Maximum flexibility and efficiency for your individual requirements – Discover the advantages of modular gear box solutions.
What are the main advantages of modular industrial gear boxes with variable ratios?
Modular industrial gear boxes with variable ratios offer maximum flexibility through adaptation to specific requirements, increased efficiency through optimized speeds and torques as well as faster delivery times thanks to standardized components. ATEK Drive Solutions enables millions of configurations.
How does ATEK Drive Solutions support the selection and configuration of these gear boxes?
ATEK Drive Solutions offers a comprehensive modular system, a online product configurator for gear box solutions and in-depth technical advice, to ensure that you receive the optimal solution for your specific application, including custom special solutions.
Can these gear boxes be adapted to different motor types from various manufacturers?
Yes, the modular design, for example with motor flanges and reducing sleeves or an input hollow shaft with clamping screw, allows the easy connection of IEC standard motors and motors from different manufacturers. This offers you manufacturer independence and flexibility..
What role does digitization play in modern industrial gear boxes?
Digitization, such as the PRODUCT.ID system from ATEK, enables quick access to product data, performance data, and exploded views directly at the gear box. This simplifies spare parts procurement, reduces downtime and can improve the OEE by up to 3%..
In which industries are modular industrial gear boxes with variable ratios particularly advantageous?
They are used in numerous industries, including the machine and plant construction, packaging industry, logistics, food industry (also stainless steel and hygienic design variants), robotics and automation, as well as in renewable energy technology,for example in wind turbines.
How do variable ratios contribute to energy efficiency?
Variable ratios allow for the precise adjustment of motor speed to the actual demand of the process. This reduces energy consumption, as the motor can operate in the optimal efficiency range. Systems like RECOVAR®-E achieve a system efficiency of about 97%..
What does “fast delivery time” mean at ATEK for modular gear boxes specifically?
Thanks to a large stock of almost 500,000 individual parts and an efficient modular system, many standard configurations and also customized solutions can often be delivered within a few working days (e.g. 4-6 days). Are custom special solutions also realizable in small quantities?
Yes, ATEK Drive Solutions specializes in the development of
customized special solutions, even in small series. This includes, for example, gear boxes with integrated servomotor or special adaptations for extreme environmental conditions.maximum adaptability
Modular industrial gear boxes with variable ratios offer efficiency, und by combining standard components with precise, variable gear ratios, which can increase theoverall equipment effectiveness (OEE) by up to 3%. Systems like ATEK’s modular system allow for kann.
Systeme wie das Baukastensystem von ATEK ermöglichen millions of configurations, und short delivery times (4-6 working days),, while advanced technologies like RECOVAR®-E can enable energy savings of over €200,000 annually for a 10 MW application.
Digital tools like the PRODUCT.ID system and maintenance-friendly designs significantly simplify maintenance,, minimize downtime, and contribute to the reduction of operating costs, which strengthens competitiveness.Learn how modular industrial gear boxes with variable ratios can optimize your production processes and enhance your competitiveness. From conception to implementation – we show you the possibilities!
Increase the efficiency of your systems with modular industrial gear boxes from ATEK. Variable ratios allow for precise adjustment to your specific needs. Contact our experts for personalized advice!
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Introduction to modular industrial gear boxes with variable ratios. für eine individuelle Beratung!
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Einführung in modulare Industriegetriebe mit variablen Übersetzungen
Modular industrial gear boxes with variable ratios increase plant flexibility and efficiency, optimize production processes, and can reduce costs.
Adaptable drive technology is crucial for responding to market requirements. Such modular industrial gear boxes with variable ratios combine the flexibility of standardized components with precise, customizable gear ratios. ATEK Drive Solutions’ approach to these adaptive gear box solutions covers the entire industrial drive train to optimize performance and energy efficiency across industries.
Standardized modules are intelligently combined. A special gear ratio for a new production line is often realizable with a modular system without complete redevelopment, reducing development times and costs. A modular system allows configuration from numerous components.
What makes the combination of modularity and variable transmission so powerful?
The synergy of modularity and variable transmission, a core feature of this industrial gear box,enhances plant efficiency by adjusting the motor speed to the process and reducing energy consumption. ATEK Drive Solutions leverages experience in gear construction and expertise in servomotors for this.
Applications and industry focus
These modular gear boxes are used in industries such as packaging, machinery, food industry (stainless steel variants), and logistics (high-performance gear boxes for fast, precise movements) and have proven themselves as industrial gear boxes with variable ratios in over 15 industries.Advantages of modular design in industrial gear boxes
Fast availability is a core advantage of modular systems, especially with modular industrial gear boxes.ATEK Drive Solutions delivered a configuration for a packaging machine under time pressure within days from such industrial gear box, out of over 400,000 individual parts. This is advantageous for custom small series that require adaptable gear box solutions. Fast availability, often within a few days, even for complex configurations from over 400,000 individual parts for
- Schnelle Verfügbarkeit, oft binnen weniger Tage, auch bei komplexen Konfigurationen aus über 400.000 Einzelteilen für modular industrial gear boxes,.
- ideal for custom small series and time-sensitive projects that require flexible gear box solutions. High cost efficiency through standardized components and optimized processes, a hallmark of the
- Hohe Kosteneffizienz durch standardisierte Komponenten und optimierte Prozesse, ein Merkmal der modular design,.
- reduction of manufacturing, maintenance, and spare part costs, which ensures good value for money in industrial gear boxes. Exact adaptation to specific requirements through versatile standard modules for diverse torques/speeds, a characteristic of
- Exakte Anpassung an spezifische Anforderungen durch vielseitige Standardmodule für diverse Drehmomente/Drehzahlen, ein Kennzeichen von modular industrial gear boxes..
- enormous variety of variants with millions of configuration options thanks to an extensive modular system (almost 500,000 individual parts) and digital infrastructure for modular gear boxes..
- Enabling the development of customized special solutions, e.g., special modular industrial gear boxes, with integrated servomotor for robotics.
Cost efficiency results from standardized components and processes, lowering manufacturing, maintenance, and spare part costs, ensuring a good value for money in modular industrial gear boxes. Exact adaptation to specific requirements through versatile standard modules for diverse torques/speeds, a characteristic of
versatility and adaptability through standard components.
Standard modules allow for precisely tailored designs, a feature of industrial gear box,for diverse torques/speeds. modular design,Online product configurators support the configuration of such solutions. Fast delivery times and enormous variant diversity gear box solutions..
Schnelle Lieferzeiten und enorme Variantenvielfalt
The modular system for modular gear boxes. allows delivery times of a few working days. Almost 500,000 individual parts and digital infrastructure enable millions of configurations.
Development of customized special solutions
Modular systems allow for the development of special gear boxes, such as special modular industrial gear boxes, for niches or small series, e.g., gear boxes with integrated servomotor for robotics with limited installation space.Variable ratios: Technologies and applications
Hydrostatically variable gear boxes, such as those from Parker Hannifin and Wikov for wind turbines, keep the output speed constant, often making frequency converters unnecessary and thus reducing complexity and costs. This type of gear box with variable transmission, like the Parker “Gold Cup” hydraulic systems, are known for their longevity.
- Hydrostatically variable gear boxes enables a constant output speed, which increases system stability.
- They can make frequency converters unnecessary, thereby reducing complexity and costs in gear boxes with variable ratios. reduce.
- Well-known systems such as Parker “Gold Cup” hydraulic systems are distinguished by their longevity as variable gear boxes aus.
- The RECOVAR®-E gear series from ZF, an example of industrial gear boxes with variable transmission capability,achieves a high system efficiency of about 97% for large drives (up to 150 MW) in the oil and gas industry.
- This leads to significant energy savings, for example, over €200,000 per year with a power of 10 MW by using such efficient gear boxes..
- In wind turbines, hydrostatic systems allow for the direct operation of synchronous generators on the grid, reducing power electronics and increasing the efficiency of gear boxes with variable ratios. .
- RECOVAR®-E gear boxes optionally offer redundancy and backup features to minimize downtime in critical applications. industrial gear box,The design of RECOVAR®-E (no tooth crown, accessible planetary shafts) simplifies the maintenance of these
- Die Konstruktion von RECOVAR®-E (kein Zahnkranz, zugängliche Planetenwellen) vereinfacht die Wartung dieser variable gear boxes..
The RECOVAR®-E gear box series from ZF for pumps/compressors (up to 150 MW) in the oil and gas industry, an example of industrial gear boxes with variable transmission, achieves approximately 97% system efficiency, allowing for significant energy savings (e.g., >200,000 €/year at 10 MW).
Hydrostatically variable gear boxes in practice
In wind turbines, hydrostatic systems enable variable transmission the direct operation of synchronous generators on the grid through constant speed, reducing power electronics and increasing efficiency (cf. Parker/Wikov project).
RECOVAR®-E: Efficiency and reliability for large drives
RECOVAR®-E gear boxes, as advanced industrial gear box,, minimize downtime through optional redundancy and backup functions. Their design (no gear ring, accessible planet shafts) simplifies maintenance.Selection criteria for modular industrial gear boxes with variable transmissions
The selection of suitable modular industrial gear boxes with variable transmissions requires a detailed requirements analysis (e.g., torque for heavy loads, precision for robotics). Specifications such as nominal torques and angular backlash are crucial for these customizable gear box systems : (cf. RPL series: high positional accuracy; RPS series: high ratios up to i=512). Performance and torque must be coordinated for each industrial gear box, .
Compatibility with existing systems and the connection of various motors (e.g., IEC standard motors) are important aspects when choosing modular industrial gear boxes.. An input hollow shaft with clamping screw allows for manufacturer-independent motor connection, which increases the flexibility of these gear boxes with variable transmissions .
Weighing performance, torque, and applications
A demand analysis prevents misplanning when selecting industrial gear boxes.. Conveying systems often require high efficiency and rapid transmission; mechanical engineering high torque density and precision, often realized through a modular bevel gear box as part of a modular industrial gear box with variable transmissions.
Size, compatibility, and motor connection
Compact designs and flexible motor connections (e.g., adapter plate for servo motors, hollow shafts like those in SITI MI A worm gear boxes) are advantageous in modular gear boxes with limited installation space.Digital product information and maintenance
The PRODUCT.ID system from ATEK Drive Solutions allows access to information such as performance data and exploded views via a digital label at the industrial gear box, , simplifies spare parts procurement for modular gear boxes. and can improve OEE by up to 3%.
- The PRODUCT.ID system provides direct access to performance data and exploded views via a digital label at the respective modular industrial gear box.
- . It simplifies spare parts procurement and can increase overall equipment effectiveness (OEE) by up to 3%. industrial gear boxes. Maintenance-friendly designs, a plus for many
- Wartungsfreundliche Konstruktionen, ein Pluspunkt vieler modular industrial gear boxes with variable transmissions, with easily accessible components significantly reduce operating costs.
- For example, RECOVAR®-E gear boxes, which are regarded as industrial gear boxes with variable transmission , allow inspections without complete disassembly, saving time and costs.
- By scanning the PRODUCT.ID label, technicians get instant access to data sheets, CAD models, and detailed maintenance instructions for the specific industrial gear box,.
- . This greatly enhances maintenance efficiency, especially when addressing unplanned downtimes of modular gear boxes.
- Design details such as easily accessible lubrication points or easily replaceable modules (an advantage of modular gear boxes, like in ZF EcoMet gear boxes) contribute to minimizing downtimes.
Maintenance-friendly designs with easy component accessibility, typical for many modular industrial gear boxes,, lower operating costs. RECOVAR®-E industrial gear box, allow, for example, inspections without disassembly.
By scanning, PRODUCT.ID provides technicians with data sheets, CAD models, and maintenance instructions for the industrial gear box,, which increases maintenance efficiency, especially during unplanned downtimes.
Maintenance-friendly designs for minimized downtimes
Details such as accessible lubrication points or replaceable modules – often a feature of modular industrial gear boxes – reduce downtimes. ZF EcoMet industrial gear box, for metros use standardized components for easy maintenance and high availability.Conclusion and outlook
Modular industrial gear boxes with variable ratios offer flexibility, efficiency, and adaptability for modern industrial requirements. The combination of modularity and variability, as ATEK Drive Solutions provides for such gear solutions , supports future-proof drive solutions and can sustainably strengthen competitiveness. Professionals are available for individual consultation on your specific modular industrial gear boxes with variable ratios .
