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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
  • 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.

          • 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 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

                  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 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 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.

              • 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 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.

                • 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 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

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

                          • 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 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

                            • 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 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

                              • 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

                                          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

                                    • 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 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 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