Everything you need to know about selection, application, and benefits.
What distinguishes a spur gear motor from other types of gearboxes, such as planetary or worm gears?
Spur gear motors often provide a cost-effective and robust solution for applications with parallel shafts. Compared to planetary gears, they are usually simpler in design, while they typically offer a higher efficiency especially at medium to high speeds.
How do I determine the correct power and suitable gear ratio for my application?
The selection is based on the required output torque and desired output speed. It is advisable to oversize the torque by about 10-15%, to increase the lifespan. ATEK Drive Solutions supports you with technical consulting and design tools, to find the optimal configuration.
What role does the mounting position (M1-M6) play in selecting a spur gear motor?
The mounting position is crucial for lubrication of the gearbox. Incorrect specifications can lead to insufficient lubrication and premature wear. ATEK considers the specified mounting position to ensure the correct oil fill quantity and, if necessary, vent valves are provided.
How do modern spur gear motors contribute to energy efficiency?
Modern spur gear motors, especially in combination with high-efficiency motors (IE3/IE4) and operation on frequency converters, can significantly reduce energy consumption. Precise speed control allows for energy savings of up to 30%.
What does “custom adaptation” mean for spur gear motors from ATEK Drive Solutions?
ATEK offers diverse customization options beyond the modular system. This includes special shaft dimensions, flange geometries, coatings, special lubricants or the integration of brakes and encoders, to precisely meet your application requirements.
What protection class (IP rating) is necessary for my spur gear motor?
The standard protection class is often IP54, sufficient for dry environments. For dusty or humid conditions, such as in washing facilities, at least IP65 is required. ATEK offers options up to IP65 even with brake, to optimally protect the motor from environmental influences.
Why is compatibility with frequency converters important for spur gear motors?
Operating with frequency converters enables precise and stepless speed control, smooth starting and braking, as well as an optimization of energy consumption. ATEK motors are designed for operation with converters, thus supporting modern, flexible drive concepts..
What maintenance measures extend the lifespan of spur gear motors?
Regular inspections for noises, vibrations, and sealing are important. Compliance with oil change intervals and the use of the correct lubricant are also crucial. Changing from mineral oil to synthetic oil can extend the change interval from 5,000 to up to 15,000 operating hours. Optimal design
Die of a spur gear motor in terms of power, torque, and gear ratio is crucial for efficiency and longevity; a slight torque oversizing of eines Stirnradgetriebemotors hinsichtlich Leistung, Drehmoment und Übersetzung ist entscheidend für Effizienz und Langlebigkeit; eine leichte Drehmoment-Überdimensionierung von 10-15% can increase the lifespan. ATEK supports with modular systems and technical expertise..
Modern spur gear motors enable significant energy savings through the use of IE3/IE4 motors and frequency converters, which can reduce operational costs by up to 30% . Predictive maintenance through integrated sensors can also kann. Predictive Maintenance durch integrierte Sensorik kann zudem reduce downtime by up to 60 hours per year..
As a system provider, ATEK Drive Solutions supplies not only components but holistic drive solutions, including custom adaptations and comprehensive service. The use of original spare parts and correct lubrication, such as switching to synthetic oil, can extend maintenance intervals from 5,000 to 15,000 hours..Explore the world of spur gear motors: from the basics to the latest innovations and custom solutions. Discover how ATEK Drive Solutions can optimize your drive technology.
Are you looking for an efficient and reliable drive solution? Spur gear motors are versatile and offer numerous advantages. Learn more about the optimal solution for your application and contact us for personalized consulting at ATEK Drive Solutions.
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Understand the basics: What makes a spur gear motor stand out?
Definition and core function
Ein spur gear motor combines an electric motor and spur gear, reduces speeds, and increases torques. The coordination of the components determines the efficiency of the overall system. An example of this: Correctly sizing such drive units in packaging machines can improve cycle times by up to 10%.
Structure and interaction of the components
Essential parts of such a motor with gearbox are: the motor itself, the motor shaft, the spur gears, and the output shaft. The quality of the tooth profile and bearings significantly influences smooth operation and durability. ATEK uses, for example, hardened gears designed for over 20,000 operating hours, as used in robotics. Gearboxes and motors form a functional unit here.
Typical applications and industries
These gear motors are commonly used in intralogistics, mechanical engineering, for pumps, and agitators. Their advantages lie in compactness and high power density. Stainless steel versions, as required in the food industry, withstand over 1000 cleaning cycles per year. Spur gear brake motors combinations are common in many applications.Decoded: How spur gears convert power precisely
The principle of power transmission through gears
Power transmission in a spur gear occurs through interlocking gears. A precise tooth flank geometry minimizes friction as well as noise development and simultaneously increases efficiency. An optimized tooth profile correction can increase the efficiency of such a gearbox by up to 2%. Multistage spur gearboxes are particularly suitable for high gear ratios.
- Power transmission occurs through precise gears.
- Optimized tooth flank geometry minimizes friction and noise.
- Tooth profile corrections can increase efficiency.
- Gear ratios reduce speed and increase torque.
- Common designs include coaxial and bevel gearboxes.
- Special designs (Hygienic Design, ATEX) meet special requirements.
Understanding and utilizing gear ratios
The gear ratio (e.g., 50:1) in a gearbox reduces the motor speed and conversely increases the output torque. The correct choice of ratio is crucial for energy efficiency and to avoid motor overload. An example from agitator technology: A 1.5kW motor with a 100:1 ratio can replace a directly driven 5kW motor.
Common designs and their advantages
Coaxial designs of gearboxes are particularly space-saving. Bevel gears, often as a conical spur gear combination, allow for a 90° change of force direction. The selection of the suitable design significantly reduces design effort. ATEK offers modular systems with various flanges as well as solid and hollow shaft gear motors for optimal adaptation.
Special designs for special requirements
For the food and pharmaceutical industry, designs in Hygienic Design made of stainless steel (e.g., 1.4404) are required. In explosion-risk areas, ATEX-certified spur gearboxes are used. Such special designs ensure a longer lifespan under demanding conditions. An example: Stainless steel gearboxes in fish processing withstand saline influences for often over 5 years.Correct selection: Your path to the optimal spur gear motor
Power, torque, and speed define
The design of a spur gear motor is based on the parameters of power (kW), torque (Nm), and speed (RPM). A slight oversizing of the torque (about 10-15%) can increase the lifespan of the drive, while excessive oversizing unnecessarily consumes energy. An example for a lifting application: A motor with a constant torque of 50-75 Nm at a speed of 20-80 RPM.
Considering environmental conditions and protection class
Factors such as temperature, humidity, dust, and aggressive media influence the choice of materials and the required protection class (IP) of the gear motor. For dry halls, IP54 may be sufficient; in washing facilities, at least IP65 is necessary. Taking these aspects into account prevents premature failures. A special coating or sealed bearings can significantly increase the service life, for example, in a cement factory.
Mounting position and electrical integration
The mounting position (defined from M1 to M6) is relevant for the lubrication of the gearbox. Also, the electrical connection values such as voltage (230V/400V) and frequency (50/60Hz) must fit the existing supply. Flexible connection options simplify the integration of the drivetrain. Operating with a frequency converter, as offered by ATEK, enables precise speed control and can achieve energy savings of up to 30%. A motor with gearbox must be optimally matched for this.Providers in focus: Who delivers the suitable drive solution for spur gear motors??
The market for spur gear motors: An overview
The market for spur gear motors? ranges from global corporations offering standard drives to specialists for niche applications. The focus of manufacturers varies on volume, precision, or robustness. Important for users are not only the product itself, but also consulting and service. Large providers like NORD or SEW have extensive catalogs, while smaller suppliers are often more flexible with special requests for their gear drive.
- The market includes global corporations and specialized niche providers.
- Key aspects are product quality, consulting, and service.
- ATEK Drive Solutions positions itself as a system partner focusing on modular and custom solutions for gear motors.
- Selection criteria for a partner are quality, price-performance ratio, and competence.
- Availability and comprehensive service (design assistance, spare parts) are crucial.
- Industry understanding of the provider is an advantage.
ATEK Drive Solutions: System competence for your success
ATEK sees itself as a system partner combining years of experience in gear construction with modern servo motors to deliver powerful spur gear drive motors. The modular system allows for a variety of configurations, fast delivery times, and custom adjustments. An example from packaging technology: A servo bevel gearbox in combination with a controller from ATEK achieves a positioning accuracy of ±0.1mm. Custom gearboxes represent a focus area.
Criteria for selecting the right partner
The selection criteria for the appropriate supplier of a spur gear motor include quality, price-performance ratio, technical competence, availability, and service. Support in design, configurators, and the availability of spare parts are also important. A deep industry understanding of the provider is also beneficial. ATEK relies on long-term customer retention and maintains a stock of approximately 500,000 parts to ensure fast response times. The right spur gear motor requires careful consideration of these factors.Future-proof drive: Innovations and trends in spur gear motors?
increasing energy efficiency
Modern electric motors of efficiency classes IE3 and IE4 significantly contribute to reducing operating costs of spur gear motors? . The use of frequency converters further optimizes energy consumption through demand-oriented speed adjustment. The amortization of such measures often occurs within one to two years. An example from climate technology: The use of IE4 motors in conjunction with frequency converters reduced energy consumption by 18%. Energy-efficient gearboxes are increasingly becoming the standard today.
Digitalization and intelligent drives
The integration of sensors for capturing temperature, vibrations, or oil condition in the gear motor enables predictive maintenance and minimizes unplanned downtimes. Intelligent drives, in the context of Industry 4.0, optimize production processes through networking and data analysis. An example from the automotive supply industry: Networked drive units with condition monitoring reduced downtime by more than 60 hours per year.
Modularity and custom adaptation
Modular system solutions for gearboxes and motors allow for a wide variety of variants and short delivery times for the required spur gear drive motor. At the same time, the demand for custom solutions is increasing, which requires high flexibility on the part of the suppliers. ATEK addresses this trend with a modular system that allows for specific shafts, flanges, or brakes for applications in robotics or medical technology, often with delivery within a few weeks. Quiet gearboxes are often custom-made.Ensuring longevity: Maintenance and care of spur gear motors?
Proactive care: Inspection and lubrication
Regular inspections of spur gear motors? for unusual noises, vibrations, or leaks, as well as proper lubrication, ensure their lifespan. It is important to adhere to oil change intervals and use the suitable lubricant, tailored to the temperature and installation position of the drive. An example for continuous operation (S1): Changing from mineral oil to synthetic oil can extend the change interval from 5,000 to 15,000 operating hours.
Fault diagnosis and quick resolution
A systematic troubleshooting approach is crucial for problems with the gear motor. Overheating may indicate overload, incorrect lubrication, or insufficient ventilation. Unusual noises often indicate bearing damage or gear wear. Modern diagnostic options, such as integrated sensors or the evaluation of data from the frequency converter, accelerate troubleshooting. Error codes from the frequency converter (e.g., in case of blockage or phase interruption) can reduce repair time by about 30%.
Original spare parts and professional service
The use of original spare parts for the spur gear motor ensures accuracy, compliance with specifications, full functionality, and the planned lifespan of the component. ATEK offers comprehensive service, which includes repairs and on-site assistance. An example: A customer received their required drive after a failure within 24 hours through express delivery of spare parts and telephone support from experts.
