressing can be used on the dressing device. Moreover, with the topological generating grinding option, it is possible to produce gears with or without targeted modifications.

                • 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

                  The KX 160 TWIN and the KX 260 TWIN are designed on a shared modular machine platform with features specifically for continuous generating grinding with dressable tools. The short set-up times are especially worth emphasising in this efficient machine concept.

                  The machines of the KX TWIN type are particularly designed for medium and large batch production of gears and shafts where quality levels are especially demanding.

                  The machine includes two identical workpiece spindles, arranged at opposing sides of an index table. While machining one part, the second workpiece spindle simultaneously unloads / loads and aligns another part. Thus, many of the auxiliary functions are carried out during the machining time, cutting the auxiliary processing time to a minimum.

                  A total of ten NC-axes align the gear wheel with the tool and perform the necessary linear and rotary motions during grinding. Both the index table and tailstock are designed as NC-axes. The workpiece spindle and tool spindle are direct drives.

                  The design of these machines includes an integrated single spindle dresser for conventional grinding worms. Mounted staggered to the workpiece spindles, the dressing unit is assembled on the tailstock column, too. For the dressing process the profile dressing unit is aligned with the tool by turning the tailstock column.

                • 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 a modular system in combination with the application possibilities of different tool and process technologies, user-specific, optimal production solutions can be configured. The following methods are possible:

                  • continuous generating grinding
                  • discontinuous profile grinding
                  • combination of both methods

                  Thanks to the flexible system and loading options, the KX 300 P is equally suitable for all gear requirements and production volumes. In this series the following tool concepts are offered:
                  • dressable ceramic tools for the flexible requirements of prototype machining as well as medium and high volume machining
                  • non-dressable CBN tools for the highly productive manufacturing of medium and high-volume series

                  Since the tool spindle (with counterbearing) can hold several tools, the cut segmentation is possible due to the sequential use of roughing and finishing tools in one single workpiece set-up. Alternatively, several gears can be machined in one set-up. In addition to the mainly used cylindrical grinding worms, single or multi-set CBN profile grinding wheels can be used for full-form machining as an alternative.
                • 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 built on a shared modular machine platform. Application-specific production solutions can be configured on this versatile machine utilising flexible process technology such as:
                  • continuous generating grinding
                  • discontinuous profile grinding
                  • combination of both methods

                  The KX 500 FLEX is designed to perform diverse processing jobs efficiently and economically. Thus, it is suitable for the production of single pieces as well as for the serial production of high-quality gears. In this series the following tool concepts are offered:
                  • dressable ceramic tools for prototype machining and grinding of medium to high-volume series
                  • non-dressable tools for the manufacturing of medium to high-volume series, as well as the grinding of more challenging gear geometry

                  The KX 500 FLEX concept features an index table which incorporates the tailstock support. The profile dressing unit is rotated into dressing position at the work spindle by the index table. Besides the common axes the index table and tailstock are designed as NC-axes, too. The workpiece and tool are directly driven.
              • Gear centres of the KNG expert series

              • max. tip diameter: 350 mm - prototype to large series production - external gears and shafts - custom automation - horizontal or vertical workpiece axis
                    • 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

                • Gear Centres ZX Series

                • max. tip diameter: 1,000 mm - prototype to large series production - cylindrical and conical gears - custom automation
                      • 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 gear grinding machines combine, both continuous generating grinding and discontinuous profile grinding in one machine. Thus, a machine can be provided with high-end productivity even for bigger gears and larger modules. On the other hand the requirements for an outstanding flexibility can easily be achieved, too.

                        For the highly dynamic generating grinding technology, a very rigid basis was developed. All main components of this gear grinding machine are made from vibration-absorbing ductile cast iron. The bed is a single unit offering extremely high stability. The machine needs no special foundation. The rotary table is largely dimensioned and accepts high table loads. It is driven by an electrical high-accuracy direct drive, providing the required positioning accuracy for profile grinding as well.

                        The one-piece gear grinding machine bed is characterised by a compact design and a very good accessibility, especially for manual part loading. The compact design enables all operation and set-up from the shop floor. The changeover between the different grinding processes is very fast and reliable, allowing the use of the optimal process, no matter if it is prototype grinding, small batches or series production. The tool spindle has a counter support for better rigidity and surface finish.

                        Several dressing processes are available, e.g. double-flank dressing with simultaneous tip dressing for mass production, or single-flank dressing with separate tip dressing for economical costs on small lots and beyond that topological dressing for almost unlimited modifications and gear types for prototypes.

                  • Rotor grinding machines of the RX series

                  • max. profile outer diameter: 120 mm - series production - screw compressors - optional: deburring parallel to grinding operation and optimised loading concept
                        • 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 patented RX 120 rotor grinding machine utilizes the advantages of continuous generating grinding in manufacturing rotor profiles. Generating grinding is used for roughing of the rotor, or alternatively, discontinuous profile grinding. Then for finishing, profile grinding is used alone. Applying this combined process reduces grinding times up to 40% as compared to using conventional grinding and finishing methods.

                          The RX 120 rotor grinding machine is designed for highly efficient and economic series-production of small and midsize screw compressors. Directly-driven tool and workpiece axes minimises non-productive times during the grinding process.

                          The RX 120 uses only non-dressable CBN tools.

                          control and software

                          The control system of the rotor grinding machine is Siemens Sinumerik 840D, which is equipped with an operator-friendly menu-driven user interface, developed by KAPP NILES to match the specific machining requirements.

                          The following options are available, including

                          • alignment of pre-machined rotors using a non-contact sensor or measuring-probe in reference to one or all gaps
                          • runout inspection on bearing journal at tailstock side
                          • adaptive control of the feed axis depending on the power input of the grinding spindle motor, to prevent overloading the grinding process due to excessive stock amounts
                    • 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

                        • max. profile outer diameter: 320 mm - prototype to series production - external gears
                              • KNG 3P READY

                              • 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

                                With the KNG 3P ready KAPP NILES offers users in the field of gear profile grinding an inexpensive entry into precision machining. The KNG 3P ready gear profile grinding machine is designed as a solution for the flexible production of small and medium lot sizes.

                                ergonomics

                                The KNG 3P ready has been optimised for manual ergonomic loading. 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 tools.

                                measuring system

                                The integrated measuring device allows to measure and to evaluate gear qualities against specifications. This function is used both for the optimisation of the set-up process and for the alignment of the toothing with optimised measurement switch.

                          • Gear centres KX series

                          • max. tip diameter: 500 mm - prototype to large series production - external gears and shafts - custom automation - horizontal or vertical workpiece axis
                              • 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 a modular system in combination with the application possibilities of different tool and process technologies, user-specific, optimal production solutions can be configured. The following methods are possible:
                                • continuous generating grinding
                                • discontinuous profile grinding
                                • combination of both methods

                                Thanks to the flexible system and loading options, the KX 300 P is equally suitable for all gear requirements and production volumes. In this series the following tool concepts are offered:
                                • dressable ceramic tools for the flexible requirements of prototype machining as well as medium and high volume machining
                                • non-dressable CBN tools for the highly productive manufacturing of medium and high-volume series

                                Since the tool spindle (with counterbearing) can hold several tools, the cut segmentation is possible due to the sequential use of roughing and finishing tools in one single workpiece set-up. Alternatively, several gears can be machined in one set-up. In addition to the mainly used cylindrical grinding worms, single or multi-set CBN profile grinding wheels can be used for full-form machining as an alternative.
                              • 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 built on a shared modular machine platform. Application-specific production solutions can be configured on this versatile machine utilising flexible process technology such as:
                                • continuous generating grinding
                                • discontinuous profile grinding
                                • combination of both methods

                                The KX 500 FLEX is designed to perform diverse processing jobs efficiently and economically. Thus, it is suitable for the production of single pieces as well as for the serial production of high-quality gears. In this series the following tool concepts are offered:
                                • dressable ceramic tools for prototype machining and grinding of medium to high-volume series
                                • non-dressable tools for the manufacturing of medium to high-volume series, as well as the grinding of more challenging gear geometry

                                The KX 500 FLEX concept features an index table which incorporates the tailstock support. The profile dressing unit is rotated into dressing position at the work spindle by the index table. Besides the common axes the index table and tailstock are designed as NC-axes, too. The workpiece and tool are directly driven.
                            • Gear Centres of the ZX Series

                            • max. tip diameter: 1,250 mm - prototype to large series production - cylindrical and conical gears - custom automation
                                  • 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 gear grinding machines combine, both continuous generating grinding and discontinuous profile grinding in one machine. Thus, a machine can be provided with high-end productivity even for bigger gears and larger modules. On the other hand the requirements for an outstanding flexibility can easily be achieved, too.

                                    For the highly dynamic generating grinding technology, a very rigid basis was developed. All main components of this gear grinding machine are made from vibration-absorbing ductile cast iron. The bed is a single unit offering extremely high stability. The machine needs no special foundation. The rotary table is largely dimensioned and accepts high table loads. It is driven by an electrical high-accuracy direct drive, providing the required positioning accuracy for profile grinding as well.

                                    The one-piece gear grinding machine bed is characterised by a compact design and a very good accessibility, especially for manual part loading. The compact design enables all operation and set-up from the shop floor. The changeover between the different grinding processes is very fast and reliable, allowing the use of the optimal process, no matter if it is prototype grinding, small batches or series production. The tool spindle has a counter support for better rigidity and surface finish.

                                    Several dressing processes are available, e.g. double-flank dressing with simultaneous tip dressing for mass production, or single-flank dressing with separate tip dressing for economical costs on small lots and beyond that topological dressing for almost unlimited modifications and gear types for prototypes.

                              • Gear Profile Grinding Machines ZE Series

                              • max. profile outer diameter: 1200 mm - prototype to large series production - external / internal gears and special profiles - highest flexibility
                                    • 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 of the ZE series are designed for precise grinding of external and internal gears. The ZE machine concept represents accuracy, long lifetime and ergonomics.

                                      Even the basic machines are equipped with coolant filtration unit, dresser, tailstock, in process measuring system, balancing unit, acoustic emission sensor and comprehensive software for grinding and measuring of involute profiles. The compact design enables all operations and set-up from the shop floor. No anchoring or fixing of the machine is necessary. Further outstanding features of the gear profile grinding machines of the ZE series are, amongst others, a well dimensioned rotary table with electrical direct drive, hydrostatic bearing and large table bores and an ergonomic machine design. 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 ZE 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 machines can be equipped with a 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.

                                • Gear centres of the KNG master series

                                • max. tip diameter: 1,250 mm - medim series - external and internal gears as well as special profiles - new functional and ergonomic design
                                      • 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 Series

                                  • max. tip diameter: 8,000 mm - external / internal gears and special profiles - stability, high drive power - electrical direct drive
                                        • 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

                                    • max. tip diameter: 630 mm - prototype to small series production - designed for internal and external gears and special profiles - machining parts of complex geometry
                                          • 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

                                            All machine types of the gear profile grinding machines VX are based on a modular system which is designed for the use of various tool technologies. All versions are exclusively configured for profile grinding.

                                            The machines of the VX series are extremely suitable for meeting the highest requirements concerning the final quality of the produced gears. Based on exchangeable grinding units, machines of this series can work both external and internal gears as well as spur and helical gears and other profiles.

                                            The following tool concepts are offered:
                                            • dressable ceramic tools for prototype machining
                                            • non-dressable CBN tools for the high-productive batch production

                                            Since the grinding adapter can hold two exchangeable grinding spindles, the cut segmentation is possible due to the sequential use of roughing and finishing tools in one single workpiece set-up. Alternatively, two or more gears can be machined in one set-up.

                                            The CNC dresser is integrated in the working area of the VX machines and allows any grinding wheel profiles to be generated.

                                            The combination of measuring system and profile dressing unit allows the automatic machining according to the so-called GMG strategy (grinding – measuring – grinding). The dressing and grinding programme is automatically generated based on the entered gear data..
                                      • Rotor Grinding Machines RX Series

                                      • max. profile outer diameter: 320 mm - series production - screw compressors - high stock removal capability for efficient manufacturing - roughing and finishing in one set-up
                                          • 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 RX series machines are designed exclusively for discontinuous profile grinding. A special highlight is the extremely high stock removal capability of the rotor grinding machine, which is required for efficient grinding of rotor profiles, and which is made possible by the drive power.

                                            The rotor grinding machines of the RX series are employed for pre-finish and finish grinding of pre-profiled steel and cast-iron profiles. The part spectrum covers screw-type compressors rotors, rotary pistons, screw-type pump spindles etc.

                                            The RX series uses only non-dressable CBN tools. The directly driven grinding spindle of the RX machine can hold two grinding wheels whereas the tools are sequentially moved into the grinding position. This allows the pre-finish and finish grinding in one set-up.

                                            Due to the innovative drive concept on the tool side, the rotor grinding machines of the RX series reach up to 46 kW in the speed range of 2,000 to 8,000 min-1. Especially for roughing this high performance is resulting in highest stock removal rates and is shortening machining times considerably. In combination with an optimally adapted tool technology, a highly productive and efficient working process will be guaranteed.

                                          • 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 patented rotor grinding machine RX 120 offers using the advantages of continuous generating grinding in manufacturing rotor profiles. Generating grinding is used for roughing of the rotor, or alternatively, discontinuous profile grinding. For the finishing operation profile grinding is used only. Applying this process combination up to 40 % reduction of grinding times can be realised compared to conventional grinding times on established machine concepts.

                                            The rotor grinding machine RX 120 is designed for high productive and economic series production of small and midsize screw compressors. The machine is equipped with direct driven tool and workpiece axes for minimised main and non-productive times during the grinding process.

                                            The RX 120 uses only non-dressable CBN tools.
                                        • Special Solutions

                                            • GAS / GIS / HGS

                                            • GIS

                                              • max. workpiece diameter [mm]: 150
                                              • max. workpiece length [mm]: 150
                                              • batch size: prototype to medium series
                                              • processing method: profile grinding

                                              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.

                                              GAS

                                              • max. workpiece diameter [mm]: 320
                                              • max. workpiece length [mm]: 800
                                              • batch size: prototype to medium series
                                              • processing method: profile grinding

                                              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.

                                              HGS

                                              • max. rotor diameter [mm]: 60
                                              • batch size: prototype to large series
                                              • processing method: profile grinding

                                              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

                                              The machines of the ZP B type are designed for the complete hard finishing of external spur and helical gears. Special feature of this series – tooth spaces, bores and faces of the gears may be machined in one set-up using two independent machine columns. Since the implementation of the electrical direct drive the combination of gear and bore grinding became possible. This hybrid process allows maximum positioning accuracy in gear grinding in connection with a fast rotation for the bore grinding.

                                              The machines of the ZP B type were designed and built to comply with the highest demands in large gear grinding. Thanks to the combination of two machining processes, they offer further advantages

                                              • savings in set-up, aligning and idle times
                                              • realisation of smaller stock allowances
                                              • no machining of auxiliary surfaces
                                              • reduction of cycle times
                                              • reduction of scrap and reworking percentage
                                              • smaller space required

                                              Like all machines of the well known ZP series, the ZP B machines may be applied for large module gear grinding because of their comprehensive equipment. Due to the combination of internal cylindrical grinding and face grinding, these machines are mainly used for the grinding of gears where quality and economic benefits can be derived from performing all tasks in a single clamping. The bore can be either cylindrical or conical.
                                            • 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

                                                    • analytical gear inspection machine for workpieces up to Ø 650 mm

                                                      machine concept

                                                      With KNM 2X / 5X / 9X series, KAPP NILES Metrology GmbH - manufacturer of the currently largest gear measuring machines (stationary or transportable) in the world – for the first time offers a newly developed series of state-of-the-art measuring machines for smaller workpieces.

                                                      Ultimate highly precise measurement of smaller size gears in the lab or on the shop floor - no foundation required..

                                                      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

                                                    • analytical gear inspection machine for workpieces up to Ø 6,000 mm

                                                      machine concept

                                                      With KNM X series, KAPP NILES Metrology GmbH - manufacrurer of the currently largest gear measuring machines (stationary or transportable) in the world - offers customised stationary state-of-the-art measuring machines as well as docking station solutions (machine base with rotary table and portable 3-axes-measuring unit).

                                                      An ultimate high precise measurement of gears with diameters from 1 m up to 6 m in the lab or on the shop-floor is possible.

                                                      The KNM X series already impresses by construction size. The solid base of granite provides sufficient stiffness and no fundation is required thanks ro the vibration dampers.

                                                      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 gear inspection and 3D measuring systems

                                                      machine concept

                                                      With KNM P series, KAPP NILES Metrology GmbH - manufacturer of the currently largest gear measuring machines (stationary or transportable) in the world - offers the first portable independent measuring equipment for larger gears, ring-shaped workpieces, housings etc. directly on the production machine or on the shop-floor.

                                                      The device is a new development based on well proven technologies, as well as innovations and has been perfectly adjusted to customer requirements specifically for the independent measurement of spur and helical gears or ring-shaped parts such as bearing rings and also housings etc. directly on the production machine or on the shop-floor without rotary table.

                                                      Its set-up as CNC-controlled 3-axis measuring equipment permits determination of profile, lead, pitch and runout deviations on gears as well as general parts contours. Proven software for fully automatic measuring cycles is available.

                                                      The system needs to be mounted on a stable support connected to the base / foundation of the production machine.

                                                      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

                                                    • ultra precise universal measuring machines

                                                      machine concept

                                                      With KNM C series, KAPP NILES Metrology GmbH - manufacturer of the currently largest gear measuring machines (stationary or transportable) in the world - offers a universal high-precision measuring equipment for max. diameters from 500 mm to 1,600 mm. The ultimate form measurement is best suited for medium and large components.

                                                      The device is a new development based on well-proven technologies, as well as innovations and has been perfectly adjusted to customer requirements specifically for the determination of form deviations of bearing rings, race rings and all kind of cylindrical workpieces.

                                                      Its setup as CNC-controlled 4-axis measuring equipment permits expansion to a larger range of parts as well, including external and internal gears or 3Dmeasuring tasks on prismatic workpieces. Proven software for fully automatic measuring cycles is available.

                                                      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

                                                        machine concept
                                                        The machine design is centred around using linear actuators to move the probe into position into the gear teeth.

                                                        Using the load cell located below the probe assembly, the actual pressure of the measurement is controlled and when the proper pressure is applied, this will trigger a limit switch to take the measurement and retract the gauge. The operator then can rotate the gear to a new tooth position or load / unload the gear.

                                                        The control of the system is available with two control systems, EDRO (enhanced Digital ReadOut is a web based digital display that can be accessed using a standard web browser or a PC based software system that takes the gauge to a new level of absolute measurements.

                                                        These shop floor hardened gauges are built to handle the demands of production floor gauges.

                                                        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

                                                        concept
                                                        The double flank rolling system was designed to handle the environment of the shop floor. The base of the machine was designed to ensure stability and longevity in operation. The dual slide rails provide a very robust base for the physical control of the machine components. The spindle has an industrial construction to handle the conditions in manufacturing.

                                                        Using the latest software, the system is operating in Windows 10 environment. The DFT system uses linear scales so positioning the slides to the proper mounting distance is easy and repeatable.

                                                        The rotary motor on the spindle has incorporated a rotary encoder to allow the user to identify a tooth that is out of specification.

                                                        We also offer a optional load cell to document the pressure of the mesh during the testing. A solid system that will provide many years of service.

                                                        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

                                                        machine concept
                                                        Kapp Niles Metrology offers a variety of functional Go and No-Go composite and variable indicating spline gauges to support your inspection needs. All spline gauges are designed, manufactured, and supplied, complete with inspection certificates, to meet your specific application requirements.

                                                        To verify our inspection system accuracy, we maintain gear artifacts which have direct traceability with the NIST–Y12 US standards laboratory.

                                                        Please provide our product specialists with your part drawings and project delivery requirements and we will develop a quotation to meet your needs.

                                                        Functional Gauges for the production environment.

                                                        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
                                                      • functional gauges

                                                      • for gear and spline inspection needs

                                                        concept
                                                        KAPP NILES Metrology offers a variety of spur and helical master gears and master worms for the purpose of composite gear roll testing and / or to serve as inspection machine calibration artifacts.

                                                        Master gears can be designed and manufactured to meet your specific application requirements or KAPP NILES Metrology can provide standard master gears up to and including ISO/DIN Q3, AGMA 2015-A3, and JIS quality standards.

                                                        All master gears are designed, manufactured, and supplied, complete with inspection certificates, to meet your specific application requirements.

                                                        To verify our inspection system accuracy, we maintain gear artifacts which have direct traceability with the NIST–Y12 US standards laboratory.

                                                        Please provide our product specialists with your part drawings and project delivery requirements and we will develop a quotation to meet your needs.

                                                        features
                                                        • spur master gears
                                                        • helical master gear
                                                        • helical master component replica
                                                        • lead and involute prototypes