Less downtime, more performance: The drive solution for demanding conveyor technology
What are the main advantages of an integrated brake-gear unit for conveyors?
Integrated units offer significant space savings of up to 30% due to their compact design, increased safety through reliable fail-safe brakes, improved energy efficiency due to the optimal coordination of components and a reduced maintenance effort due to fewer components and interfaces.
How does ATEK ensure the reliability of its integrated brake-gear units in demanding environments?
ATEK ensures reliability through the use of high-quality materials such as stainless steel for housings, robust designs with special seals (e.g., double chamber shaft seals) and a precise manufacturing. Each unit is carefully designed for the specific environmental conditions to ensure maximum durability and performance .
Can ATEK deliver customized integrated brake-gear units for specific conveyor applications?
Yes, ATEK specializes in customized drive solutions.. Our modular construction system allows for millions of configurations. We develop custom special gears and units, even in small series, to realize the perfect technical and economic solution for your specific conveyor application.
What role does thermal management play in integrated brake-gear units, and how does ATEK address this?
Efficient thermal management is crucial for the lifespan and consistent performance of the drive unit, especially in heavy-duty applications or at high ambient temperatures. ATEK considers the thermal resistance already in the design phase and can offer solutions with optimized cooling, such as special housing designs or forced cooling.
How do integrated brake-gear units contribute to Industry 4.0 concepts?
Modern integrated units from ATEK can be equipped with smart sensors for parameters such as temperature, vibration, and brake wear. This enables real-time condition monitoring und and predictive maintenance,, which maximizes plant availability and minimizes downtime – a core aspect of Industry 4.0.
For which industries are ATEK’s integrated brake-gear units particularly suitable?
ATEK’s drive solutions are versatile and proven in numerous industries. These include especially the machine and plant engineering, packaging industry, logistics and warehousing, food industry, medical technology as well as demanding areas such as the mining or automotive industry, where the highest reliability and precision are required.
What support does ATEK provide in selecting and implementing an integrated brake-gear unit?
ATEK sees itself as a system provider and partner. We offer comprehensive technical consulting from the initial needs analysis through the detailed design and configuration of the drive solution to assistance with the integration into your system and commissioning.. Our goal is your long-term success.
How do integrated units differ from separate components in terms of installation and maintenance?
Integrated brake-gear units significantly reduce the installation effort, as the motor, gear, and brake are already optimally coordinated and often delivered as a pre-assembled unit. This leads to fewer interfaces, lower system complexity and a significantly reduced maintenance requirement compared to managing multiple individual components.
ATEK’s integrated brake-gear units optimize conveyor systems by significant space savings (up to 30%), increased safety through fail-safe brakes and enhanced energy efficiency, which lowers operating costs.
Thanks to a modular construction system and the ability to develop special solutions, ATEK delivers customized drive systems for conveyors in numerous industries, from the food industry to heavy machinery.
ATEK’s integrated solutions are future-proof through Industry 4.0 compatibility with sensor integration for predictive maintenance and contribute to the energy-efficient motors zur reduction of energy consumption .Discover how integrated brake-gear units optimize your conveyor systems, reduce costs, and increase operational safety. Learn more about the benefits, application areas, and innovative solutions from ATEK Drive Solutions.
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Introduction to integrated brake-gear units for conveyors
ATEK Drive Solutions’ drive solutions enhance the performance of conveyor systems and minimize downtime. In particular, an integrated brake-gear unit for conveyors offers specific advantages as a comprehensive system for various requirements.
Compactness and space saving
Such integrated drive and brake units reduce the required installation space by up to 30%. ATEK achieves this through intelligent design, as seen in the compact brake-gear motors .
Increased safety
Integrated fail-safe brakes, a core component of many integrated brake-gear units,, prevent continued operation during a power failure and stop conveyors immediately and safely. Bonfiglioli emphasizes the importance of such safety features. ATEK uses proven industrial brakes..
Efficiency improvements and reduced costs
The optimal coordination of gear and brake within the unit minimizes energy losses and thus lowers operating costs. The elimination of couplings in an integrated brake-gear unit for conveyors improves efficiency and reduces maintenance effort. IE3 motors (e.g., mk) also contribute to the efficiency improvement.Advantages of integrated brake-gear units
Types of gears and their specific strengths
The choice of gear type (bevel, planetary, worm gear) is crucial for the torque and lifespan of an integrated brake-gear unit for conveyors. ATEK offers, for example, hypoid gears for heavy-duty conveyors, which realize high torques in a compact installation space. A detailed application analysis ensures the optimal design of the drive solution; special gears are also possible.
- The choice of gear type (bevel, planetary, worm) is crucial for the performance of the drive unit.
- The gear type significantly determines the torque and lifespan of the integrated brake-gear unit..
- ATEK offers specialized solutions such as hypoid gears for heavy-duty conveyors as part of these units.
- Hypoid gears combine high torque with compact installation space, ideal for integrated systems.
- A careful application analysis ensures the optimal system design of the combined brake-gear motors..
- Individual requirements can be met through special gears within the integrated unit.
- The right gear selection is a core aspect of the efficiency of the entire integrated brake-gear unit for conveyors.
Modern brake technologies in focus
Modern electric brakes, as an important component of the integrated brake-gear unit., stop conveyors precisely, even at high cycle frequencies. They provide high holding forces and excellent controllability for cyclic operation (mm accuracy, e.g., in packaging). ATEK integrates appropriate brakes, from holding to working brakes, such as pneumatic disc brakes,into the drive systems.
Materials and structural details for longevity
High-quality materials (e.g., stainless steel housings) and special seals (such as double chamber shaft seals) protect the integrated brake-gear unit for conveyors from corrosion and dirt. LAT drum motors, for example, use IP69K for food industry applications. ATEK consistently considers these aspects for a high longevity of the drive solutions, even under extreme conditions.Technical aspects and design considerations
Applications in heavy industry and mining
Special designs, such as increased thermal resistance and robust housings, enable the use of integrated brake-gear units for conveyors even in demanding mining. Flender, for example, offers systems with optimized cooling. ATEK delivers solutions that are designed for large loads and frequent load changes (cf. Stiebel QuarryMaster). Such integrated motor-gear units reduce the complexity of the overall system.
- Special designs of the integrated brake-gear unit. are essential for use in heavy industry and mining.
- High thermal resistance of the components of the drive unit must be ensured.
- Robust housings protect the systems with integrated brake and gear from harsh environmental conditions.
- ATEK delivers solutions designed for large loads and frequent load changes, often as part of a integrated brake-gear unit for conveyors.
- Integrated motor-gear units help reduce the complexity of systems and increase reliability.
- Optimized cooling, as seen in Flender systems, is often an important design feature for high-performance integrated brake-gear units.
solutions for the food and pharmaceutical industries.
The food and pharmaceutical industry requires strict hygienic design: smooth surfaces, stainless steel (AISI 316L), and FDA-compliant lubricants are standard for every integrated brake-gear unit. LAT drum motors (IP69K) facilitate cleaning and prevent contamination. ATEK offers stainless steel gear boxes and special designs that avoid dirt traps and are suitable for high-pressure cleaning, making them ideal for use in integrated brake-gear units for conveyors these sensitive areas.
Precision in logistics and packaging technology
Integrated encoders and fast-switching brakes within the integrated brake-gear unit. ensure precise positioning and controlled processes, as required in fast packaging processes. Framo Morat’s intralogistics solutions demonstrate the achievable millimeter precision. ATEK configures flange gear motors with brake and encoder as a core component of the integrated brake-gear unit for conveyors for cycle times of under one second.Areas of application and industries
Correctly evaluate torque, speed, and environmental conditions
A precise design regarding torque, speed, and environmental conditions is the basis for the longevity of every integrated brake-gear unit for conveyors. For example, dusty operation (e.g., mk Fördertechnik) may require higher motor power. ATEK assists in accurate demand determination to avoid oversizing and unnecessary costs, always considering the thermal capacity of the components, which according to Flender is a critical factor.
- The precise design of torque and speed is fundamental for the longevity of the integrated brake-gear unit..
- Environmental conditions must always be considered in the design of the drive solution with integrated brake .
- ATEK supports demand determination to avoid oversizing of the integrated brake-gear unit for conveyors.
- The thermal capacity of the components is a critical design factor for every combined brake-gear motor.
- A correct assessment of all parameters ensures optimal performance and cost efficiency of the chosen integrated brake-gear unit..
The role of modularity for customized solutions
ATEK’s modular system allows for a variety of configurations to meet specific requirements of the integrated brake-gear unit for conveyors . This leads to optimal performance and, thanks to a large stock of parts, often to faster delivery times. Thus, custom-made modular brake-gear units, which are perfectly tailored to the respective conveyor application.
Partnership and technical support as a success factor
ATEK positions itself as a system provider offering comprehensive technical consulting from the design to the commissioning of your integrated brake-gear unit for conveyors . Similar to BEGE Engineering, ATEK accompanies its customers throughout the drive system integration process. The goal is the long-term success of the customer, based on experience and cooperative collaboration in the implementation of the drive solutions with integrated brake.Selection criteria and manufacturers
Digitalization: Smart drives for Industry 4.0
Integrated sensors for temperature, vibration, and brake wear enable real-time condition monitoring and predictive maintenance of the integrated brake-gear unit for conveyors. Flender’s DIAGNOSTEX® is a well-known example here. ATEK integrates such technologies to maximize plant availability and reduce downtime, thus providing smart integrated brake-gear units solutions for the demands of Industry 4.0.
Increase in energy efficiency as a continuous process
The continuous optimization of gear box efficiencies and the use of motors in higher efficiency classes (IE4/IE5) significantly reduce energy consumption of the integrated brake-gear unit for conveyors . The transition to IE3 motors (as at mk in 2021) was an important step in this direction. ATEK consistently focuses on energy-efficient components and a loss-minimizing design of each drive solution with integrated brake, which conserves both the environment and the budget.
More compact and lighter designs through new materials
The use of high-strength lightweight materials and optimized housing designs reduces weight and installation space of the integrated brake-gear unit. without loss of performance. This is particularly advantageous for mobile applications or in space-critical installations. ATEK continuously researches new materials and manufacturing processes to develop even more compact solutions, such as the compact screw drive system, which is often part of a integrated brake-gear unit for conveyors .
Future-proof, integrated brake-gear units for conveyor belts from ATEK are designed to sustainably optimize the efficiency and reliability of conveyor systems. ATEK experts provide individual consulting to achieve a sustainable increase in productivity through the use of these advanced combined brake-gear motors. .
