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An associate of ETG, KAPP NILES, is a leading manufacturer of machines and tools for the finishing of gears and profiles, operational on a global level through their partnership with ETG.
Designed for the machining of internal and external gears and special profiles, the XV Series allows for the prototyping and production of complex components.
The ZE Series is the most flexible machine tool in our range, allowing operators to take components from prototype to production. The ZE can be used for the production of external and internal gears and special profiles.
Allowing for the prototyping and production of components, the KX Series specialises in the machining of external gears and shafts. With custom automation, the KX can operate on both vertical and horizontal workpieces axes.
The RX 120 Rotor Grinding Machine is designed for series production, including screw compressors. Available as an option is deburring parallel to the grinding operation, as well as an optimised loading concept.
Trust in Technology
Trust in us to successfully implement your e-mobility projects. We are ready to shape the future of mobility together with you and set new standards.
For over 10 years, KAPP NILES has been intensively involved with the topic of gears in e-mobility and has established itself as a pioneer in this rapidly developing industry. Thanks to our many years of experience, we can offer you customised solutions for the production of gearboxes and gears in electric vehicles.
We are proud to be at the top of technological developments in e-mobility. With our extensive know-how, we are able to meet the requirements of this dynamic industry and offer you innovative solutions.
Our dedicated team of highly qualified employees is at your side. We understand the specific challenges of e-mobility and work closely with you to meet your requirements and deliver world-class results.
Discover the benefits of partnering with KAPP NILES and learn how our technologies can advance your business. Contact us today to learn more about our customised solutions for finishing gears in e-mobility. Together, we are leading the way to sustainable and future-oriented mobility. Trust in Technology with KAPP NILES!
E-mobility has brought about various application areas with new challenges for gear manufacturing. From miniature gears in bicycle drives to the gears installed in cars and even larger workpieces in trucks – KAPP NILES machines offer the flexibility to meet a wide range of requirements.
The majority of electric cars use simple, non-shiftable transmissions consisting of input shaft, intermediate gear, intermediate shaft and differential gear. However, the demands on these gears are even higher due to the extremely wide speed and torque range. KAPP NILES offers the answer for reliable machining of these workpieces with highest quality.
When top speed is required in an electrically driven sports car, transmissions have to function under maximum load.
Read our success story to find out more about how KAPP NILES supported the development of a new drive train for a fully electric sports car.
The demands on the quality of gears have increased by leaps and bounds, not only in passenger cars but also in electrically driven commercial vehicles. Higher torques must be transmitted over a wide load range with high efficiency. At the same time, durability plays an important role.
To support you in meeting these requirements, we have advanced our grinding and measuring machines as well as their machining processes and chains accordingly.
Gears for bicycle drives are both very small and difficult to machine due to unfavourable workpiece geometries. Nevertheless, solutions are needed to manufacture these components in an equally productive, economical and consistent quality manner. All previously known fine machining processes have reached their limits here. Only through the development of generating grinding with the smallest tools is there a process that meets all requirements. KAPP NILES grinding machines with high-speed grinding spindles (HS) up to 25,000 rpm and correspondingly dynamic workpiece drives up to 5,000 rpm provide you with the basis for using this technology. This enables you to machine even the most complex gears precisely and efficiently.
By improving the surface quality of gears, a significant increase in performance can be achieved in electrically driven vehicles.
A smoother surface with a higher contact ratio can increase the efficiency of torque transmission and thus the achievable range of the vehicle. The maximum surface pressure can also be further increased in order to be able to transmit higher torques of the electric motors and to take account of the lightweight design concept through smaller gears.
KAPP NILES offers various solutions here, from fine or polish grinding as a combined process to polish grinding as a single process, and thus the right technology for your requirements.
Conventional generating grinding uses a ceramic-bonded corundum grinding worm that consists of one specification throughout.
Fine grinding uses a combined tool with two specifications. In addition to the conventional grinding area, the tool has a fine grinding area that differs in terms of the tool specification. This allows surface finishes of Rz = 1 – 2.5 µm to be achieved with process reliability.
For even higher requirements, conventional grinding is combined with polish grinding. For this process, a tool with two areas is used. For polish grinding, a tool area with an elastic polyurethane or synthetic resin bond is used. Surface qualities of Rz < 1 µm can be achieved.
After hardening, gears are conventionally ground to remove the existing allowance including hardening distortions and to produce the final workpiece geometry. The tooth flanks are then shot-peened to harden the surface. In the final work step, they are polish-ground with a one-piece polyurethane-bonded tool as a single technology to achieve a high surface quality.
Conference paper Aachen Forum on Gear Production
While the quantity of gears within drive trains for e-mobility has drastically decreased compared to drive trains for vehicles with combustion engines, their design has changed significantly and alongside the geometrical tolerances were massively sharpened. Find out more about new requirements and challenges in gear grinding for electric vehicles and suitable optimisation strategies.
AGMA Emerging Technology Webinar Patrick Duhre, Team Leader Test Grinding / Contract Grinding at KAPP NILES, presents more on the topic of “Generating Ultrafine Surface Finishes on Gear Teeth for EV Applications”:
The gears used in E-vehicle transmissions have highly increased quality requirements. That is why we offer you dressing tools in a separate, high-precision design.
The special feature of such a dressing roll is, in addition to the reference surface optimisation, the reworking of the diamond grains after the coating of the dressing roll base body. This is carried out in such a way that the remaining profile form error of the dressing roll profile is smaller than with our standard dressing rolls. With these high quality dressers and the matching generating grinding worm specifications, significantly higher qualities can then be achieved on the ground workpiece.
Transmissions in e-mobility do not only have to be efficient, but also quiet. Up to now, workpieces with negative noise behaviour have usually been detected in EOL or in some cases on the roller test bench. The common random measurement of machined workpieces can only detect individual deviations, which later have an effect on the noise behaviour of the gearbox. This is where the Process Monitoring developed by KAPP NILES comes into the picture.
Based on internal machine control signals and signals from specifically used acceleration sensors, characteristic values are formed to assess the grinding process. This allows you to effectively and cost-efficiently identify workpieces with noticeable noise during machining. This reduces the amount of scrapped parts.
In addition to noise anomalies, you can also detect other deviations with the support of Process Monitoring in order to meet the high quality requirements in the field of e-mobility.
The data obtained with Process Monitoring can be used, among other things, to establish a correlation between the processing machine and the transmission test bench or measuring machine. This makes it possible to derive further findings for process optimisation.
A closer look at the surface condition of the tooth flanks, especially the waviness, is becoming increasingly important in electric drives with regard to noise behaviour.
A waviness evaluation of the tactile measurement serves as a link between the grinding process and the noise behaviour of the gearing. This enables you to determine the cause of deviations by upstream process steps. The workpieces can be evaluated on the basis of definable tolerance curves.
For series-accompanying, random sample quality assurance, the KN gear-waviness software option for order analysis is integrated directly on KAPP NILES measuring machines and enables an immediate analysis automatically.
In addition, the measuring effort can considerably be optimised by a reduction of measured teeth compared to an all-tooth measurement. With KAPP NILES measuring machines and the integrated waviness evaluation, you can ensure low-noise gears for electric drives – precisely and efficiently.
