Discover the advantages of play-free gear motors for maximum accuracy and efficiency in your applications.
What exactly does a gear play of “under one arc minute” mean?
A gear play of under one arc minute (Sub-Arcminute) means extreme high precision, where the twisting between the input and output shaft of the gearbox during load changes is minimal – often finer than the diameter of a human hair. This precision is crucial for applications that require the highest positioning accuracy.
Why is such high precision in gear motors important for my company?
Ein precision gear motor with play under one arc minute increases the product quality through precise movements, increases the productivity through faster and error-free cycles and reduces the scrap rates. This leads to lower overall operating costs and higher competitiveness, e.g., the repeat accuracy of a robotic arm can be improved from ±0.1 mm to < ±0.02 mm.
Which gearbox types are best suited for play under one arc minute?
For a play under one arc minute, especially harmonic drives (wave gears) are known to often achieve values < 0.5 arc minutes . Also, high-precision planetary gears und specifically preloaded spur gears can achieve this precision class but require the highest manufacturing quality and special design features.
How is such a low gear play technically realized?
A minimal gear play is achieved through a combination of high-precision manufacturing (tolerances in the micrometer range for gears and housings), the selection of high-strength materials, special preloading mechanisms e.g., counter-rotating gear strands and optimized bearing and lubrication are achieved.
Can ATEK Drive Solutions provide gear motors with less than one arc minute of play?
Yes, ATEK Drive Solutions as a system provider for the complete industrial drive chain configures and delivers precise gear motors that are designed for a play of under one arc minute. We utilize our modular system design and our expertise in custom special solutions, to develop the optimal drive unit for your specific requirements.
For which applications are precision gear motors with sub-arcminute play typically required?
Such high-precision drives are essential in robotics (e.g., assembly, welding), medical technology (surgical robots, dialysis machines), in machining technology (improving surface quality), in semiconductor manufacturing, the packaging industry and the aerospace industry..
What role do lubrication and bearing play in low-play gear motors?
Special lubricants with defined viscosity and temperature stability minimize friction, wear, and provide damping. A lifetime lubrication ensures constant operating conditions. High-quality bearings, e.g., ceramic bearings, increase system stiffness and can further reduce play, which is important for the consistency of the sub-arcminute precision .
How does ATEK support the selection of the right precision gear motor?
ATEK provides comprehensive technical consulting by experienced engineers, from the initial analysis of your application to commissioning. We support you in the design and optimization of drives, even for complex special solutions, and provide with our online product configurator a first orientation.
Ein precision gear motor with play under one arc minute is crucial for applications that require the highest positioning accuracy and can improve the repeat accuracy, for example, of robotic arms from ±0.1 mm to under ±0.02 mm.
Technologies such as preloading, high-precision manufacturing in the micrometer range, and special gear types (e.g., harmonic drives with <0.5 arc minutes of play) enable this extreme precision and can increase the surface quality in machining technology by over 20%..
ATEK Drive Solutions offers as a system provider modular and custom drive solutions, including precise gear motors with minimal play, supported by comprehensive technical consulting and fast delivery times.Find out how precise gear motors with minimal play can revolutionize your machines and what factors are crucial in selecting them.
In demanding applications where the highest precision is critical, gear motors with minimal play are essential. Discover how ATEK Drive Solutions meets your requirements. Contact us today for personalized advice at Contact.
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Understand: What precision under 1 arc minute really means
What does “play under one arc minute” mean?
Positioning deviations finer than a human hair affect product quality and efficiency. Reducing the gear play to values under one arc minute increases productivity and reduces scrap rates. For demanding applications, e.g., semiconductor manufacturing, it is precision gear motor with play under one arc minute essential; high-precision gears are key factors here.
The relevance of sub-arcminute precision
In robotics, a gear motor with play <1 arc minute can improve the repeat accuracy of a robotic arm from ±0.1 mm to < ±0.02 mm. This sub-arcminute precision enables more complex tasks and faster cycle times. Example: Pick-and-place robots with play-free gearbox compensation.
Impact of play on positioning accuracy
Play in the drive train causes inaccuracies. A precise gear motor with play <1 arc minute minimizes deviations for reproducible movements. In printing machines, such a high-precision drive enables sharp results at high speeds (runs >1 million/day).Explore: Functioning principles and types of low-play gear motors.
The interaction of motor and gearbox
The gear motor, especially a low-play drive, is a precisely tuned unit that adjusts speed and torque to the respective application. Core function: Converting high motor speed into lower output speed while simultaneously increasing torque – fundamental for many applications. Example: A heavy turntable is precisely positioned by a gear motor with a gear ratio of 10:1, where a precision gear motor with play under one arc minute is responsible for the highest accuracy.
- Core function of the gear motor: Speed adjustment and torque increase.
- Spur gears: Robust and cost-effective, play-free variants possible through preloading.
- Planetary gears: Compact, high torque density, play of 1-3 arc minutes achievable.
- Harmonic gears: Almost play-free (<0.5 arc minutes) through deformation principle.
- Suitability of harmonic gears for the highest precision in robotics and medical technology.
- Importance of matching motor and gearbox as a functional unit.
Spur gears: Advantages and disadvantages for low play
Spur gears are robust and cost-effective but often exhibit higher play. However, special play-free variants, for example with preloaded gears, achieve values of <5 arc minutes. FAULHABER reduces play in its gears through constructive measures such as preloading. An alternative are play-free planetary gears .
Planetary gears: Compact design and high torque
Planetary gears are excellent for applications with critical installation space and high torque density as the load distribution occurs over multiple gear engagements. This enables high torques with a compact design and, with good manufacturing quality, a play of 1-3 arc minutes.Servo-ready systems often leverage these advantages.
Harmonic gears (wave gears): The deformation principle for the highest precision
Harmonic gears, also known as wave gears, operate almost play-free through the elastic deformation of a flexspline. This special design allows for a gear play of under 0.5 arc minutes and thus excellent positioning accuracy; ideal for applications in robotics and medical technology. A surgical robot arm powered by a Harmonic Drive gearbox can achieve micrometer precision, for example.Optimize: Technologies for effective minimization of gear play
Preloading in gears: Methods and effectiveness
Preloading is a key technology for minimizing gear play. By precisely mounting components (e.g., twisting two gear strands against each other), the flank play is eliminated. This method, often applied in final assembly, ensures a defined, minimal play over the entire lifespan of the drive. FAULHABER achieves values of play <1 arc minute, an important requirement for a precise gear motor..
High-precision manufacturing: Tolerances and materials
Manufacturing accuracy is crucial: Tolerances in the micrometer range for gears, bearing seats, and housings are essential to realize a gear motor with play under one arc minute. High-strength steels or ceramic materials, combined with precise grinding and honing processes, reduce wear and thermal expansion and thus ensure play consistency over time. Hochfeste Stähle oder Keramikmaterialien, kombiniert mit präzisen Schleif- und Honverfahren, reduzieren Verschleiß sowie thermische Ausdehnung und sichern so die Spielkonstanz über die Zeit. Tooth flank profiles often achieve an accuracy of under 2 µm. This is equally important for high-precision bevel gears..
Special lubricants and bearing.
Special lubricants with defined viscosity and temperature stability minimize friction and wear and dampen the system. A lifetime lubrication ensures constant operating conditions and reduces maintenance effort, especially in hard-to-reach installation locations. High-quality ceramic bearings can increase the stiffness of the system and further reduce play, as is the case in high-speed spindles with over 50,000 RPM.Select: Criteria and application areas for the highest drive precision
Torque, speed and gear ratio
When selecting a precise gear motor with play of less than one arcminute the output torque, output speed and gear ratio are crucial parameters. A detailed analysis of the load profile, including acceleration and braking moments, is essential to avoid misdimensioning. For dynamic positioning tasks, a motor with low inertia and a suitable gearing (e.g. 10:1) is often selected to fully exploit the benefits of the minimal gear play to the fullest.
- Important selection parameters include output torque, speed and gear ratio.
- A detailed analysis of the load profile is critical to avoid misdimensioning.
- Load requirements such as radial/axial shaft loads, frequency of load changes and required lifespan must be taken into account.
- Operating conditions such as ambient temperature, humidity and media contact influence the choice of seals, materials and protection types.
- Precision drives, such as a gear motor with sub-arcminute precision, are essential in robotics for demanding assembly and welding tasks.
- In medical technology, for example in dialysis machines and surgical robots, the highest reliability and accuracy is required, often realized through drives with minimal play.
- Low-play gears (<1 arcminute) can significantly improve the surface quality in machine tools.
Load requirements and operating conditions
Furthermore, load requirements such as radial and axial shaft loads, frequency of load changes, and required lifespan (e.g. 20,000 operating hours) must be considered. The environmental conditions such as temperature, humidity and media contact often require special seals, materials (e.g. stainless steel) and protection types (e.g. IP65). ATEK offers, for example, gears in hygienic design for sensitive areas. These factors also influence the long-term performance of a precision gear motor with minimal play.
Application areas: From robotics to medical technology
Typical applications for drives with the highest precision can be found in robotics (demanding assembly and welding tasks) and in medical technology (e.g. dialysis machines, surgical robots), where reliability and accuracy are absolutely critical. In machine tools, a gear motor with play <1 arc minute can improve surface quality by over 20%. Other fields of application include micro-gears for micro-production robotics, where every micrometer counts and a precision gear motor with play under one arc minute is often the key to success.Benefit: Utilize ATEK’s system competence for your complete drive train
Modularity and custom solutions
ATEK Drive Solutions positions itself as a system provider for the entire industrial drive train. Our modular system allows for millions of configurations, offers a high variety of options and ensures fast delivery times (often under 4 weeks). We combine many years of experience in gear manufacturing with extensive servo motor expertise to also configure the ideal precise gear motor with play of less than one arcminute for your specific application. Example: a customized servo bevel gear for high-performance packaging machines.
Combination of experience and innovation
We combine proven drive technology with continuous new developments. Our engineers utilize the latest calculation and manufacturing methods to achieve optimal results. A core advantage lies in the ability to realize cost-effective custom special solutions even in small series, including high-precision drives with minimal play. For instance, we develop gears with integrated servo motors specifically for use in CNC machines. See also our servo-ready integrated gear motors.
Comprehensive technical advice and support
Our experienced technician team supports you from the first idea to commissioning and beyond. We help you select the optimal precision gear motor, especially when a gear motor with play of less than one arcminute is required, even for highly complex drive solutions. Use our online product configurator for a quick initial configuration and direct inquiries for gears up to 2,000 Nm.Looking ahead: Future trends and the conclusion for precise drive technology
Future developments in gear technology
The future of gear technology will be characterized by new materials such as high-performance plastics and powder metallurgical materials, which contribute to weight reduction while increasing strength. The integration of sensors for condition monitoring and predictive maintenance directly in the gear motor will further increase operational reliability. Such intelligent gears can report failures early (e.g. through vibration analysis with an accuracy of 0.01g), which further optimizes the performance of precise gear motors with low play .
Integration of sensors and control
Modern gear motors are becoming increasingly intelligent: the merging of gears, motors, sensors and control electronics into compact mechatronic units is advancing. This not only enables greater compactness and simplified commissioning but also allows for even more precise control of the drive – an important aspect in the context of Industry 4.0. An example of this is servo motors with integrated fieldbus interface.
Conclusion: Precision as a key component
Ein precision gear motor with play under one arc minute is more than just a component; it is a driver of innovation and efficiency in numerous industries. Investing in high-quality drive technology, exhibiting a gear play of less than 1 arcminute, enhances product quality, increases productivity, and sustainably lowers the total cost of ownership (TCO). ATEK Drive Solutions is your partner in finding the optimal drive solution. Contact us for personalized advice.
