Precision manufacturing of large gears, gearboxes and generator components with engineering and service for large rotating machinery
KPG Rotating Solutions GmbH
Albbruck (headquarters)New on Amplifa
About KPG Rotating Solutions
KPG Rotating Solutions is a mid-sized family-owned company based in Albbruck in the southern Black Forest and a specialised partner for rotating equipment. The company manufactures large gears, integral, synchronisation, reduction and planetary gearboxes as well as generator components such as rotor end rings, copper windings, blades, sealing rings, bearings and slip rings. Manufacturing covers soft and hard machining with 5-axis machining centres, gear cutting and grinding as well as assembly including balancing, all in-house; tempering, hardening and wear-protection coatings are carried out with partner heat-treatment shops. Materials include case-hardening, tempering, nitriding and stainless steels, special alloys, high-strength aluminium alloys and copper. Customers come from power plant and plant engineering, compressor, vacuum pump, robotics and machine tool industries. In addition to manufacturing, KPG offers engineering with digital twins and vibration diagnostics as well as OEM-independent service for turbogenerators up to 1000 MVA and large gearboxes.
- Site
- Albbruck
- Processes
- Machining (soft machining): sawing, turning, gear cutting, slotting, milling with, Hard machining: hard turning and milling, bore grinding, cylindrical grinding, surface grinding,, Gear cutting / gear manufacturing (production of large gears, gear quality Q4 to DIN 3961, Tempering, hardening and application of wear-protection coatings (with partner heat-treatment shops), Surface hardening (consulting/optimisation), Assembly of form-fit and force-fit shaft-hub connections, assemblies and wheel sets incl., Quality inspection: CNC gear and coordinate measuring machines, runout checks, hardness and, Non-destructive testing
- Materials
- Case-hardening steels, Tempering steels, Nitriding steels, Stainless steels, Special alloys, Chromium-manganese steel, Aluminium alloys (high-strength), Steel alloys (high-strength)
- Certificates
- DIN EN ISO 9001:2015, DIN EN ISO 14001:2015, DIN ISO 45001:2018, ISO 9001, ISO 14001, ISO 45001
- Industries
- Energy/power plant technology (turbogenerators), Plant engineering, Radial compressors, Vacuum pumps and compressors, Industrial robots, Machine tools
- 01
Engineering (measurement, design, calculation, simulation)
- 02
Material procurement with inspection certificates 3.1/3.2 to DIN EN 10204
- 03
Soft machining (sawing, turning, milling, gear cutting, slotting)
- 04
Heat treatment with partner heat-treatment shops
- 05
Hard machining (hard turning/milling, grinding)
- 06
Assembly incl. balancing
- 07
Quality inspection
- 08
Logistics and worldwide service
Materials and processes
Case-hardening steels
For carburisable gears and gearbox components with high wear resistance.
Tempering steels
For gearbox parts and shafts with high strength requirements.
Nitriding steels
For nitridable gearing with low distortion and high surface hardness.
Stainless steels
For shaft sealing rings, labyrinth rings, bearings and slip rings.
Chromium-manganese steel
High-strength, corrosion-resistant material for rotor end rings up to 2000 mm diameter.
High-strength aluminium alloys
For blades of air- and hydrogen-cooled machines.
Copper
For windings, brazed joints and spare rotors.
Special alloys
For application-specific generator and gearbox components.
Locations
Albbruck
DEHeadquarters, manufacturing, engineering, service
- Part weight / size
- Gear shafts up to 2000 mm tip diameter, 1700 mm length
- Materials
- Case-hardening, tempering, nitriding and stainless steels, special alloys, aluminium and copper materials
- 5-axis machining centres
- 5-axis simultaneous machining machines
- CNC gear measuring machine
- Coordinate measuring machine
- Saws
- Crane for assembly of large machines
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Machining (soft machining): sawing, turning, gear cutting, slotting, milling withMachining | – | 1700 mm (gear shafts) × 2000 mm (tip diameter) | – | – | Case-hardening steels, Tempering steels, Nitriding steels, Stainless steels, Special alloys, Chromium-manganese steel, Aluminium alloys, Copper |
| Hard machining: hard turning and milling, bore grinding, cylindrical grinding, surface grinding,Machining | – | – | – | – | Tempering steels, Nitriding steels, Case-hardening steels |
| Gear cutting / gear manufacturing (production of large gears, gear quality Q4 to DIN 3961Machining | – | 1700 mm × 2000 mm | – | – | Case-hardening steels, Tempering steels, Nitriding steels, Special alloys |
| Tempering, hardening and application of wear-protection coatings (with partner heat-treatment shops)Heat treatment | – | – | – | – | Case-hardening steels, Tempering steels, Nitriding steels |
| Surface hardening (consulting/optimisation)Heat treatment | – | – | – | – | – |
| Assembly of form-fit and force-fit shaft-hub connections, assemblies and wheel sets incl.Assembly | – | – | – | – | – |
| Quality inspection: CNC gear and coordinate measuring machines, runout checks, hardness andInspection | – | – | – | – | – |
| Non-destructive testingInspection | – | – | – | – | – |
| Manufacture of ready-to-install integral gearboxes for multistage radial compressors (wheel andMachining | Gear quality Q4 to DIN 3961 / DIN ISO 1328 | 1700 mm × 2000 mm | – | – | Tempering steels, Case-hardening steels |
| Manufacture of synchronisation gearboxes for vacuum pumps and compressorsMachining | – | – | – | – | different materials |
| Manufacture of integrated reduction gearboxes for plant engineering (sizes up to 2000 mm)Machining | – | 2000 mm | – | – | Tempering steels |
| Manufacture of planetary gearboxes for industrial robots and reduction gearboxes forMachining | – | – | – | – | Tempering steels, Case-hardening steels |
| Manufacture of rotor end rings from chromium-manganese steel up to 2000 mm diameterMachining | – | 2000 mm diameter | – | – | Chromium-manganese steel |
| Construction of copper windings incl. closing wedges, brazed jointsAssembly | – | – | – | – | Copper |
| Brazing of winding connectionsJoining | – | – | – | – | Copper |
| Manufacture of blades on 5-axis simultaneous machining machinesMachining | – | – | – | – | high-strength aluminium alloys, high-strength steel alloys |
| Manufacture of shaft sealing rings, labyrinth rings, bearings and slip ringsMachining | – | – | – | – | Stainless steels, Special alloys |
| Generator service: inspection and measurement (bump tests, insulation testing, PI measurement,Inspection | – | – | – | – | – |
| Generator overhauls (rotor removal, labyrinth ring/sealing ring/bearing replacement, alignment,Assembly | – | – | – | – | – |
| Generator smart repairs: stator rewedging, winding repairs, laminated core repairs,Assembly | – | – | – | – | – |
| Rotor and stator rewinding, spare rotorsAssembly | – | – | – | – | Copper |
| Large gearbox service: inspection, vibration/temperature analyses, video endoscopy,Inspection | – | – | – | – | – |
| Gearbox repairs with 3D metrology and remanufacturing of defective partsAssembly | – | – | – | – | – |
| Polar wedge repair (proprietary repair method for turbogenerators)Assembly | – | – | – | – | – |
| Engineering: measurement, design, calculation, simulation with digital twins,Engineering | – | – | – | – | – |
| Robotic Inspection System: generator-internal diagnostics with robotic crawler, high-resolutionInspection | Slot depths up to 35 mm | – | – | – | – |
| Generator performance increase through design modificationsEngineering | – | – | – | – | – |
| Manufacturing-optimised design of gear teethEngineering | – | – | – | – | – |
| Production of new gear sets up to 2000 mm diameter to ISO standardMachining | – | 2000 mm | – | – | Tempering steels, Case-hardening steels, Nitriding steels |
6 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 5-axis machining centre | – | – | – | – | Albbruck |
| 5-axis simultaneous machining machine | – | – | – | – | Albbruck |
| CNC gear measuring machine | – | – | – | – | Albbruck |
| Coordinate measuring machine | – | – | – | – | Albbruck |
| Saws | – | – | – | – | Albbruck |
| Crane (expanded crane capacities for assembly of large machines) | – | – | – | – | Albbruck |
Additional services
Reference customers
Quality and certification
Quality inspection is carried out with CNC gear and coordinate measuring machines, runout checks as well as hardness and residual magnetism measurements; non-destructive testing is also offered. Material procurement takes place with inspection certificates to DIN EN 10204 (3.1 and 3.2).
| Evidence | Albbruck |
|---|---|
| ISO 9001 | |
| ISO 14001 | |
| ISO 45001 |
History
- 2017
Dr. Günter Ebi becomes Managing Director of Kownatzki Premium Gears GmbH.
- 2019
Dr. Dominik Ebi joins Kownatzki Premium Gears GmbH as Head of Engineering.
- 2023
Dr. Dominik Ebi and Dr. Manuel Ebi become Managing Directors of KPG Rotating Solutions GmbH; conversion and expansion of the Zukunftsfabrik (Future Factory) in Albbruck with increased production capacities, modern logistics and expanded crane capacities.