Discover the advantages of compact drive solutions for smooth processes and optimized performance.
What are the main advantages of integrated motor-gear box units for conveyor belts?
They offer a compact design, saving space, a higher energy efficiency through direct power transmission, improved hygienic properties especially with drum motors, and often a lower maintenance effort compared to traditional, separate components.
Which type of integrated unit is best suited for the food industry?
For the food industry, drum motors und gear motors in hygienic design e.g., made of stainless steel with smooth surfaces, are ideal. Their enclosed design facilitates cleaning and minimizes contamination risks, which is crucial for compliance with standards such as HACCP is critical.
How do integrated motor-gear box units contribute to energy savings?
Through the direct coupling of motor and gear box in a single unit, energy losses that can occur with external couplings and transmissions are significantly reduced. This leads to lower electricity costs and an improved CO2 balance of the entire conveyor system.
What should be considered when selecting an integrated unit for heavy-duty applications?
For heavy-duty conveyors, robust gear boxes (e.g., hypoid or bevel gear boxes from ATEK) with sufficient torque and a high service factor are crucial. Heat dissipation and bearing sizing also play an important role in longevity. spielen eine wichtige Rolle für die Langlebigkeit.
Can ATEK Drive Solutions offer custom motor-gear box solutions for conveyor belts?
Yes, ATEK Drive Solutions specializes in the development of custom special solutions. Thanks to a modular system concept and decades of experience, drive solutions for very specific requirements can also be efficiently implemented in small series. und bereits in kleinen Serien effizient realisiert werden.
How does sensor integration in these units improve maintenance and reduce downtime?
Integrated sensors enable the real-time monitoring of operating parameters such as temperature, vibration, and performance. This supports predictive maintenance,which optimizes maintenance intervals and significantly minimizes unplanned downtimes .
Are ATEK’s integrated drive solutions suitable for automated storage systems?
Yes, ATEK’s high-dynamic servomotors and precise gear solutions are very well suited for demanding applications in automated storage systems and intralogistics. Here, high positioning accuracy, fast acceleration and braking cycles as well as reliable communication with the control system are often required. zuverlässige Kommunikation mit der Steuerung gefordert.
What role does the system integration of the motor-gear box unit with the control system play?
A seamless system integration of the motor-gear box unit with the superior control system (PLC) and frequency converters/controllers is critical for overall performance and efficiency of the conveyor system. ATEK assists in the selection of compatible components and modern interfaces such as Profinet or EtherCAT for smart drives..
Integrated motor-gear box units optimize conveyor systems through a compact design, which often reduces space requirements by 20-30%, and a direct power transmission, minimizing energy losses and increasing efficiency.
The right selection, based on load, speed, and environmental conditions, is critical for performance; ATEK supports with modular system concepts for high variation and quick delivery times as well as customized drive solutions..
Future trends such as sensor integration for predictive maintenance,which can reduce unplanned downtimes by up to 70%, and, und energy-efficient smart drives (e.g., IE4/IE5 motors) significantly increase the overall efficiency and sustainability of conveyor systems.Learn how integrated motor-gear box units can revolutionize your conveyor systems. From space-saving designs to energy-efficient solutions – we show you the latest trends and technologies.
Are you looking for an efficient and reliable drive solution for your conveyor belts? Integrated motor-gear box units offer numerous advantages. Contact us at ATEK Drive Solutions, to find the optimal solution for your individual requirements.
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Introduction to integrated motor-gear box units for conveyor belts.
The selection of the right integrated motor-gear box unit for conveyor belts is crucial for process optimization, performance enhancement, and cost reduction.
Such combined drive solutions unite motor and gear box space-savingly, optimize power transmission, and can reduce energy consumption (relevant e.g., in logistics, Interroll). The key is to match the load dynamics. As the heart of automated processes, these motor-gear box combinations for conveyor systems influence reliability and lifespan; precise tuning is essential. Modular systems (ATEK, similar to SEW Eurodrive) and integrated brake systems are options. Selection criteria include performance, torque, environmental conditions, and maintenance. System integration with the control system is important. ATEK Drive Solutions GmbH advises on compact or custom solutions..Advantages of integrated motor-gear box units
Compact design and space savings
Integrated drive units for conveyor belts reduce installation space. This compactness simplifies machine designs and shortens assembly times (e.g., in Gebhardt Fördertechnik systems).
- Reduced installation space due to compact design.
- Simplified machine designs and shorter assembly times.
- Minimized energy losses through direct coupling of motor and gear box.
- Lower electricity costs and improved CO2 balance.
- Easier cleaning and reduced maintenance effort through enclosed design.
- Reduced risk of contamination since external lubricants are often omitted.
- Potential for higher overall system efficiency beyond individual components.
Higher efficiency and lower energy costs
The direct coupling in a motor-gear box combination for conveyor systems minimizes energy losses, lowers electricity costs, and improves the CO2 balance. Overall system efficiency is often more critical than just motor efficiency class (IE3/IE4). Ein continuously variable gear motor is suitable for variable speeds.
Improved hygienic properties and lower maintenance effort
The enclosed design of integrated gear motors for conveyor belts drum motors, hygienic design, facilitates cleaning and reduces maintenance effort. Vorteilhaft ist die geringere Kontaminationsgefahr durch fehlende externe Schmierstoffe. ATEK offers stainless steel and temperature-resistant gear boxes..Types of integrated motor-gear box units for conveyor belts
drum motors
Drum motors (e.g., Van der Graaf) are a special form of integrated motor-gear box unit for conveyor belts, where components are integrated in the drum; ideal for hygienic areas and bulk materials. Advantages: compactness, inherent safety (no external rotating parts).
Gear motors
Classical gear motors (spur gear, bevel gear, worm gear) represent a common variant of motor-gear box combination for conveyor systems and offer great variety. ATEK has modular systems available here. Hypoid gear boxes allow for high torques in compact designs. See torque-strong gear motors..
Wheel hub drives (AGV Wheel Hub Drives)
For FTS/AGV, wheel hub drives (e.g., Framo Morat) integrate as a compact drive solution components directly in the wheel. This enables better maneuverability and individual wheel control.
Planetary gear boxes in drum motors
Planetary gear boxes in drum motors (e.g., Rulmeca), as another version of the integrated drive unit for conveyor belts,offer compactness, hygiene, high power density, and quiet operation. Advantage: high ratios in the smallest space for slow, powerful applications.Selection criteria for integrated motor-gear box units
Load requirements and torque
The correct sizing of a integrated motor-gear box unit for conveyor belts (with respect to load, acceleration, speed, starting torques) is fundamental. System inertia affects the dynamic torque. ATEK uses software for drives for heavy-duty applications..
- Accurate definition of load requirements (load, acceleration, speed, starting torques).
- Consideration of dynamic torque and system inertia.
- Matching of motor, frequency converter/controller, and encoder for the desired speed range.
- Ensuring the required control accuracy.
- Selection of the appropriate degree of protection (IP class) according to environmental conditions.
- Consideration of material resistance to chemicals and extreme temperatures.
- Checking the necessity for special certifications (e.g., ATEX for explosive areas).
Speed range and controllability
In a integrated drive unit for conveyor belts, must be compatible with the motor, frequency inverter/controller, and encoder for the desired speed range and control accuracy (e.g., ATEK servomotors). This compatibility is crucial for the performance of the drive system for conveyor belts.
Environmental conditions and degree of protection
For a durable motor-gear box combination for conveyor systems degree of protection (IP class) and materials are important, especially in the presence of chemicals or extreme temperatures. Cleaning agents and temperature fluctuations affect seals and housings of the drive solution.ATEX-certified gear motors are necessary for explosive areas.Applications of integrated motor-gear units
Food industry
Integrated motor-gear units for conveyor belts (such as drum motors or solutions in hygienic design made of stainless steel) meet HACCP requirements through easy cleanability. Advantage: reduction of dead space, which is crucial for such drive solutions. ATEK offers stainless steel gears.
Logistics and warehousing
In logistics (e.g., Amazon, DHL sorting facilities), fast, precise drive systems for conveyor belts (often servomotors as part of a motor-gear combination) standard. Synchronization is often key.Modular drive units are flexible.
Packaging industry
In compact packaging machines, integrated gear motors for conveyor belts are ideal for precise product transport. Here, the ability of the drive unit to handle quick start-stop cycles is important. ATEK servo bevel gears are suitable for this.Trends and innovations in integrated motor-gear units
sensor integration for predictive maintenance,
Integrated sensors (temperature, vibration) in motor-gear blocks for conveyor belts enable condition monitoring for predictive maintenance. Intelligent data connectivity allows for precise failure predictions and optimized maintenance planning for these drive solutions.
- Increasing integration of sensors (temperature, vibration) for condition monitoring.
- Use of predictive maintenance through intelligent data connectivity for failure prediction.
- Development of ‘smart drives’ with their own intelligence and communication capability (Profinet, EtherCAT).
- Stronger networking in the context of Industry 4.0 through decentralized intelligence.
- Focus on more energy-efficient motors (IE4, IE5) and gear concepts.
- Emphasis on overall system efficiency over the entire lifecycle.
- Implementation of energy recovery mechanisms for further efficiency gains.
Smart drives and automation
‘Smart drives’ as further developments of integrated motor-gear box unit for conveyor belts, equipped with their own intelligence, communicate via fieldbuses (Profinet, EtherCAT) and thus are an important building block for Industry 4.0 applications. Decentralized intelligence in these drive systems relieves central controls. ATEK continuously expands the available interfaces.
Energy-efficient drives and sustainability
More efficient motors (IE4, IE5) and optimized gear concepts are an important trend in drive systems for conveyor belts.. The focus is on the system efficiency of the entire motor-gear combination over the lifecycle, including mechanisms for energy recovery.
The careful selection of a integrated motor-gear box unit for conveyor belts considering all factors is crucial for powerful and economical conveyor systems. ATEK supports the design of customized drive solutions.
