Discover how ATEK Drive Solutions enhances the precision and efficiency of your CNC machining with innovative drive solutions.
What exactly is a servo-ready integrated gear motor for CNC machines?
Ein servo-ready integrated gear motor is a compact drive unit where the servomotor and precision gear are optimally matched and directly connected. This enables precise control of position, speed, and torque, which is essential for the high accuracy and dynamics of CNC machines and can reduce system inertia by up to 15%.
What are the main advantages of integrated gear motors in CNC applications?
Integrated gear motors offer significant advantages: they save space (up to 25% reduction), increase precision and dynamics, reduce assembly effort (up to 40 min. per axis) and commissioning times. Additionally, the motor and gearbox are optimally matched, resulting in higher efficiency and longer lifespan .
How does ATEK ensure the optimal performance of its integrated gear motors for CNC machines?
ATEK follows a system approach, where the motor, gearbox, and optional controller harmonize perfectly. Our modular system allows for millions of configurations for customized solutions. This, combined with decades of experience and new servomotor expertise, ensures maximum performance and reliability for your CNC application.
What criteria should I consider when selecting a servo-ready integrated gear motor for my CNC machine?
Important criteria include the required torque and speed, the appropriate gearbox type (e.g., planetary gears for low backlash), the servomotor technology including encoder resolution (often >20 bits for CNC precision), the compatibility of interfaces (e.g., EtherCAT, Profinet) with your CNC control system, as well as the protection class according to the environmental conditions (e.g., IP65 in coolants).
Does ATEK also offer custom integrated gear motors for specific CNC requirements?
Yes, ATEK specializes in the development of custom solutions, even in small series. Thanks to our modular system and engineering expertise, we can adapt integrated gear motors precisely to your specific requirements in CNC technology to achieve optimal results.
How do servo-ready integrated gear motors support the reduction of operating costs for CNC machines?
They contribute to cost reduction in multiple ways: through increased energy efficiency (up to 8% savings), reduced assembly and commissioning effort, longer lifespan through optimal coordination, and potentially lower maintenance costs, especially with predictive maintenance features, which help avoid unplanned downtimes.
What role does the compactness of integrated gear motors play in modern CNC machine construction?
Die Compactness is a crucial factor. It allows for smaller machine footprints, saving valuable production space. Alternatively, the gained space can be used for additional functionalities or improved accessibility in the CNC machine, which promotes innovative machine designs. What future trends can be expected for integrated gear motors in CNC machines?
Welche zukünftigen Trends sind bei integrierten Getriebemotoren für CNC-Maschinen zu erwarten?
Future trends include a continuously increasing energy efficiency, advanced predictive maintenance features integrated sensors, the use of artificial intelligence (AI) for optimizing drive control, and even more compact, high-performance designs, which open up new application possibilities.
Servo-ready integrated gear motors are crucial for modern CNC machines as they combine precision, dynamics, and compactness in one unit. This leads to a improved surface quality by a factor of 1.5 and a reduction of space requirements by up to 25%.
Der ATEK’s system approach, which includes optimally matched components and a modular system, allows for customized drive solutions. This can shorten assembly time by up to 40 minutes per axis and optimize delivery times. Future innovations such as
Zukünftige Innovationen wie predictive maintenance and AI-supported control further enhance the efficiency and reliability of CNC drives. Already today, energy savings of up to 8% can be achieved through the use of modern integrated gear motors.Learn how ATEK’s servo-ready integrated gear motors elevate your CNC machines to a new level of performance and optimize your production processes.
CNC technology is evolving rapidly. Servo-ready integrated gear motors are the key to higher precision and efficiency. Optimize your manufacturing with ATEK Drive Solutions. Contact us for a personalized consultation at this link.
Would you like to optimize the performance of your CNC machines and receive advice from our experts?
Request a free consultation now!
Understand: The role of servo-ready integrated gear motors in CNC machines
Improving precision and efficiency in CNC machines is essential. The specially developed servo-ready integrated gear motors significantly optimize production processes.
What makes an integrated gear motor servo-ready?
Ein servo-ready integrated gear motor is a perfectly synchronized unit of motor and gearbox designed for demanding applications. The direct connection of a servomotor to a precision gearbox can reduce system inertia, for example, by up to 15% compared to traditional attachments. This allows for precise control of position, speed, and torque, which is CNC machines essential. Drive train solutions with servomotors are a key focus.
Why are these drive units so critical for CNC machines?
Poorly tuned drives significantly impair production quality. Servo-ready integrated gear motors for CNC machines minimize mechanical play and elasticity. For example, a precision parts manufacturer reduced its scrap rate by 5% with such integrated drive solutions through improved repeatability. The direct coupling in these motor-gear units significantly increases drive stiffness.
The ATEK system approach: More than the sum of parts
The system approach considers the entire drive train; the motor, gearbox, and optional controller are optimally matchedto achieve the best performance for your CNC machine . For example, the modular system configures optimal servo-ready integrated gear motors for CNC applications from over a million options, often with 20% shorter delivery times. This approach also includes specialized solutions such as modular bevel gears und high-torque servo gear motors for robots.Benefit: Leverage clear advantages of integrated gear motors for your CNC applications
Compactness and optimized space requirements: A true gain for your CNC machine?
Servo-ready integrated gear motors significantly reduce the required installation space, enabling more compact machine designs or the integration of additional functionalities in your CNC machine . For example, by eliminating couplings and motor brackets, a customer reduced the drive space requirement of a CNC lathe by 25% thanks to such a compact drive unit.
- Reduced installation space through the servo-ready integrated gear motor enables more compact machine designs and additional functionalities.
- Increased system stiffness of the drive solution leads to the highest precision and improved dynamics in CNC applications.
- Shortened cycle times and significantly improved surface quality in demanding machining with your CNC machine.
- Simplified and accelerated assembly of the motor-gear unit by eliminating separate alignment and coupling processes.
- Faster commissioning of the entire drive systems in CNC machines.
- Optimized efficiency and extended lifespan of the integrated components of the servo-gear motor.
- Lowered energy consumption through precise tuning of motor and gearbox in the integrated gear motor.
Highest precision and dynamics for demanding machining with CNC machines
The drive dynamics are of utmost importance for surface quality and contour accuracy in machining with CNC machines . The direct coupling in servo-ready integrated gear motors increases system stiffness and lowers mass inertia moments. For example, in high-speed machining of aluminum, cycle times were reduced by 10% and surface quality improved by a factor of 1.5 (Ra). servo-ready integrated gear motors Zykluszeiten um 10% und verbesserten die Oberflächenqualität um Faktor 1,5 (Ra).
Reduced assembly effort and faster commissioning of CNC drives
The elimination of separate alignment and coupling processes simplifies the assembly of a servo-ready integrated gear motor for CNC machines considerably. For example, customers report a reduction of up to 40 minutes per axis in the assembly of the drive train. This also accelerates the overall commissioning of the CNC machine.
Optimal tuning for efficiency and longevity in CNC operations
The optimal tuning of motor and gearbox in a servo-ready integrated unit improves efficiency and the lifespan of the drive of your CNC machine. For example, a precise design and avoidance of oversizing reduced the energy consumption of the feed axes in a machine tool manufacturer equipped with integrated gear motors by an average of 8%.Selection: Define the right criteria for servo-ready integrated gear motors
Torque and speed: The basis for any design for CNC application
Die correct sizing of torque and speed is fundamental for performance and lifespan of a servo-ready integrated gear motor for CNC machines. For example, for heavy cutting in a portal milling machine, a continuous torque of 120 Nm at up to 2000 rpm was covered by a powerful servo planetary gear motor. An incorrect sizing of the drive for the CNC machine can lead to premature wear or unnecessary additional costs.
- Careful determination of the required torque and speed characteristics for the specific CNC application.
- Selection of the optimal gearbox design (e.g., planetary, bevel gear, worm gear) for the servo-ready integrated gear motor according to the specific requirements of the CNC machine.
- Consideration of the employed servo motor technology, especially the resolution of encoders, to achieve the highest precision in the CNC process .
- Testing of the control technology and its ability to ensure the required precision and dynamics. servo-ready integrated gear motor Ensuring the compatibility of the
- drive system for CNC machines with existing or planned CNC controls. Definition of the required interfaces and communication protocols (e.g., field buses such as EtherCAT, Profinet) for the seamless integration of the
- Definition der erforderlichen Schnittstellen und Kommunikationsprotokolle (z.B. Feldbusse wie EtherCAT, Profinet) für die nahtlose Integration des gear motor into the CNC environment.
- Consideration of the environmental conditions at the place of use of the CNC machine and selection of the appropriate degree of protection (e.g., IP65) for the integrated gear motor.
The suitable gearbox design for your CNC application
The choice of gearbox design (planetary, bevel, worm gear) for your servo-ready integrated gear motor depends on the specific requirements of your CNC application. For example, for high-dynamic positioning tasks with low backlash, as found in many CNC machines cases, servo planetary gear motors are often used with under 3 arc minutes of backlash. Bevel gears are excellent for redirects in the drive train of the CNC machine.
Modern servo motor technology and control technology for CNC precision
High-resolution encoders and advanced control algorithms are crucial for the precision and dynamics, that a servo-ready integrated gear motor must deliver in CNC machines. For example, the latest servo motors use encoders with over 20-bit resolution for extremely accurate position detection, which is particularly important for path fidelity in complex machining (e.g., contour milling on a CNC machine) is. The compatibility with common CNC controls is naturally given.
Interfaces, communication, and environmental conditions for the gear motor in CNC manufacturing
Standardized field bus interfaces (e.g., EtherCAT, Profinet) and the appropriate protection class ensure seamless integration and reliable operation des of the servo-ready integrated gear motor in the CNC environment.. For example, for machining centers where coolants are used, integrated gear motors are typically delivered in IP65. A customer from the medical technology sector received drives with CANopen interface for a special CNC system , highlighting the flexibility of these drive solutions. Integrate: Learn how to optimally incorporate servo-ready integrated gear motors into CNC machines and discover application examples Axis drives in CNC machines: The heart of the movement
Integrieren: Servobereite integrierte Getriebemotoren optimal in CNC-Maschinen einbinden und Anwendungsbeispiele kennenlernen
are excellently suited as main and feed axis drives in various
Servo-ready integrated gear motors , including milling, turning, and grinding machines. For example, a manufacturer of 5-axis machining centers uses compact servo bevel gear motors as CNC machinesdrive solutions for CNC swivel and rotary axes to achieve high dynamics while maintaining a small footprint. Such ein, um hohe Dynamik bei gleichzeitig geringem Bauraumbedarf zu realisieren. Solche precision drives for CNC machines are often critical for performance. See also: Precision gear motors with minimal backlash.
Tool changers and handling systems in CNC automation: Fast and reliable
In peripheral components of CNC machines, such as tool changers or automated loading and unloading systems, increase servo-ready integrated gear motors efficiency and productivity. For example, a manufacturer of pick-and-place robots used in conjunction with CNC machines uses brushless servo gear motors, to achieve tool change cycle times of under 0.5 seconds. The reliability of these drive units for CNC peripherals is critical.
Rotary tables and swivel units: Precise positioning in space with the right CNC drive
For precise positioning of workpieces on rotary tables and in swivel units of CNC machines are backlash-free servo-ready integrated gear motors is crucial. For example, in turbine blade manufacturing, where tight tolerances must be maintained, these drive systems for CNC machines provide indexing accuracies of a few arc seconds, which is essential for producing precise 3D contours.Innovate: Recognize and utilize future trends in servo-ready integrated gear motors for CNC machines
Increase energy efficiency: Reduce costs, protect the environment with efficient CNC drives
Die continuous improvement of energy efficiency is a central development focus bei of servo-ready integrated gear motors for CNC machines. For example, by using the latest servo motors and optimized gear efficiency ratings, modern drive systems achieve high energy efficiency classes (often above IE4), which can reduce operating costs by CNC machines up to 10%.
Predictive Maintenance: Predict failures, maximize availability of CNC machines
Die Integration of sensors and intelligent algorithms into servo-ready integrated gear motors enables predictive maintenance. For example, optional digital servo gear motors with predictive maintenance sensors continuously monitor parameters such as temperature and vibrations. A customer was able to avoid an unplanned downtime worth approximately 20,000 Euros. CNC machine Artificial Intelligence for optimized drive control in CNC systems
Artificial Intelligence (AI) in the drive control of servo-ready integrated gear motors for CNC machines
holds enormous potential for optimizing machine performance and process stability. For example, AI-based algorithms can adjust control parameters in real-time to compensate for load fluctuations or wear in the birgt enormes Potenzial zur Optimierung der Maschinenperformance und Prozessstabilität. For example, KI-basierte Algorithmen können Regelparameter in Echtzeit anpassen, um Lastschwankungen oder Verschleiß im CNC drive system . The research aims at further precision and efficiency improvements.
More compact and power-dense designs for modern CNC machines
Die Miniaturization while increasing performance is an ongoing trend in the development of servo-ready integrated gear motors. For example, new materials and innovative manufacturing technologies have increased the power density of servo planetary gears by an average of 12% over the past three years. This opens up new possibilities in the field of robotics or for compact machining modules in CNC machines.
Servo-ready integrated gear motors for CNC machines are a crucial factor for the performance of modern manufacturing plants, as they combine precision, dynamics, and compactness. A careful selection of these drive solutions for CNC applications and consideration of future trends can significantly contribute to optimizing your manufacturing processes.
