Discover how lubrication-free gear boxes can optimize your production processes and reduce costs.
What does “maintenance-free and lubrication-free” mean for gear boxes in continuous operation?
This means that these gear boxes can operate without regular relubrication and are designed for a continuous long-term use . This is achieved through special materials, coatings, and encapsulated designs, resulting in higher operational reliability .
For which industries are such gear boxes particularly advantageous?
They are ideal for industries with high demands for reliability and hygiene, such as the food and packaging industry, medical technology, industrial automation, and robotics.. Wherever downtimes must be minimized, und contamination must be avoided. .
What concrete cost advantages do maintenance-free gear boxes offer?
The main advantages are reduced operating costs due to the elimination of lubricants and maintenance personnel (savings of up to 20% annually possible) as well as minimized downtime costs.. For example, a food manufacturer saved over 5,000 euros annually by using such gear boxes.
How do these gear boxes contribute to increasing operational reliability?
By eliminating oil or grease changes, human error sources and contamination risks are eliminated.. The robust construction and low-wear materials ensure a consistently high reliability in continuous operation.
Are there limitations to using these gear boxes?
Yes, the initial investment is often higher.In addition, extreme shock loads or very high continuous temperatures require a careful examination and special design.Efficient heat dissipation in encapsulated systems is also an important aspect that needs to be considered.
What distinguishes the maintenance-free gear box solutions from ATEK Drive Solutions?
ATEK offers a broad portfolio from standard to custom solutions. Our strengths are the modular system concept for variety and quick delivery, decades of experience combined with newly developed motor expertise and comprehensive technical consulting..
Can ATEK also provide custom maintenance-free gear boxes for specific requirements?
Yes, ATEK specializes in the development of custom special solutions, even in small series. Our modular system allows for millions of configurations, to precisely address customer needs, for example for applications in stage technology or hygienic design.
How quickly do the higher acquisition costs for maintenance-free gear boxes pay off?
The amortization occurs through significant savings in maintenance efforts and reduced downtimes.. A total cost of ownership (TCO) analysis often shows a break-even point within, for example, 18 months, depending on the specific application and operating conditions.
Maintenance-free, lubrication-free gear boxes are crucial for continuous operation in demanding industries, as they significantly reduce downtimes (e.g., by 10% in packaging systems) and lower the total operating costs..
By using special materials, innovative coatings (such as DLC), and precise construction, these gear boxes offer an increased lifespan (e.g., 25% runtime increase), und improved operational reliability, which can increase OEE by up to 3%. ATEK Drive Solutions not only provides standard products as a systems provider but also
ATEK Drive Solutions liefert als Systemanbieter nicht nur Standardprodukte, sondern auch highly customized, maintenance-free drive solutions,, supported by a modular system concept und competent technical consulting, to ensure optimal performance and cost-effectiveness.Learn all about the benefits of maintenance-free gear boxes in continuous operation, from cost savings to increased efficiency. Ideal for demanding industrial applications!
In modern industry, reliability and efficiency are crucial. Maintenance-free, lubrication-free gear boxes for continuous operation provide an optimal solution. Are you looking for a drive solution that optimizes your processes? Contact us! Contact us for personalized consulting.
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Maintenance-free gear boxes: continuous operation, performance, reduced downtimes.
ATEK Drive Solutions’ lubrication-free gear boxes increase efficiency and reduce costs in production facilities designed for continuous operation without maintenance interruptions. A maintenance-free, lubrication-free gear box for continuous operation is often the key component. This article explains their benefits.Understand the basics of maintenance-free gear boxes for continuous operation.
Maintenance-free gear boxes: A necessity for continuous operation.
Downtimes are critical. ‘Maintenance-free’ means more than just the absence of lubrication intervals; it stands for higher operational reliability. A packaging manufacturer reduced downtimes by 10%, which increased profits. It is important to optimize the operating factor..
Applications for maintenance-free gear boxes
Dental handpieces (up to 400,000 rpm) require reliable gear boxes. Precision and failure safety are central in medical technology and industrial automation. Robotics manufacturers use such maintenance-free gear boxes for continuous operation for continuous production. Stainless steel gear boxes for hygienic areas offer additional options.
Industrial Automation: Continuous Performance.
Automated lines require reliable components for continuous operation. Maintenance-free, lubrication-free gear boxes, designed for continuous operation , can maximize OEE (Overall Equipment Effectiveness). An automotive supplier reduced unplanned downtimes by 5%. Often integration into hygienic design gear boxes is required.Benefit from technological advances in maintenance-free gear boxes.
Materials and coatings.
Long-term lubrication-free operation, as characteristic of a maintenance-free gear box for continuous operation , is enabled by special materials. High-performance polymers and ceramic components reduce friction values by up to 70%. Sintered bronze with solid lubricant deposits serves for self-lubrication. Even a maintenance-free motor benefits from this.
- Use of special materials for long-lasting lubrication-free operation.
- Utilization of high-performance polymers and ceramic components to significantly reduce friction values (by up to 70%).
- Use of sintered bronze with integrated solid lubricant deposits for continuous self-lubrication.
- Application of special coatings such as DLC (Diamond-Like Carbon) to minimize friction without liquid lubricants.
- DLC coatings are characterized by high hardness and extremely low friction coefficients (often below 0.1).
- Encapsulated design principles for effective protection against dirt and moisture ingress.
- Precision manufacturing with tolerances in the micrometer range to minimize wear and maximize lifespan.
Special coatings for friction minimization.
Friction without liquid lubricants is reduced by coatings. DLC (Diamond-Like Carbon) offers hardness and low friction coefficients (often <0.1). This technology, known from Formula 1, extends the lifespan of industrial gear boxes, especially in a maintenance-free, lubrication-free gear box for continuous operation.; tests showed a 25% runtime increase.
Design principles.
Maintenance-free gear boxes,especially those designed as lubrication-free solutions for continuous operation, are often encapsulated. This prevents dirt and moisture ingress, promoting longevity. Precision manufacturing (µm tolerances) minimizes wear. For extreme conditions, there are IP69K rated gear boxes..Maximize your advantages by using maintenance-free gear boxes.
Reduced maintenance costs.
Traditional gear box maintenance is costly. Eliminating lubrication tasks, personnel, and material can reduce operating costs by up to 20% annually. A food manufacturer saves over 5,000 euros annually by using a maintenance-free, lubrication-free gear box for continuous operation. Similar benefits are offered by a maintenance-free brake..
Increased operational reliability.
Minimized production downtimes are valuable. Without oil/grease changes, sources of error from humans or contamination are eliminated. This is critical in medical technology, where maintenance-free, lubrication-free gear box for continuous operation the highest reliability must be ensured. Gear boxes for water treatment (maintenance-free gear boxes water treatment) are an example.
Longer lifespan and reduced downtimes.
A longer gear box lifespan improves the balance. Low-wear materials and optimized designs extend the service life. A logistics center that switched to a maintenance-free, lubrication-free gear box for continuous operation maintenance-free solution extended exchange intervals from 2 to 3 years, which increased OEE by 3%. This also applies to corrosion-resistant units..Recognize the challenges and limitations of maintenance-free gear boxes.
Higher initial investment.
The acquisition of a maintenance-free, lubrication-free gear box for continuous operation. maintenance-free gear box can involve higher initial costs, but is often amortized through savings on maintenance and downtimes. A TCO analysis showed a break-even point after 18 months for a textile machine manufacturer. It is an investment in long-term reliability.
- Higher acquisition costs compared to conventional gear boxes can represent an initial hurdle.
- The amortization of higher initial costs often occurs through significant savings in maintenance efforts and reduced downtimes.
- A thorough total cost of ownership (TCO) analysis is recommended to evaluate long-term cost-effectiveness.
- Not every load situation is ideal; extreme shock loads or very high continuous temperatures require a careful review and possibly special designs.
- The heat dissipation in encapsulated, lubrication-free gear boxes poses a technical challenge that requires special design solutions.
- Special housing materials, cooling fins, or thermal pastes are often necessary to keep the operating temperature within the optimal range.
- Transparent consulting and precise knowledge of the operational limits are crucial for successful implementation.
Specific load requirements
Not every load situation is ideal for every maintenance-free, lubrication-free gear box for continuous operation. Extreme impact loads or high continuous temperatures require precise examination and, if necessary, special designs. For heavy-duty applications in mining (>50 kN), a low-maintenance solution has been developed. Transparent consulting about operational limits is important.
Heat dissipation
The heat dissipation in an encapsulated maintenance-free, lubrication-free gear box for continuous operation. is a technical challenge. Special housing materials and designs, e.g., with cooling fins or thermal pastes, keep temperatures during continuous operation below 60°C. Also relevant for a motor for continuous operation.Count on ATEK Drive Solutions for your maintenance-free continuous operation
ATEK’s range of maintenance-free gear boxes
ATEK offers standard and special drives, including a wide range of solutions that are designed as maintenance-free, lubrication-free gear box for continuous operation designed. The portfolio ranges from miniature bevel gear boxes to servo planetary gear boxes optimized for maintenance-free continuous operation. The V-series operates maintenance-free for over 10,000 hours. Stainless steel gear boxes are available for special requirements.
Custom adaptations
Going beyond standard, ATEK’s modular system enables millions of configurations and custom solutions, even in small series. A stage technology customer received their custom-made maintenance-free, lubrication-free gear box for continuous operation in just 8 weeks. Flexibility is also demonstrated in Hygienic Design gear boxes.
Technical consulting and support
Our engineering team advises on the optimal drive solution for your application case, especially when a maintenance-free, lubrication-free gear box for continuous operation is the requirement. Design software and an online configurator provide precise suggestions, which, for example, reduced design time in food processing by 30%. The goal is an optimal operating factor.
ATEK’s modular design system
Short delivery times despite a variety of variants are ensured by the modular structure with around 500,000 individual parts. For a machine builder, the delivery time for 50 special gear boxes was halved to 6 weeks. This flexibility is also of great benefit when configuring a maintenance-free, lubrication-free gear box for continuous operation. .
Ein maintenance-free, lubrication-free gear box for continuous operation is an important component for reliable production processes. ATEK places value on correct design and material choice. We are available for individual consulting.
