KESSLER
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- Offer Profile
End-to-end precision from the
Founded in 1923 by Franz Kessler, the company has developed to become the leading supplier of motor spindles as well as directly driven 2-axis heads and rotary tilt tables for the machine tool industry. KESSLER is proud to list many major companies from the mechanical engineering sector amongst its long-standing customers.
components to the on-site service
With the expertise of more than 95 years, the KESSLER Group is continuously developing and optimising its products. The KESSLER product range serves a wide range of sectors, processes and applications. Close cooperation with our customers remains our key focus. The extensive product range, from hightech spindles, 2-axis heads, rotary and rotary tilt tables to motors and direct drive systems, enables KESSLER to implement customised solutions with speed and flexibility.
Product Portfolio
Spindle Technology
MILLING SPINDLES
The KESSLER milling spindles have a modular design.
Configure your own milling spindle model by specifying the installation position, motor,
speed, bearing, lubrication and sensory system – the perfect customized solution for your
individual branch and application needs.
KESSLER offers more: As an internationally successful company with extensive and highly specialized expertise, we provide comprehensive advice about the design and manufacture of individual components and project management of complex system solutions. We use the very latest technology and analytical processes to test our components under realistic conditions, so that our products help your business to stay flexible and maintain its competitive edge.
Our in-house development division is supported by extensive calculation and analysis skills
and covers everything from drive technology to the construction of all-in-one systems.
Furthermore, optimized production and assembly lines provide the framework for stable processes
and the superior quality of our milling spindles.V LINE
- The V line is all about
- Vertical machining
- Suitable for tilting operation
- Milling spindle for processing of different materials
- Milling spindle for processing of workpieces with varying geometries
- Use in small and large-scale production
- Short duration until reaching the stable Tool Centre Point (TCP)
- Equipped with shaft clamping for turning operation
- Option to measure the axial shaft displacement
V100
- Spindle
fitting: Ã 202 mm
KESSLER COOLMOTION® motor
Rotary union: Internal coolant supply with high volume flow
Cooling: Closed cooling circuit
Bearing lubrication: Grease / re-greasing / oil-air
V200
- Spindle fitting: Ã 230 mm
KESSLER COOLMOTION® motor
Rotary union: Internal coolant supply with high volume flow
Cooling: Closed cooling circuit
Bearing lubrication: Grease / re-greasing / oil-air
V400
- Spindle fitting: Ã 270 mm
KESSLER COOLMOTION® motor
Rotary union: Internal coolant supply with high volume flow
Cooling: Closed cooling circuit
Bearing lubrication: Grease / re-greasing / oil-air
MT LINE
- The MT line is all about
- 5-axis machining
- Very short construction thanks to release unit and rotary union integrated in the shaft
- Can be used in tilting heads
- Processing of different materials
- Machining of workpieces with varying geometries
- Use in small and large-scale production
- Short duration until reaching the stable Tool Centre Point (TCP)
- As an option, can be supplied with clamps for turning operations
- Option to measure the axial shaft displacement
MT80
- Spindle fitting: Ã 170 mm
- KESSLER COOLMOTION® motor
- Cooling: Open cooling housing
- Bearing lubrication: Oil-air / re-greasing
MT100 S / L / H
- Spindle fitting: Ã 202 mm
- KESSLER COOLMOTION® motor
- Cooling: Open cooling housing
- Bearing lubrication: Oil-air / re-greasing
MT400
- Spindle fitting: Ã 270 mm
- KESSLER COOLMOTION® motor
- Cooling: Open cooling housing
- Bearing lubrication: Oil-air / re-greasing
MT500
- Spindle fitting: Ã 325 mm
- KESSLER COOLMOTION® motor
- Cooling: Open cooling housing
- Bearing lubrication: Oil-air
MT600
- Spindle fitting: Ã 395 mm
- KESSLER COOLMOTION® motor
- Cooling: Open cooling housing
- Bearing lubrication: Oil-air
H LINE
- The H line is all about
- Horizontal machining
- Typical applications: Automotive industry, process machines
- Milling spindle for machining of similar work pieces, with similar working cycles with a high work frequency
- Milling, drilling, thread cutting, grinding, boring of
- aluminium, castiron and steel
- Internal monitoring of milling spindles (condition monitoring)
- Tool clamping system designed for a maximum amount of tool changes
- High speed: Up to 25,000 rpm
- High torque: More than 400 Nm
H80
- Spindle fitting: Ã 170 mm
- KESSLER COOLMOTION® motor
- KESSLER tool clamping system: Clamping spring package is designed for 5 million tool changes
- Rotary union: Inner coolant supply with large volume flow
- Cooling: Closed cooling circuit
- Bearing lubrication: Grease / re-greasing / oil-air
H100
- Spindle fitting: Ã 200 mm
- KESSLER COOLMOTION® motor
- KESSLER tool clamping system: Clamping spring package is designed for 5 million tool changes
- Rotary union: Inner coolant supply with large volume flow
- Cooling: Closed cooling circuit
- Bearing lubrication: Grease / re-greasing / oil-air
H200
- Spindle fitting: Ã 240 mm
- KESSLER COOLMOTION® motor
- KESSLER tool clamping system: Clamping spring package is designed for 5 million tool changes
- Rotary union: Inner coolant supply with large volume flow
- Cooling: Closed cooling circuit
- Bearing lubrication: Grease / re-greasing / oil-air
LATHE SPINDLES
KESSLER lathe spindles – delivering excellent results for decades.
A wide variety of designs and a vast quantity of interfaces offer flexibility and maximum performance reserves for machine design. With operating speed ranges of up to 8,000 rpm and torque values of over 1,700 Nm, KESSLER lathe spindles offer the right drive for any application. Standard interfaces ranging from A4 to A15 enable variable connections. Special-purpose options, such as clamps, integrated temperature sensors or special-purpose interfaces, such as cylinder mounts, round off the product range.GRINDING SPINDLES
KESSLER grinding spindles have been established on the market for many years.
Compact design, durable and very reliable operation are just some of the product characteristics. Internal and external grinding spindles with sizes from 80 to 250 mm are available. Variants with hybrid bearings have a very high radial and axial rigidity across the entire operating range.
They are the basis for highly precise concentricity, thermal stability, and maximum vibration quality. Countless options, such as speed sensors or integrated balancing systems offer maximum flexibility and compatibility with a wide range of applications.System Engineering
HEAD LINE
- Two-axis heads
with KESSLER spindles and motors
Intelligent systems: KESSLER heads think ahead – Head line
Applications with high requirements need a reliable partner. KESSLER 2-axis heads provide a compact and rigid design with high flexibility for numerous applications within your machine.
KESSLER’s latest torque motor generation achieves a high dynamic which is required especially when milling very intricate and narrow workpiece contours.
High positioning accuracy, high clamping force and a large tilting angle ensure that precise results are achieved in 5-axis machining.
KESSLER also offers compatible spindles for use with our 2-axis heads, to fulfill your machining needs.
Advantages- Individual configurability due to modular design
- Reliable skilled partner - for 2-axis heads, spindles and motors
- High clamping torque in the C-axis
- High maximum torque
- High accuracy Secondary cooling in the C-axis reduces the heat input in the headstock to a minimum
- Very maintenance friendly Wear parts can be easily replaced on site
- Spindles are optionally available with shaft clamping for turning operations
- Robust design with monolithic fork
- Precise machining results - due to high positioning accuracy
- High flexibility – and suitability for numerous applications
- High productivity due to high tilting speed
- High clamping torque in the A-axis
- High dynamics due to the newest generation of powerful COOLMOTION® motors
- High degree of operational safety thanks to LEDs due to optimal illumination of the tool intervention
- High productivity thanks to high-torque motor spindles
- With new spindle-generation MT + PC line
- With Quick Connect Cartridge (QCC)*
MINI 2AH
- Compact and highly dynamic.
The entry-level model for processing high-strength aluminium alloys and composite materials. With a fitting diameter of 335 mm and upwards, the MINI 2AH supports a highly compact tool machine design.
SMALL 2AH
- Bestseller for numerous application options.
This ultrafast and highly efficient professional choice achieves a speed of 20,000 rpm (MT) for stell and composite machining, and a maximum of 30,000 rpm for aerospace applications. Spindles with a torque S1 of up to 200 Nm can be used.
MEDIUM 2AH
- High-performance machine.
The large and highly dynamic MEDIUM 2AH impresses with performance high chip removal rate and precise results whilst machining steel, with spindles up to 400 Nm torque S1.
LARGE 2AH
- Power solution for heavy cutting requirements.
Large-scale 2-axis head for powerful operation with spindles up to 1,200 Nm torque S1, for effortlessly mastering the machining of challenging materials such as titanium Inconel.
TABLE LINE
- Rotary tables and
rotary tilt tables with KESSLER motors
The KESSLER Table line includes single-axis rotary tables and dual-axis rotary tilt tables. It incorporates the renowned KESSLER know-how for superior quality and innovative technology. The individual components form a modular system which can be configured to suit your specific requirements. Allow us to build the ideal system for your application environment.
Heavy workpieces can be quickly positioned and secured. High positioning accuracy ensures precise results for 5-axis machining. KESSLER`s very latest torque motor generation, the ultra-flexible rotary and rotary tilt tables feature high acceleration and tilting speeds for maximum productivity. High-speed rotary tables can also be used for turning operations.
Advantages- Individual configurability due to modular design
- Reliable skilled partner - for 2-axis heads, spindles and motors
- High clamping torque in the C-axis
- High maximum torque
- High accuracy Secondary cooling in the C-axis reduces the heat input in the headstock to a minimum
- Very maintenance friendly Wear parts can be easily replaced on site
- Spindles are optionally available with shaft clamping for turning operations
- Robust design with monolithic fork
- Precise machining results - due to high positioning accuracy
- High flexibility – and suitability for numerous applications
- High productivity due to high tilting speed
- High clamping torque in the A-axis
- High dynamics due to the newest generation of powerful COOLMOTION® motors
- High degree of operational safety thanks to LEDs due to optimal illumination of the tool intervention
- High productivity thanks to high-torque motor spindles
- With new spindle-generation MT + PC line
- With Quick Connect Cartridge (QCC)*
2-AXES ROTARY TILT TABLES (2AT)
MINI 2AT
- A-axis (tilting axis)
- Torque S1: 1,040 Nm
- Maximum torque: 2,080 Nm
- Maximum speed: 100 rpm
- Clamping: Hydraulic / pneumatic table
- Clamping torque: 3,200 Nm
- Tilting angle: ± 120°
- Measuring system: Absolute
- Accuracy of measuring system: ± 5“
C-axis (turning axis)- Torque S1: 400 Nm
- Maximum torque: 800 Nm
- Maximum speed: 200 rpm
- Clamping: Hydraulic / pneumatic table
- Clamping torque: 2,000 Nm
- Measuring system: Absolute
- Accuracy of measuring system: ± 5“
SMALL 2AT
- A-axis (tilting axis, one-sided drive)
- Torque S1: 1,850 Nm
- Maximum torque: 3,700 Nm
- Maximum speed: 100 rpm
- Clamping: Hydraulic / pneumatic table
- Clamping torque: 4,000 Nm
- Tilting angle: ± 120°
- Measuring system: Absolute
- Accuracy of measuring system: ± 5“
A-axis (tilting axis, driven on both sides)- Torque S1: 2 x 1,040 Nm
- Maximum torque: 2 x 2,080 Nm
- Maximum speed: 100 rpm
- Clamping: Hydraulic / pneumatic tabl
- Clamping torque: 2 x 3,200 Nm
- Tilting angle: ± 120°
- Measuring system: Absolute
- Accuracy of measuring system: ± 5“
C-axis (turning axis)- Torque S1: 1,040 Nm
- Maximum torque: 2,080 Nm
- Maximum speed: 100 rpm
- Clamping: Hydraulic / pneumatic table
- Clamping torque: 3,200 Nm
- Measuring system: Absolute
- Accuracy of measuring system: ± 5“
MEDIUM 2AT
- A-axis (tilting axis)
- Torque S1: 2 x 1,850 Nm
- Maximum torque: 2 x 3,700 Nm
- Maximum speed: 100 rpm
- Clamping: Hydraulic / pneumatic table
- Clamping torque: 2 x 4,000 Nm
- Tilting angle: ± 120°
- Measuring system: Absolute
- Accuracy of measuring system: ± 5“
C-axis (turning axis)- Torque S1: 1,850 Nm
- Maximum torque: 3,700 Nm
- Maximum speed: 100 rpm
- Clamping: Hydraulic / pneumatic table
- Clamping torque: 4,000 Nm
- Measuring system: Absolute
- Accuracy of measuring system: ± 5“‘
1-AXIS ROTARY TABLES (1AT)
MINI 1AT
- Table plate diameter (mm) 400 - 600
- Maximum speed (rpm) 25 - 1500
- Maximum vertical workpiece weight (kg) 700 - 1000
- Maximum horizontal workpiece weight (kg) 350 - 500
- Total height (mm) 215 - 300
- Maximum torque (Nm) 750 - 800
- Clamping Hydraulic / Pneumatic table
SMALL 1AT
- Table plate diameter (mm) 500 - 630
- Maximum speed (rpm) 25 - 1200
- Maximum vertical workpiece weight (kg) 1000 - 2000
- Maximum horizontal workpiece weight (kg) 500 - 850
- Total height (mm) 300 - 335
- Maximum torque (Nm) 1290 - 2080
- Clamping Hydraulic / Pneumatic table
MEDIUM 1AT
- Table plate diameter (mm) 630 - 800
- Maximum speed (rpm) 25 - 1000
- Maximum vertical workpiece weight (kg) 1700 - 3000
- Maximum horizontal workpiece weight (kg) 850 - 1200
- Total height (mm) 300 - 353
- Maximum torque (Nm) 2240 - 3700
- Clamping Hydraulic / Pneumatic table
LARGE 1AT
- Table plate diameter (mm) 1000
- Maximum speed (rpm) 25 - 800
- Maximum vertical workpiece weight (kg) 3000 - 4000
- Maximum horizontal workpiece weight (kg) 1500
- Total height (mm) 300 - 394
- Maximum torque (Nm) 2720 - 3000
- Clamping Hydraulic / Pneumatic table
TABLE LINE SPECIALS
- Multi-axis rotary tilt tables
for simultaneous machining in multi-spindle machines
- Highly dynamic positioning tables
for up to 1,000 positioning cycles per minute
- 45° tables:
High-compact design, optimal for use in machines with little available space
- One-arm rotary tilt tables:
Compact design for simple table loading and good access during the machining process
DIRECT DRIVE TECHNOLOGY - KESSLER ENERGY
-
KESSLER energy GmbH operates within the KESSLER Group, using optimized assembly lines for the production of electrical drives. KESSLER motors meet the highest efficiency requirements.
The company also reinforces the drive technology expertise of the KESSLER Group in new application areas.
STANDARD MOTORS
KESSLER COOLMOTION®
The COOLMOTION® technology optimizes efficiency to a maximum.
- KESSLER is the innovation engine behind state-of-the-art
direct drive technology and is renowned for powerful and energy-efficient
motors with high torque density and top reliability even in high-demand
applications. Practically-based simulations and individual customer
calculations are a prerequisite for the development excellence of KESSLER
motors.
The inverter-optimized COOLMOTION® motors are recognized for their low-loss design and enhanced heat dissipation. Innovative modifications of the motor components have enabled us to reduce the rotor and stator losses by 25 %. Special construction measures have resulted in significantly enhanced heat dissipation.
COOLMOTION® in drive technology
- achieves a very high torque density with
up to
30 % more torque in a minimized design - facilitates a compact design
- achieves a significantly more robust design
- in relation to resonance and reflection effects
- facilitates applications even during continuous loads
- provides maximum standstill torque
- achieves a very high torque density with
up to
Optimization measures
- 1. Cooling surface
2. Thermal connection of coil ends
3. Sheet metal material
4. Thermal connection of stator slots
5. Magnetic materials
6. Design re. additional power loss
7. Design re. field weakening
TORQUE MOTORS
KESSLER torque motors - MOTOR CATALOG
- High torque motor HTMx: Optimized torque
- Speed torque motor STMx: High speed
- High torque motor HTM: Installation compatibility
SPECIAL MOTORS
Advantages
- Very compact design
- High dynamic for fast motion
- Optimized cogging torque designed for minimum power ripple
- Nominal force (Fn) up to 10,000 N
- Max. speed up to 300 m/min
- Maintenance-free drive concept
- Minimum power losses
- Temperature optimized motor design
SLM series
- Nominal force Fn (N) 610 - 2730
- Height (mm) 34
- Width (mm) 116 - 166
- Length (mm) 178 - 498
Examples of applications
Torque motor for direct ship propulsion- Motor data:
Torque S1: 6,090 Nm
Maximum torque: 13,800 Nm
Speed S1: 420 rpm
Maximum speed: 494 rpm
Examples of applications
Torque motor for steam boiler- Motor data:
Torque S1: 11,000 Nm
Maximum torque: 15,500 Nm
Speed S1: 40 1/min
Maximum speed: 60 1/min
DRIVE SYSTEMS
Drive Technology / ADRENALINE
- The ADRENALINE propulsion system is equipped
with a KESSLER direct drive – based on innovative
COOLMOTION® technology with an integrated
frequency converter. The converter and motor are
perfectly matched modules and are available individually
as an option. The motor is powered by a fail-safe
storage system from our own battery design section
and offers very high energy density and durability.
The skipper can monitor key parameters by means
of the on-board computer, developed specially by
KESSLER energy, which displays the speed, the
state of charge and the range. Maximum safety is
guaranteed by a monitoring system consisting of an
interlock and insulation monitoring as well as the
state-of-the-art high-voltage system based on the
latest e-mobility standards.
Product focus: Direct drive system for electric boats
- 1. KESSLER energy on-board computer (HMI) with
display of speed, charge status and range.
2. High-voltage battery systems for maximum performance.
3. High-voltage electric motor, based on state-of-the-art synchronous motor technology with an integrated frequency converter. Scalable system, i.e. the drive systems are also available for different performance classes. Thanks to our own in-house battery cell configuration section, we can cater for all sizes and capacities. The converter and motor are perfectly matched to the application.
4. KESSLER energy supplies the complete system with the wiring, charging technology and battery management, and also supports customers during installation on site.
The KESSLER energy direct drive system for electric boats features a 100 kW KESSLER energy direct drive based on state-of-the-art synchronous motor technology with an integrated frequency converter. The motor is powered by a fail-safe storage system from our own battery design section and offers very high energy density and durability.
The skipper can monitor key parameters by means of the on-board computer, developed specially by KESSLER energy, which displays the speed, the state of charge and the range. Maximum safety is guaranteed by a monitoring system consisting of an interlock and insulation monitoring as well as the state-of-the-art high-voltage system based on the latest e-mobility standards.
Examples of applications
Synchronous motor for electrical vehicle- Motor data:
Torque S1: 800 Nm
Maximum torque: 2,500 Nm
Speed S1: 800 rpm
Maximum speed: 1,500 rpm
MOTOR ACCESSORIES
Temperature converter with intelligent thermal motor protection
- The solution for the discontinued KTY sensors
- Converts KTY ↔ PT1000
- Digital early warning signal for extreme temperature increases
- Compensation of the response time (thermal time constant)
- Suitable for operation in switch cabinet and IP 65, exposure to rough environment
- Galvanic isolated output from power supply
- Status display with Multicolor LED
KESSLER SNUBBER
- Reliably reduces critical voltage peaks at the star point
of the motor, which are generated by converter operation
- Max. power loss: 180 W
- Max. ambient temperature: 45°C
- Max. operating temperature: 100°C
- Connection PE: 10 mm², cable shoe M5
- Connection star point: 0,75 mm² - 16 mm²
- Fan voltage: 24 V (DC)
Plug connectors for torque motors
- Motor assembly and disassembly
- Simple connection and disconnection during assembly/disassembly or when replacing cables
- Ready-made connection cable
- Trained electrician not required
- Incorrect connection impossible
Construction design- Minimum space requirement
- Optionally with or without sealing plate and with identical mating connector
- Freely selectable cable outlet: right, left, radial or axial
- No cable cable tension from bending radiuses
- Only two mating connector sizes for all motor diameters from 210 to
990 mm
- Impervious, resistant, robust against water, dust, emulsions
- IP 67 tested
- Very robust design
- Vibration and shock-proof
AFE Unit
- The alternative filter package for your converter system
- Includes: 1. AFE mains filter, 2. Commutating choke, 3. Capacitor module
- Prevention of critical voltage peaks in the entire system
- Reduction of interfering signals in the signal and control circuit
- Compliance with the EMC directive in complex application areas with multiple axes, high parasitic capacitance of cable lengths or powerful drives
- Available in three sizes: 60, 90 and 130 A
