ATEK Drive Solutions

Heat-Resistant Power Packs: Temperature Compensated Gear Boxes for Extreme Environments

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Maximum performance and reliability for your high-temperature applications – ATEK Drive Solutions explains the technology.

What is a temperature-compensated gear motor for high-temperature systems?

Ein temperature-compensated gear motor for high-temperature systems is a specially designed drive that is engineered for reliable operation at extreme temperatures (e.g., over 150°C) . It uses heat-resistant materials (e.g., insulation class H), customized designs to compensate for thermal expansion, and often special cooling methods..

Why do standard gear motors often fail in high-temperature applications?

Standard gear motors are not designed for extreme heat. Their materials can fail or lose their properties (e.g., magnets demagnetizing), lubricants can oxidize or lose their viscosity, and seals can become brittle.This leads to premature wear and failures..

What critical design aspects must be considered for gear motors for high temperatures?

Important aspects include the selection of heat-resistant materials for gears, motors, and seals (e.g., SmCo magnets, FKM/FFKM seals) that compensation of thermal expansion,effective cooling strategies (e.g., forced ventilation, liquid cooling), and the use of appropriate high-temperature lubricants..

In which industries are temperature-compensated gear motors particularly advantageous?

They are essential in industries such as metal processing, ceramics, glass manufacturing, food industry (e.g., ovens), paper industry, and plant engineering for thermal processes. Wherever drives must operate reliably under extreme heat. .

How does ATEK Drive Solutions support companies in high-temperature applications?

As a system provider, ATEK offers comprehensive solutions, based on decades of experience. We combine high-quality standard components from our modular system with the capability to develop customized special solutions that are precisely tailored to the thermal and mechanical requirements of your application.

What role does lubrication play in the performance of high-temperature gear motors?

Lubrication is crucial.Standard oils fail at high temperatures. Synthetic high-temperature oils (e.g., PAO, PG) must be used, which retain their lubrication properties even in heat and allow for longer maintenance intervals. The correct amount and selection of oil, also depending on the installation position, is critical. längere Wartungsintervalle ermöglichen. Die richtige Ölmenge und -auswahl, auch abhängig von der Einbaulage, ist kritisch.

What should I consider when selecting a temperature-compensated gear motor?

Consider the maximum ambient temperature, the required torque at operating temperature, the ambient conditions (dust, moisture, Ex-zone), the installation position, the desired service life, and the type of cooling.A detailed analysis of these factors is essential for the correct design. What does ATEX compliance mean in relation to high-temperature gear motors?.

In explosion-prone areas that are also exposed to high temperatures, gear motors must be

ATEX certified. The temperature class (e.g., T3 = max. 200°C surface temperature) is an important factor in ensuring that the motor does not present an ignition source. Temperature-compensated gear motors ensure

reliable operation in extreme heat environments through special materials, customized design, and optimized cooling, which can prolong the lifespan by up to 25% and minimize production downtimes. Application-specific adaptation.

Die is critical for optimal performance; ATEK’s modular system allows for the configuration of solutions that deliver up to 30% more torque at target temperature and take specific thermal profiles into account. Correct high-temperature lubrication and proactive maintenance

are essential for longevity; the use of synthetic oils can extend oil change intervals by a factor of 2-3 and lower the total operating costs. Discover how temperature-compensated gear motors overcome the challenges of extreme heat and keep your plants running efficiently. Learn more about materials, cooling, and customized solutions.

In high-temperature environments, reliable drive solutions are essential. Temperature-compensated gear motors from ATEK Drive Solutions guarantee maximum performance even under extreme conditions. Do you need a tailored solution? Contact us at Gesamtbetriebskosten senken.

Entdecken Sie, wie temperaturkompensierte Getriebemotoren die Herausforderungen extremer Hitze meistern und Ihre Anlagen effizient am Laufen halten. Erfahren Sie mehr über Materialien, Kühlung und kundenspezifische Lösungen.

In Hochtemperaturumgebungen sind zuverlässige Antriebslösungen unerlässlich. Temperaturkompensierte Getriebemotoren von ATEK Drive Solutions garantieren höchste Leistung auch unter extremen Bedingungen. Benötigen Sie eine massgeschneiderte Lösung? Kontaktieren Sie uns unter ATEK Drive Solutions for individual consulting.

Do you need a reliable gear motor for your high-temperature application?

Request a custom solution now!

Understand: Basics of temperature-compensated gear motors for heat environments.

The reliability of gear motors at extreme temperatures (e.g., >150°C in industrial furnaces) is critical to avoid production downtimes. Standard drives often fail due to material fatigue or lubricant issues. Temperature-compensated gear motors for high-temperature systems, on the other hand, utilize special materials (e.g., insulation class H up to 180°C), customized designs, and cooling methods. Their development requires precise component tuning and drive technology-expertise.

The importance of temperature-compensated gear motors in high-temperature applications.

Such special designs, often referred to as temperature-compensated gear motors , can withstand temperatures up to 200°C by compensating for thermal expansion and maintaining material properties, relevant in the food industry, for example.

Applications and industries that benefit from this technology.

Industries such as metal processing, ceramics, paper industry, medical technology, and steel production (up to 1000°C) rely on heat-resistant drives, such as high-temperature motors for furnaces, which are considered a specialized form of temperature-compensated gear motors for demanding high-temperature systems.

Overview of challenges and solutions in the development of gear motors for extreme temperatures.

Important development aspects for drives in thermally demanding environments are material selection, cooling, and sealing technology (e.g., Viton up to 200°C) against lubricant loss.Optimize: Master material selection and design aspects for extreme temperatures.

Material selection is crucial for the performance of a temperature-compensated gear motor for high-temperature systems.Standard magnets lose effectiveness above 80°C; above 130°C, special rare-earth magnets (e.g., SmCo up to 350°C) and heat-resistant adhesives (e.g., high-temperature epoxies) are needed. Different coefficients of thermal expansion require tailored materials, design elements, and optimized fits/clearances. Low thermal expansion rotor designs can increase the lifespan of such drives in extreme heat conditions by up to 25%.

  • Critical material selection: The choice of the right materials is fundamental for performance in high-temperature environments, especially for a temperature-compensated gear motor.
  • Magnetic materials for heat: Standard magnets lose strength from 80°C; specialized rare-earth magnets such as Samarium-Cobalt (SmCo) are required for temperatures over 130°C (up to 350°C).
  • Heat-resistant adhesives: The use of high-temperature epoxies is essential for bonding components under thermal stress.
  • Management of thermal expansion: Different coefficients of thermal expansion of the components must be compensated through careful material pairing and design adjustments (fits, clearances).
  • Optimized rotor designs: Special rotor designs with low thermal expansion can significantly extend motor lifespan by up to 25%.
  • Dimensionally stable housing materials: Gear housings made of cast iron EN-GJL-200 or special steel alloys ensure dimensional stability even at temperatures above 200°C.

High-temperature materials for gears and motor components.

Gear housings made of cast iron EN-GJL-200 or special steel alloys maintain dimensional stability above 200°C, relevant for high-temperature resistant brakes for oven doors, which are often used in conjunction with gear motors for high temperatures.

Specific types of magnets and adhesives for use above 130°C.

Instead of neodymium magnets (demagnetizing at 150°C), AlNiCo or SmCo types are used, which deliver up to 30% more torque at target temperature, critical for the efficiency of drives in high-temperature systems.

Sealing technologies for protection against environmental influences and the maintenance of lubrication.

At 120°C continuous temperature, FKM or FFKM seals offer a 5- to 10-fold longer lifespan than standard NBR seals, an important aspect for durable temperature-resistant gear motors.Ensure: Implement effective cooling strategies and thermal management in high-temperature operations.

Effective heat dissipation is critical at high ambient temperatures, especially for the longevity of. temperature-compensated gear motor for high-temperature systems.. Forced-air cooling lowers the motor surface temperature by up to 30°C. Liquid cooling (e.g., water-glycol) is suitable for higher demands. Integrated temperature sensors (PT100, KTY) allow for monitoring and control interventions against overheating. For explosive zones, ATEX conformity is relevant, with the maximum surface temperature (e.g., T3 = 200°C) being classified. Corresponding Gear Boxes and motors, designed for such conditions, meet these requirements.

Various cooling techniques for high-temperature motors.

In 150°C ovens, forced-air cooling or water cooling is often necessary to keep winding temperatures of gear motors in heat environments below limits (e.g., 180°C, Class H).

Integrated temperature sensors and control systems for monitoring and regulating motor temperature.

A PT100 sensor for direct winding temperature measurement with a warning function (e.g., at 175°C) can prevent failures in thermally stressed drives.

ATEX conformity and temperature classes for explosive environments.

ATEX T4 means that the motor surface temperature does not exceed 135°C, allowing the use of specially certified temperature-compensated gear motors in certain explosive atmospheres.Maximize: Extend lifespan through proper lubrication and proactive maintenance

The choice of lubricant significantly influences the gearbox lifespan at high temperatures, a central aspect for any temperature-compensated gear motor for high-temperature systems.. Standard mineral oils oxidize quickly at 120°C; synthetic oils (PG, PAO) offer higher thermal stability. PAO oils (e.g., ISO VG 220) can extend oil change intervals at 100°C by a factor of 2-3. Vertical mounting requires careful design to prevent inadequate lubrication. The gearbox load capacity decreases with rising temperature (derating of the service factor); an SF of 1.5 at 20°C can drop to 1.2 at 60°C.

  1. Significance of lubricant choice: The correct selection of lubricant is critical for the lifespan of the gearbox under heat exposure, especially in drives for extreme heat conditions.
  2. Thermal stability of oils: Synthetic oils (e.g., polyglycols (PG), polyalphaolefins (PAO)) exhibit significantly higher thermal stability than standard mineral oils, which oxidize rapidly at 120°C.
  3. Extended maintenance intervals: PAO oils (e.g., ISO VG 220) can extend oil change intervals at operating temperatures around 100°C by a factor of 2 to 3.
  4. Challenges of vertical mounting: Special attention is needed for vertical installation positions to prevent inadequate lubrication, especially of the upper bearing.
  5. Service factor derating: The load capacity of a gearbox decreases with rising temperature (derating). A service factor (SF) of 1.5 at 20°C can drop to 1.2 or lower at 60°C, which may require redesign for lifespan (e.g., 20,000 hours), especially if it is a critical temperature-compensated gear motor.

Selection of high-temperature lubricants and their properties.

At 90°C oil temperature, synthetic oils (e.g., PAO ISO VG 220) have up to four times the lifespan of mineral oils, enhancing the reliability of gear motors in thermally demanding environments.

Vertical mounting positions and their influence on lubrication.

In vertical worm gears in hot areas, lubrication grooves or optimized oil amounts ensure the lubrication of the upper bearing, an important point for temperature-compensated drives.

Service factor derating at high temperatures.

A gearbox rated for 40°C with SF 1.0 may show an SF <0.7 at 70°C, requiring redesign for lifespan (e.g., 20,000 hours), especially when it is a critical temperature-compensated gear motor.Adapt: Develop custom gear motors for specific high-temperature requirements

Standard drives are often unsuitable for extreme temperatures due to specific requirements (profiles, torques, environment). Here, customized temperature-compensated gear motors for high-temperature systems come into play. Precise adaptation is crucial for performance and longevity, e.g., in agricultural ventilation systems (ammonia) or industrial furnaces (>100°C) that require specific insulation classes (H, C), bearings, and cooling systems. Modular building block systems enable quick, flexible configurations for niches such as textile drying ovens, often without the cost of new developments for such heat-resistant gear motors.

The importance of application-specific adaptation of gear motors.

Special machines (e.g., glass forming at 400°C) often require specific shaft materials, special bearings, and precise heat dissipation, which standard catalog motors cannot offer, making a specially adapted temperature-compensated gear motor necessary.

Examples of custom solutions in various industries.

Agitation drives in chemical containers (150°C, corrosive) may require stainless steel gearboxes (hygienic design) and special seals, similar to pharmaceutical solutions that rely on reliable drives for high temperatures.

The role of modular building block systems in realizing special solutions.

Modular systems shorten delivery times for customized high-temperature solutions (e.g., conveyors) that require a temperature-compensated gear motor , often to 4-6 weeks.Identify: Select the right gear motors and recognize future technology trends

Choosing the right drive requires a thorough analysis of the requirements: maximum ambient temperature, required power, torque, ATEX conformity, and available installation space are key factors in deciding on a temperature-compensated gear motor for high-temperature systems.. A checklist (performance, size, cooling, materials, protection class IP66) assists in this process. Future trends for drives in extreme heat conditions include even more temperature-resistant materials, intelligent cooling systems, and advanced sensors for predictive maintenance. Research and development focus on innovative coatings to improve heat dissipation and corrosion protection.

Checklist for selecting the right temperature-compensated gear motor.

Core criteria for selecting a suitable temperature-resistant gear motor: 1. Maximum operating temperature in the system. 2. Required torque at this temperature. 3. Specific environmental conditions (dust, humidity, ATEX zones). These points significantly narrow down the selection of potential drives for high-temperature applications.

Future trends and developments in high-temperature drive technology.

Current developments aim for improved insulation and materials to reduce the need for active cooling while simultaneously increasing the power density of gear motors for high temperatures by 15-20%.

The importance of research and development for the continuous improvement of technology.

R&D is essential as new technologies (e.g., SiC semiconductors) enable efficiency gains of over 5%, and market demands for temperature-compensated gear motors are steadily changing.

Temperature-compensated gear motors for high-temperature systems, are essential for reliable operation in extreme heat. The careful coordination of materials, design, cooling, and lubrication is crucial for developing powerful and durable solutions.

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