Maximum performance with minimal weight – Discover the advantages of lightweight gear boxes for your application.
What are the main advantages of lightweight gear boxes in industrial applications?
Lightweight gear boxes offer significant weight savings, leading to improved machine dynamics, higher energy efficiency and potentially faster cycle times . This can increase the overall productivity of your facility, for example, by shortening cycle times by 5-10% with a mass reduction of 20 kg.
What materials does ATEK use for lightweight gear boxes and how is stability ensured?
ATEK primarily relies on high-strength aluminum alloys (e.g., AlSi7Mg with >240 MPa tensile strength), which can be up to 50% lighter than cast iron. Additionally, some fiber-reinforced plastics are used. Stability is ensured by intelligent design through FEA simulations and topology optimization, without compromising on longevity.
Can lightweight gear boxes also be used for demanding applications with high loads?
Yes, ATEK’s lightweight gear boxes are designed to meet high performance requirements despite weight reduction. Optimized gear geometries, special heat treatments (e.g., increasing the endurance strength of aluminum gears by 20%), and robust bearings ensurereliability under load. How does the use of lightweight gear boxes affect the total cost of ownership (TCO)? sichergestellt.
Wie wirkt sich der Einsatz von Leichtgetrieben auf die Gesamtbetriebskosten (TCO) aus?
Although the initial purchase costs for lightweight gear boxes can be 10-20% higher , they often pay for themselves within 12-24 months.This happens through energy savings (up to 8% less energy for acceleration with a 2kg lighter gear box), the ability to use smaller motors , and increased productivity..
Does ATEK also offer custom lightweight gear box solutions?
Yes, the development of custom special solutions is a core competency of ATEK. Thanks to our modular system platform and a large stock, we can also develop tailor-made lightweight gear boxes for small series that are precisely adapted to your application requirements.
How does ATEK assist in selecting the right lightweight gear box?
ATEK offers comprehensive technical advice and support from design to commissioning. Our engineers analyze your specific application to ensure the optimal interaction of gear box, motor, and control system and to exploit the full potential of lightweight design. Lightweight gear boxes allow for a
Leichtgetriebe ermöglichen eine significant increase in plant efficiency through weight reduction, leading to improved dynamics and a possible reduction in motor power by up to 10% .
By using advanced materials such as aluminum alloys and intelligent design, lightweight gear boxes can reduce weight by up to 50% compared to cast iron and shorten cycle times by 5-10%..
ATEK Drive Solutions offers as a system provider tailored lightweight gear box solutions, which lower the total cost of ownership through a modular system platform and comprehensive advice and can increase productivity by 5-12%. Discover how ATEK’s lightweight gear boxes make your systems more efficient, dynamic, and cost-effective. Get informed now!
Are you looking for a way to increase the efficiency of your drive technology? ATEK Drive Solutions offers you innovative lightweight gear boxes that guarantee maximum performance at minimal weight. Contact us today at Produktivität um 5-12% steigern können.
Erfahren Sie, wie Leichtgetriebe von ATEK Ihre Anlagen effizienter, dynamischer und kostengünstiger machen. Jetzt informieren!
Sie suchen nach einer Möglichkeit, die Effizienz Ihrer Antriebstechnik zu steigern? ATEK Drive Solutions bietet Ihnen innovative Leichtgetriebe, die höchste Leistung bei minimalem Gewicht garantieren. Kontaktieren Sie uns noch heute unter /contact, to learn more!
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Understanding the basics: What lightweight gear boxes can do for your system
Lightweight gear boxes: Optimizing drive technology
Lightweight gear boxes enable high performance with low weight and can make plants more efficient, dynamic, and cost-effective.
Introduction to lightweight gear boxes
Suitable gear boxes can increase machine acceleration by 15%. Lightweight gear boxes are not only weight-reduced but also a factor for higher overall equipment effectiveness. Design and material selection minimize weight, influencing performance/costs. Example robotics: Weight reduction on the gripper arm can reduce motor power by 10%.
What makes a gear box lightweight?
Weight savings while maintaining full functionality are based on material science and design principles.ATEK utilizes aluminum alloys and some plastics. An aluminum housing is up to 50% lighter than cast iron; aluminum gear boxes are often the solution.
Why is low weight so crucial?
Lower weight improves dynamics and reduces energy costs.Example packaging machine: 20 kg less mass can shorten cycle times by 5-10%.Precisely define: Show features and benefits of lightweight gear boxes
Definition and characteristics of lightweight gear boxes
A lightweight gear box offers less weight than standard versions through material selection/design optimization, without compromising on lifespan. Lightweight construction must not diminish performance.. Aluminum alloys for servo bevel gear boxes save up to 30% weight compared to steel. Components are analyzed; miniature gear boxes benefit.
- Less weight than standard versions without loss of performance or compromises on lifespan.
- Use of advanced materials such as aluminum alloys (e.g., AlSi7Mg) and fiber-reinforced plastics.
- Intelligent design through FEA simulations and topology optimization for material efficiency.
- Significant increase in energy efficiency and machine dynamics.
- Reduction in operating costs through lower energy consumption and faster cycle times.
- Enabling higher productivity, often in the range of 5-12%.
Materials: The foundation of lightweight construction
Aluminum alloys are often standard for housings/structural components (strength, low density). AlSi7Mg alloys: >240 MPa tensile strength. Fiber-reinforced plastics can reduce weight by a further 15%.
Design: Intelligence over mass
FEA simulations serve material efficiency, optimize wall thicknesses. Topology-optimized rib structures reduced the mass of planetary gear box housings by 18%, increasing stiffness by 5%. Our gear boxes are designed that way.
Benefits that convince
Weight-reduced gear boxes increase energy efficiency/dynamics.. A robotic arm with a 2 kg lighter gear box needs up to 8% less energy for acceleration. This reduces operating costs, allows faster reactions, and boosts productivity (often 5-12%).Recognize potentials: Successfully deploy lightweight gear boxes across industries
Applications of lightweight gear boxes
Gear boxes with low weight are advantageous where mass is moved and dynamics matter. In pick-and-place machines, a 500g lighter gear box can shorten cycle time by 0.1s. Applications are diverse: Mechanical engineering, automation, stage technology. Drone drives are an example.
Mechanical engineering and automation
In tool/packaging Anlagen, they enable higher speeds/precision.. A customer increased the output of his carton erector by 12% through aluminum bevel gear boxes. Lower mass inertia moments benefit the drive train.
Special applications: From medical technology to e-mobility
Medical technology (surgical robots): every gram counts for precision/handling.. Miniature lightweight gear boxes (<200g) offer advantages. Similarly, intralogistics/e-mobility (range/efficiency). E-bike manufacturers increased range by about 5% through 300g lighter gear boxes.
Aerospace: The supreme discipline
Lightweight construction principles are also relevant for extreme environments (aerospace).Insights (e.g., surface treatments) flow into industrial gear box solutions. The weight of a drone actuator was reduced by 25%.Shape the future: Overcome technical challenges and leverage innovations in lightweight gear boxes
Challenges and future perspectives
Weight reduction must not compromise reliability/lifespan. Challenge: Balance lightweight construction, stability, heat dissipation.. Aluminum conducts heat differently. Optimized housing designs/ lubricants (up to 80°C) are solutions. Our modular system platform helps.
- The core challenge is balancing lightweight construction, stability, and effective heat dissipation.
- Technical hurdles are overcome through material research, intensive load testing, and optimized design details.
- Despite potentially higher initial costs, weight-optimized drives often pay off through lower total cost of ownership (TCO).
- Additive manufacturing (3D printing) opens new possibilities for complex, weight-optimized components.
- The integration of sensors contributes to further increases in efficiency and monitoring.
- Future innovations include new material combinations, optimized manufacturing processes, and the use of digital twins.
Mastering technical challenges
Material research/tests ensure performance.. Designs undergo load testing (1.5 times nominal load). Important: Bearings, gear geometry, material. Example: Heat treatment increased the endurance strength of aluminum gears by 20%.
Keep cost aspects in mind
Weight-reduced gear box solutions are not necessarily more expensive when considering TCO.. Initial additional costs (10-20%) amortize (12-24 months) through savings (motors, energy, productivity). Special gear boxes offer optimization.
Looking ahead: Innovations in lightweight construction
Additive manufacturing (3D printing) enables complex, weight-optimized geometries (Prototypes: -25% material). Integrated sensors increase efficiency. Developments:
- New material combinations
- Intelligent sensor integration
- Optimized manufacturing processes
- Digital twins for simulation
Collaboratively optimize: Realize your ideal lightweight gear solution with ATEK
ATEK Drive Solutions and lightweight gears
ATEK supports selection/implementation. Basis: Experience, tailored solutions. Modular building block system: millions of variants. Customer received angle gearbox (4.2 kg instead of max. 5 kg). Our gear boxes and motors are aligned.
- Comprehensive support in the selection and implementation of lightweight gear solutions.
- System competence for the optimal alignment of gear boxes, motors, and controls.
- Development of customized special solutions as a core competency, even for small series.
- High product quality through strict quality controls for every gear box.
- Continuous technical support from design to commissioning.
- Modular building block system enables enormous variety for tailored solutions.
- Use of online tools such as the configurator to accelerate inquiries.
System provider for your lightweight construction requirements
System competence: Consideration of the application for optimal interaction (gear boxes, motors, controls). A lighter gear box can enable a smaller motor (total costs -15%). ATEK engineers provide advice.
Customized solutions and variety of variants
Customer-specific special solutions: Core competency. Inventory (almost 500,000 parts), flexible manufacturing for economical small series. Laboratory automation manufacturer received miniaturized planetary gear box (weight -10% vs. standard).
Quality and service you can rely on
Product quality/customer service centralized. Every gear box undergoes quality controls. Technical support accompanies from design to commissioning. Online configurator accelerates inquiries (up to -30%).Increase efficiency: Secure sustainable competitive advantages with ATEK lightweight gear boxes
Conclusion
Weight-optimized gear boxes are important for efficient, dynamic drive systems. Targeted weight reduction brings advantages (energy, dynamics, TCO). Advanced materials/constructions, as ATEK uses, improve plant performance (energy savings of 10-15% possible). ATEK supports the utilization of lightweight construction potential. Experts provide individual advice.
