Maximize your energy efficiency with ATEK’s innovative solutions for energy recovery systems
What are the main advantages of an integrated inverter gear motor for my company in mechanical engineering?
For your company in mechanical engineering, an integrated inverter gear motor offers significant space savings due to its compact design, a higher system efficiency through optimized coordination and reduced losses, as well as lower assembly and wiring costs. This leads to more powerful and economical machines.
How does ATEK Drive Solutions support the selection and implementation of such energy recovery systems?
ATEK Drive Solutions provides you with comprehensive technical consulting from design to commissioning. With our modular system we configure the optimal drive solution for your specific energy recovery requirements and ensure fast delivery times even for custom adaptations.
For which industrial applications are integrated inverter gear motors with energy recovery especially suitable?
These systems are excellent for applications with frequent braking and acceleration cycles, such as in robotics, conveyor systems, packaging machines, machine tools and autonomous transport systems. Wherever energy efficiency and precision are required, they show their strengths.
What role does inverter technology, for example with silicon carbide (SiC), play in energy recovery?
Modern inverter technologies, especially those with silicon carbide (SiC) semiconductors, enable higher switching frequencies and lower switching losses. This leads to a more efficient conversion of the energy recovered during braking and a higher power density of the entire drive system.
Can ATEK also develop completely custom integrated inverter gear motors if standard solutions do not fit?
Yes, one of our core competencies is the development of custom special solutions. Even though our modular system allows for millions of configurations, we also develop completely tailored integrated inverter gear motors, even in small series.
How does the integration of motor, gear, and inverter affect overall costs and delivery times?
The integration often leads to lower total costs (Total Cost of Ownership) due to reduced assembly effort, fewer components, and optimized efficiency. Thanks to our large inventory and the modular system ATEK can also achieve very fast delivery times for integrated solutions.
What specific efficiency increases are realistic through energy recovery with integrated systems in industry?
The efficiency increase depends on the application. In industrial automation, for example, up to 20% of energy can be recovered . Overall system efficiencies of over 95% are achievable with optimally designed integrated drives with energy recovery. sind bei optimal ausgelegten integrierten Antrieben mit Energierückspeisung erreichbar.
How does an integrated inverter gear motor contribute to the sustainability of my production processes?
Through the effective energy recovery these systems reduce the overall energy consumption of your machines and systems. This leads to lower CO2 emissions and a more responsible use of resources, which directly improves the sustainability of your production.
Integrated inverter gear motors optimize energy recovery through a compact design and minimized electrical losses, which can lead to system efficiencies of over 96% and significantly reduces the space requirement.
Modern technologies such as SiC-based inverters und highly efficient PMSM motors are crucial for the performance of these systems, enabling higher recovery rates of up to 20% in certain industrial applications and a better power density..
ATEK Drive Solutions supports companies as a system provider with flexible and quickly deliverable integrated drive solutions, made possible by a modular system custom adaptations for maximum recovery efficiency and thus contribute to the achievement of performance and cost targets .Discover how integrated inverter gear motors are revolutionizing energy recovery and what advantages they offer for your applications.
Energy recovery is a crucial factor for the efficiency of modern drive systems. ATEK Drive Solutions presents innovative, integrated inverter gear motors that set new standards. Learn more about our customized solutions – contact us at /contact!
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Understanding the basics: How integrated systems optimize energy recovery
What exactly is an integrated inverter gear motor?
Ein integrated inverter gear motor, often the heart of modern energy recovery systems, combines motor, gear, and inverter in a compact unit. The inverter converts the electric current while the gear adjusts speed and torque to the respective requirement. The seamless coordination of these components is especially critical in energy recovery systems . An example of this is Bosch’s IMG Gen3, which utilizes up to 400 Nm for recuperation.
The principle of energy recovery simply explained
Energy recovery (recuperation) converts kinetic energy (e.g., braking) into electrical energy, which is fed back to the battery via the inverter. This conversion is crucial for range and efficiency. ZF eDrive achieves over 96% efficiency.
Why is integration the key to success?
Integration minimizes electrical losses and optimizes thermal management (e.g., Schaeffler 4in1 electric axle). Compact design saves space/weight, increases power density, reduces assembly times, and improves as an optimized drive system overall costs.Analyze the core components and their synergies in detail
Modern inverter technologies: The brain of the system
Modern frequency converters, often based on silicon carbide (SiC), are a central element for efficient recovery in an integrated inverter gear motor for energy recovery systems. They enable high switching frequencies and thus reduce losses. Bidirectional inverters are essential to process and reuse the recovered energy. A precise and fast energy control is crucial here. The AVL SPECTRA™ Universal Inverter, for example, supports switching frequencies up to 96 kHz.
Optimized gear solutions: Precisely convert power
Integrated gears, such as planetary gears for high torque density or bevel gears for power flow redirection, perform significantly more in such systems than standard solutions. An optimal gear adjustment within the drive unit maximizes recovery efficiency. ATEK’s modular system offers millions of configuration options, including for controllable gear motors with integrated frequency inverter, which represent an important variant.
Efficient motor types: The muscle of energy recovery
Permanent magnet synchronous motors (PMSM) are often the first choice for an integrated inverter gear motor. Their ability to generate high recuperation torque even at low speeds is particularly advantageous for energy recovery systems. Transfluid Tier G drives, based on PMSM technology, achieve an efficiency of 97%. Asynchronous motors (ASM) generally offer lower recuperation performance.Show benefits that go beyond mere energy savings
Compactness and reduced weight: More than just space savings
A mechanical engineering customer was able to reduce the required space by 25% by using a integrated inverter gear motor . This reduction in space and weight not only lowers material costs but also significantly simplifies the overall machine design , as impressively demonstrated by the Schaeffler 4in1 electric axle. Such advantages are typical for a integrated inverter gear motor for energy recovery systems.
- reduction in space and weight that lowers material costs and significantly simplifies machine design.
- Increased system efficiency is achieved through minimized electrical interfaces and optimally matched components.
- Improved utilization of recovered energy leads to longer operating times and noticeably lower energy costs.
- More efficient cooling concepts, made possible by integration, increase the lifespan of electronics as well as the motor and enhance system reliability.
- The reduced number of individual parts, interfaces, and the lower wiring effort significantly simplify assembly.
- Fewer different components reduce storage and procurement costs, improving overall economics.
Increased system efficiency and performance: Achieving the optimum
Through minimized electrical interfaces and optimally matched components, integrated drive systems with recuperation capability significantly enhance overall efficiency (ZF eDrive achieves over 96%). High efficiency means less energy loss, better utilization of recovered energy, which in turn leads to longer operating times and lower energy costs.
Improved thermal management and reliability: Ensuring longevity
The integration of components into a compact motor-gear-inverter unit for energy recovery enables more efficient cooling concepts. A stable temperature range increases the service life of electronics and motor and enhances system reliability, an aspect that Sonplas also emphasizes in the field of power electronics.
Reduced complexity and costs: Economics in focus
Integration reduces the number of individual parts, interfaces, and wiring effort, which simplifies assembly. Fewer different components reduce storage and procurement costs.ATEK’s modular system (with around 500,000 stock items) ensures fast delivery times and underscores the cost-effectiveness of such system solutions.Demonstrating applications: Where integrated systems are already excelling today
Revolution in electromobility: Enhancing range and driving pleasure
In electric vehicles, they enable integrated inverter gear motors, often considered the heart of e-axles (like those from ZF or Schaeffler), providing efficient energy recovery during braking. Efficient energy feedback is crucial for the practicality of electric vehicles (EVs) and plug-in hybrid vehicles (PHEVs), as it increases range. For example, Bosch’s IMG Gen3 achieves an efficiency of 95%.
Increasing efficiency in industrial automation: Precision meets economy
In industrial automation, for instance with robots and conveyor systems, integrated systems with feedback functions significantly reduce operating costs. Precise control and the ability for recuperation (up to 20% energy savings with robotic arms) are particularly advantageous here . ATEK provides special servo solutions as integrated drive units for such applications.. ATEK bietet für solche Anwendungen Contributing to sustainability in renewable energies: Utilizing every kilowatt hour.
The principles that distinguish a
are also applied in the integrated inverter gear motor for energy recovery systems renewable energy sector , such as in solar tracking systems or small wind turbines. High efficiency and compactness optimize energy yield here. . Transfluid systems utilizing PMSM with an efficiency of 97% demonstrate the great potential of this technology.Mastering challenges and shaping the future of drive technology
Herausforderungen meistern und die Zukunft der Antriebstechnik gestalten
Current challenges: Keeping costs and complexity in mind
The initial investment for a integrated inverter gear motor for energy recovery systems can be higher than for conventional, decentralized solutions. Additionally, effective thermal management of the closely integrated components is demanding. The development and integration of such systems require comprehensive know-how in mechanics, electronics, and software, for example in the characterization of SiC MOSFETs.
- Higher initial investments compared to conventional systems can present a barrier to entry.
- Effective thermal management of the closely integrated components is challenging and requires specific expertise.
- The development and integration of such complex systems rely on extensive interdisciplinary knowledge in mechanics, power electronics, and software.
- Future developments are strongly focused on further miniaturization and efficiency enhancement, for example through the use of wide-bandgap semiconductors like gallium nitride (GaN) and silicon carbide (SiC) in drive systems with integrated frequency converters and gearboxes for recuperative applications..
- The integration of artificial intelligence (AI) promises optimized control algorithms and the realization of predictive maintenance to increase system availability.
- Progressive standardization of interfaces and communication protocols is essential to simplify integration and reduce development costs.
- ATEK Drive Solutions positions itself as a competent system provider that realizes flexible and quickly deliverable drive solutions for specific customer requirements with its modular kit system, particularly in the area of integrated drive units with recuperation capability..
Future developments: Smarter and more efficient
Future developments in integrated drive solutions for energy recovery target further miniaturization and efficiency enhancement, for instance through the use of wide-bandgap semiconductors like gallium nitride (GaN) and silicon carbide (SiC). The integration of artificial intelligence (AI) for optimized control algorithms and predictive maintenance also plays a significant role. The standardization of interfaces and communication protocols will simplify integration and reduce development costs.. Research projects, like Tektronix SOLN-IMDA-EV, are driving these innovations forward.
ATEK’s role as a system provider: Your partner for integrated solutions
ATEK Drive Solutions is your system provider for industrial drives, specialized in solutions like the integrated inverter gear motor for energy recovery systems. Our modular kit system enables millions of configurations and fast delivery times for standard and custom solutions, such as integrated motor-gear units for conveyors.. We offer comprehensive technical consulting and an excellent price-performance ratio (aiming to increase revenue by +50% by 2029).
Integrated inverter gear motors for energy recovery systems are a key factor for greater efficiency and sustainability in numerous applications. Their compactness, high power density, and ability for effective energy feedback are key features that make them ideally suited for future-oriented drive concepts. ATEK’s expertise and our modular kit system support you in realizing the optimal, future-proof drive solution for your specific requirements. Contact us to learn more about our system solutions with integrated inverter and gear motor for energy feedback. to learn more.
