Maximal performance and reliability even under extreme conditions: ATEK Drive Solutions explains what matters.
What distinguishes an ATEK temperature-tolerant gear box from standard solutions?
Ein temperature-tolerant gear boxes for outdoor conveyors ensured by ATEK constant, reliable performance over the entire specified temperature range, not just surviving short-term peaks. This is achieved through specific design, material selection, optimized lubrication und extensive testing (e.g. 500 hours of continuous operation) ensured.
What temperature range do gear boxes for outdoor conveyors typically need to cover?
Gear boxes for outdoor conveyors can be exposed to extreme conditions, ranging from low temperatures around -20°C to high temperatures around +90°C during operation. ATEK designs gear boxes for the specific application case to withstand these fluctuations.
How much do extreme temperatures shorten the lifespan of gear boxes?
Extreme temperatures can shorten the lifespan of standard gear boxes by due to lubrication deficiency, material fatigue, and seal damage by up to 50% . Special seals like FKM can last significantly longer under temperature fluctuations than standard NBR seals, whose lifespan can be reduced by up to 60%.. Spezielle Dichtungen wie FKM können bei Temperaturschwankungen deutlich länger halten als Standard-NBR-Dichtungen, deren Lebensdauer um bis zu 60% reduziert werden kann.
Why are synthetic lubricants better for temperature-stressed gear boxes?
Synthetic lubricants, e.g. based on PAO, offer a higher thermal stability and a better viscosity index (VI > 150). This ensures a reliable lubrication both in cold and heat and can extend oil change intervals compared to mineral oils.
What materials and seals does ATEK use for outdoor applications?
ATEK relies on special alloys, high-strength aluminum alloys, or stainless steels (e.g. 1.4404) for housings. For seals, high-quality materials like FKM (Viton®) or multi-lip cassette seals are used to ensure resistance to temperature extremes and corrosion .
Can the operating temperature of an outdoor conveyor gear box be optimized?
Yes, through an optimized housing design with cooling fins, the use of fans or special coatings can lower the operating temperature of a gear box by up to 15°C. This improves performance and lifespan.
How does preventive maintenance help with temperature-tolerant gear boxes?
Regular inspections, temperature checks, and condition-based lubricant analyses (often only 50-100 euros) detect wear or contamination early on. This extends lifespan and helps to avoid costly unplanned downtimes.
Are ATEK gear boxes also suitable for dusty or corrosive outdoor environments?
Yes, ATEK develops robust gear boxes for outdoor use, which are also designed for dusty and corrosive environments. This is achieved through appropriate material selection (e.g. stainless steel), special sealing systems (e.g. labyrinth seals), and protection classes such as IP65 .
Ein temperature-tolerant gear boxes for outdoor conveyors is crucial to avoid costly downtimes (over 10,000 €/hour possible) and ensure operational safety even under extreme conditions such as -20°C to +90°C.
ATEK achieves superior temperature tolerance through special materials, optimized housing cooling (up to 15°C reduction in operating temperature) und high-performance lubricants, which can extend the lifespan of gear boxes compared to standard components by up to 200%..
Ein systemic approach for the entire powertrain und proactive maintenance, including oil analyses, are keys to maximizing facility availability and efficiency, supported by ATEK’s comprehensive consulting and custom solutions..Learn how to increase the efficiency of your outdoor conveyor systems and avoid costly failures with the right gear box solutions – even in heat, cold, or dust.
Outdoor conveyors are exposed to extreme weather conditions. A temperature-tolerant gear box is therefore essential. We show you what to pay attention to when selecting to minimize downtime and maximize the lifespan of your facility. Do you have special requirements? [Contact us](/contact) for personalized consulting!
Do you need a gear box that withstands extreme temperatures? We would be happy to advise you!
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Introduction: Why temperature-tolerant gear boxes are crucial for outdoor conveyors.
Unplanned downtimes of outdoor conveyors, especially in extreme weather conditions, lead to production losses and increased maintenance costs. ATEK Drive Solutions explains how a temperature-tolerant gear boxes for outdoor conveyors maximizes reliability and ensures plant operation even under difficult conditions. This contributes to increased productivity.
A downtime of the outdoor conveyor due to overheating of the gear box at, for example, 35°C outside temperature is a known issue for standard components. Such failures can incur costs of over 10,000 euros per hour of downtime. Selecting the right gear box is a strategic decision for operational safety. A robustly designed IP65 gear motor often forms a solid basis, especially when a gear box for demanding environmental conditions is needed outdoors.
In the context of industrial gear boxes, “temperature-tolerant” means more than just temporarily withstanding a surface temperature of 80°C, especially when the average operating temperature is 60°C and peaks reach 90°C. True temperature tolerance, as offered by a specially designed temperature-tolerant gear box for outdoor conveyors, ensures constant and reliable performance over the entire specified temperature range of the application, not just surviving short-term peaks. ATEK ensures this through extensive test cycles that simulate up to 500 hours of continuous operation under load, thus guaranteeing the performance of the gear boxes. The invisible enemies: How extreme temperatures threaten your gear boxes.
Die unsichtbaren Feinde: Wie extreme Temperaturen Ihre Getriebe gefährden
At low temperatures around -20°C, gear oil can thicken significantly, increasing starting resistance and hindering lubrication. Conversely, at high temperatures around +90°C, it becomes very thin, causing the lubricating film to break. Both lead to lubrication deficiency and increased wear, which can shorten the lifespan of gear boxes by up to 50%. The selection of the correct viscosity grade and a high viscosity index (VI), ideally above 150 for synthetic oils, are crucial for the protection of custom gear boxes.. For use in outdoor conveyors, it’s therefore essential to rely on thermally stable drive solutions. Increased starting resistance and hindered lubrication in cold (e.g. -20°C).
- Risk of lubricant film breaking due to thinned oil in heat (e.g. +90°C).
- Resulting lubrication deficiency and increased wear.
- Possible reduction of gear box lifespan by up to 50%.
- Material fatigue and seal damage due to temperature fluctuations (e.g. 40°C).
- Threat to precision fits due to thermal expansion/contraction of metallic components.
- Requirement for special materials and high-quality seals (e.g. FKM) for outdoor use.
- Erfordernis spezieller Werkstoffe und hochwertiger Dichtungen (z.B. FKM) für den Außeneinsatz.
Extreme temperatures also lead to material fatigue and seal damage. Temperature fluctuations of 40°C can reduce the lifespan of standard NBR seals by up to 60%. At the same time, metallic components expand or contract, threatening precision fits and potentially causing jamming or increased play. Special materials with adjusted thermal expansion coefficients and high-quality sealing materials, for example FKM (Viton®), are required for the demanding outdoor use of integrated motor-gear box units. must precisely meet these requirements. Ein temperature-tolerant gear boxes for outdoor conveyors Construction for extremes: How we build robust gear boxes.In corrosive or thermally demanding environments, the failure rate of gear box housings made of standard structural steel can be up to 40% higher.
Special alloys, high-strength aluminum alloys, or stainless steels like 1.4404 combined with optimized sealing systems, such as multi-lip cassette seals, provide better protection and longer service life, which is essential for a robust gear box for outdoor use. Corrosion-resistant unitsKorrosionsbeständige Einheiten from ATEK illustrate this approach.
A gear box housing with a smooth surface often does not dissipate operating heat effectively, especially when the ambient temperature is 40°C and the surface temperature of the gear box reaches 80°C. An optimized housing design with cooling fins, the use of fans, or special coatings can reduce the operating temperature by up to 15°C, further improving the performance of a temperature-tolerant gear box for outdoor conveyors. Additionally, the tuning of the initial filling with high-performance lubricants is important, especially for thermally highly stressed heavy-duty gear boxes..Lubricant management and maintenance: keys to longevity.
Mineral oils age more quickly at operating temperatures above 80°C, which can reduce oil change intervals by up to 50% and lead to additional costs and downtimes. Synthetic lubricants, such as those based on polyalphaolefins (PAO), offer higher thermal stability, a better viscosity index, and enable optimized wear protection for the entire drive technology.. This is particularly beneficial for the longevity of gear boxes for extreme outdoor temperatures..
- Accelerated aging of mineral oils and shortened change intervals at temperatures above 80°C.
- Superior thermal stability and viscosity index of synthetic lubricants (e.g., PAO-based).
- Optimized wear protection through synthetic oils combined with specific additives.
- Higher cost efficiency of proactive maintenance measures (e.g., oil analysis) compared to repairs.
- Early detection of critical wear or contamination (e.g., water content 0.05%).
- Extension of gear box service life through regular inspections, temperature monitoring, and condition-based analyses.
- Use of ATEX-certified gear motors with integrated sensors as an option for explosion-prone areas.
Proactive measures are more cost-efficient than reacting to already occurred gear box damages. An oil analysis, which often costs between 50 and 100 euros, can uncover early critical wear or contamination such as water content of only 0.05%. Regular inspections, continuous temperature monitoring, and condition-based lubricant analyses extend the life of gear boxes, especially when it comes to a heavily loaded temperature-tolerant gear box for outdoor conveyors, and help prevent unscheduled failures. For explosion-prone areas, ATEX-certified gear motors with integrated sensors are a suitable option.ATEK in action: Reliability under the harshest conditions.
A copper mine in Chile experienced frequent failures of its conveyor belt gear boxes due to extreme conditions (temperatures ranging from -10°C to +45°C, high dust load), resulting in production losses of approximately 15%. By employing ATEK’s tailor-made solutions, realized as a specific temperature-tolerant gear box for outdoor conveyors in the form of bevel gear boxes with special labyrinth seals and synthetic high-performance oil, the service life of the gear boxes was extended by 200%, meeting the demands of hypoid gear boxes for heavy loads. corresponds to.
Optimizing individual components in the drivetrain is often insufficient if the entire chain does not harmonize, leading to efficiency losses of up to 8%. ATEK Drive Solutions considers the entire drivetrain – from motor to gear boxes. to the brake – in order to configure the suitable temperature-tolerant gear box for outdoor conveyors for specific requirements. Experienced engineers also use simulation tools like Ansys for detailed thermal analysis and design.
Extreme temperatures represent a manageable risk for outdoor conveyor systems when carefully selected and designed gear box components are considered – a core aspect in any temperature-tolerant gear box for outdoor conveyors, and a systematic approach. ATEK Drive Solutions helps to secure the availability and efficiency of systems. Our experts are available for individual consulting to optimize system performance.
