Kapp Niles technology sets standards in e-mobility

Grinding of an e-mobility shaft with a combined grinding worm. (Courtesy: Kapp Niles)

For more than 10 years, the mechanical engineering company Kapp Niles has been working intensively on the topic of gears in e-mobility and has established itself as a pioneer in this rapidly growing industry. With a focus on innovation and quality, Kapp Niles offers customized solutions for the production of gearboxes and gears in electric vehicles.

Electric vehicles are the future of mobility. Kapp Niles is actively shaping this future with a dedicated team of highly qualified employees.

“We understand the specific challenges of e-mobility and work closely with our customers to fulfill their requirements and achieve first-class results with our machines and technologies,” said Matthias Kapp, managing director at Kapp Niles.

E-mobility requires different gearing solutions for different areas of application.

“Flexibility in the range of components is one of our strengths,” said Friedrich Wölfel, head of sales at Kapp Niles. “We can fulfill a wide range of requirements here, from the fine machining of miniature gears in e-bikes and components for electrically powered cars to larger components in electric commercial vehicles.”

The drivetrain in electric vehicles must be optimized even more than in conventional vehicles with combustion engines in terms of efficiency, and therefore range. A key component of the measures used for this is the optimization of the gear surfaces in the transmission. Fine or polishing grinding on Kapp Niles machines enables the highest surface accuracies to be produced economically and reproducibly.

“An ultra-fine surface with an increased material contact ratio can extend the efficiency of torque transmission and improve the range of electric vehicles,” said Patrick Duhre, team leader subcontracting at Kapp Niles. “Our technologies offer customized solutions for this.”

In e-mobility, gearboxes not only have to be efficient, but also particularly quiet. Kapp Niles relies on intelligent process monitoring to identify noisy components during machining and reduce the return rate. This is an effective and cost-saving option and fulfils the high-quality requirements of e-mobility.

For the same reason, waviness analysis is becoming increasingly important for assessing the quality of gearing in electric drives. A software option for order analysis is directly integrated on the Kapp Niles measuring machines to enable quality testing for low-noise gears during series production.

“With our waviness analysis, we offer a precise and efficient way to determine the smallest geometric deviations as a result of preliminary process steps and to evaluate components using definable tolerance curves,” said Dr. Philip Geilert, testing/fundamentals at Kapp Niles.

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