Manufacturing of mechanical gear units – extruder gear units, variators, planetary and gear drives for plastics and rubber.
Dana Motion Systems Deutschland GmbH
Bad Homburg v. d. HöheNew on Amplifa
About Dana Motion Systems (PIV)
Dana Motion Systems Deutschland GmbH manufactures mechanical gear units under the PIV™ brand for industrial applications, with a focus on the plastics and rubber industry. The product portfolio includes variators, helical and gear drives, single and double extruder gear units as well as planetary gear units. At the production and administration site in Bad Homburg (60,000 m², including a new gear assembly hall for up to 50 t), all essential manufacturing steps are performed in-house – from raw material through turning, drilling, milling, grinding, broaching and hardening to CNC housing machining and assembly according to Kaizen principles. Engineering services such as 3D design, gear and bearing calculations, FEM calculations and simulations are also carried out in-house. Fields of application include pipe and profile extrusion, blown film, film and foam extrusion lines, tire production as well as plastics and rubber recycling plants. Since 1928, more than one million gear units have been installed worldwide; a service network provides 24/7 support.
- Site
- Bad Homburg v. d. Höhe
- Processes
- Turning, Drilling, Milling, Grinding, Broaching, Hardening (Heat Treatment), CNC machining of gear housings, Manufacture of mechanical gear units (variators, helical and gear drives, extruder gear units,
- Materials
- CNC Machining, Turning, Drilling, Milling, Grinding, Broaching, Hardening (Heat Treatment), FEM Calculation and Simulation
- Certificates
- ISO 9001, ISO 14001, ISO 45001
- Founded
- 1928 (bran
- Industries
- Plastics and rubber industry (extrusion), Tire production, Recycling of plastics and rubber, General industry, Plastics and rubber industry (extrusion: pipe/profile, blown film, film/foam), General industry (variators, planetary gear units)
- 01
Design / 3D Engineering
- 02
Gear and bearing calculations, FEM, simulation
- 03
Manufacturing from raw material (turning, drilling, milling, grinding,
- 04
CNC housing machining
- 05
Assembly (Kaizen)
- 06
Quality inspection
- 07
Logistics / shipping / 24/7 service
Manufacturing Processes
CNC Machining
Machining center for gear housings and components from raw material.
Turning, Drilling, Milling, Grinding, Broaching
In-house machining of all major gear components from raw material.
Hardening (Heat Treatment)
Heat treatment to achieve the required case depths and wear resistance.
FEM Calculation and Simulation
In-house calculation and optimization of gears and bearings.
Site
Bad Homburg v. d. Höhe
DEProduction and administration site (research, development, design, production, testing)
- Part weight / size
- Gear assembly up to 50 t
- Materials
- Steel, castings (housings)
- CNC machining center for housing machining
- 3D coordinate measuring center
- Assembly hall for up to 50 t
Gear Units and Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| TurningMachining | – | – | – | – | – |
| DrillingMachining | – | – | – | – | – |
| MillingMachining | – | – | – | – | – |
| GrindingMachining | – | – | – | – | – |
| BroachingMachining | – | – | – | – | – |
| Hardening (Heat Treatment)Heat Treatment | – | – | – | – | – |
| CNC machining of gear housingsMachining | – | – | – | – | – |
| Manufacture of mechanical gear units (variators, helical and gear drives, extruder gear units,Assembly | – | – | 50 t (gear assembly up to 50 tonnes) | – | – |
| Assembly according to Kaizen principlesAssembly | – | – | – | – | – |
| 3D design, gear and bearing calculations, FEM calculations, simulations,Engineering | – | – | – | – | – |
| Inspection: three-dimensional measurement with measuring centers, surface roughness and case depthInspection | – | – | – | – | – |
3 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC machining center for housing machining | – | – | – | – | Bad Homburg |
| Measuring center (3D coordinate measuring machine) | – | – | – | – | Bad Homburg |
| Production plant Bad Homburg (60,000 m², new gear assembly hall for up to 50 t) | – | 1 | 60,000 m² | – | Bad Homburg |
Additional services
Certified Quality
Gear units and manufacturing steps are inspected in-house: 3D measuring centers, surface roughness and case depth determination, contour measurement, spectral analysis, hardness testing as well as acceptance testing – results are fully documented. Certifications to ISO 9001, ISO 14001 and ISO 45001 have been in place since 1994.
| Evidence | Bad Homburg v. d. Höhe |
|---|---|
| ISO 9001 | |
| ISO 14001 | |
| ISO 45001 |
History
- 1928
Founding of PIV in Germany (PIV™ brand).
- 2003
Registration of PIV Drives GmbH (today Dana Motion Systems Deutschland GmbH) on 19.08.2003, registered office in Bad Homburg.
- 2006
Merger with BREVINI Getriebe GmbH (18.01.2006).
- 2021
Renaming to Dana Motion Systems Deutschland (18.05.2021).
- 2022
Relocation to Werner-Reimers-Str. 6 (24.08.2022).
- 2025
Capital increase to €30 million (23.06.2025); acquisition of Dana Off-Highway by Allison Transmission – PIV is not part of Allison's global portfolio strategy.
- 2026
Announced plant closure of the Bad Homburg site according to employee reports.