Process Monitoring
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.
Conference paper Aachen Conference on Gear Production
"Hard fine machining of e-components in the border area of quality requirements and productivity"
Learn more in our conference paper* in the chapter "Process Monitoring for noise related components".
*Published in: Thomas Bergs, Christian Brecher (eds.): Aachener Tagung zur Zahnradfertigung. 9-10 November 2022, Apprimus Verlag, 2022.
"Particularly with the varying and constantly increasing requirements for transmissions of electrified vehicles, it is always impressive to see how profound the knowledge of KAPP NILES is in this area. Here, the expertise goes far beyond the limits of the grinding machine, which is a prerequisite for understanding current customer requirements and translating them into a grinding process.“
Dr.-Ing. André Wagner - Head of Grinding Technology | Hermes
„Together with KAPP NILES, we were able to work on a number of interesting research projects on the hard fine machining of gears. The highlight was certainly the integration of the polishing process directly on the gear grinding machine - which is now indispensable for a wide range of applications in the field of e-mobility."
Prof. Dr.-Ing. habil. Carsten Heinzel | Leibniz Institute for Materials Engineering (IWT) & University Bremen
"E-mobility needs high-precision gears, high precision gears need high precision diamond dressers and for high precision dressers we have KAPP NILES!"
Baocheng Feng - Tool Management Manager | Shuanghuan
"KAPP NILES is an invaluable partner in realising the complex gear tooth geometries that are needed for race and hypercar transmissions. We use their experience and support in both the profile and generate grinding technology for gears of the highest quality for quiet operation and for durability."
Martin Halley - Production Engineering Director | Xtrac
"E-mobility projects are very easy to realise with KAPP NILES. KAPP NILES is a competent supplier for e-mobility and offers top quality for every application."
Jürgen Kempf - Head of Technical Application Consulting and Sales | König MTM
"Manufacturing engineering is major key to economically and ecologically balanced powertrain production. KAPP NILES supports production-based innovation in FVA giving impulses and know how for innovative and up-to-date research projects. On the other hand KAPP NILES is lead applicator of FVA research results to set the pace for excellent production equipment and machines."
Dipl.-Ing. Christian Kunze | FVA (Research Association for Drive Technology - Support Association MOBIMA e.V.)
"KAPP NILES gear grinding machines have a reasonable layout, smooth automation system and excellent rigidity. After decades of years of advancement and optimisation, they have always remained in the first front of worm gear grinding machines. In particular, the KX 300 P and KX 260 TWIN models continue to provide excellent stability and efficiency in the grinding of e-mobility gears, providing a good machining experience for the user."
Wu Youxiang - Manufacturing Engineering | Shuanghuan
"We completed long test runs of the gearbox with the development department. This resulted in change requests to the process and the tools, which always had to be implemented under time pressure. I had a contact person at KAPP NILES at all times - even at weekends if things had to be done quickly. This meant that we had a new batch of prototypes in the shortest possible time with which we could go to the test stand. KAPP NILES helped us a lot during the prototype phase of our new development for a fully electric transmission for a super sports car and was always an optimal partner for us."
Roberto Di Geronimo - Competence Leader Gears & Gauges | FPT
"Highest quality through first-class cooperation: With KAPP NILES we realise a large number of innovative clamping solutions for gears. An absolute win-win situation with maximum benefit for our joint customers."
Thomas Hübl - Head of Key Account | Hainbuch
"The investment in a KAPP NILES gear grinding machine was the basis for our competence development in gear hard machining. With the flexibility of this machine, we can map all current research topics in gear grinding around e-mobility."
Carsten Hochmuth | Fraunhofer IWU, Chemnitz
„With KAPP NILES we started the demanding topic of e-mobility gears at a new production site. We got perfect support for the package consisting of gear grinding and measuring machine.“
Elias Häggström - Director of Gear Technology | LEAX
Optimise your gear solutions for e-drives
At KAPP NILES, you not only get the technology, but also the flexibility to adapt to a wide range of e-mobility requirements. Contact us to learn more about our advanced solutions. We will be pleased to show you how to increase your manufacturing potential in the field of e-mobility with KAPP NILES. Trust in Technology with KAPP NILES!
Markus Reißenweber
Head of Sales Europe & America
"I will be pleased to show you how to increase your manufacturing potential in the field of e-mobility with KAPP NILES."