Customized gear boxes for individual challenges – ATEK Drive Solutions
What is a special gear box and how does it differ from a standard gear box?
Ein Special gear boxes is a custom drive solution, precisely tailored to specific customer requirements regarding performance, shape, material, or environmental conditions. In contrast, standard gear boxes are series products with defined specifications that not always optimal for complex or unique applications fit.
When should I consider a special gear box instead of a standard solution?
A special gear box is recommended when standard solutions reach technical limits. This is the case with extremely limited installation space, very high demands for precision (e.g. play < 1 arcmin), special environmental conditions (e.g. ATEX zones, low temperatures), specific material requirements (e.g. stainless steel for the food industry), or when an optimized system integration with motor and control is required.
In which industries are ATEK’s special gear boxes particularly beneficial?
ATEK special gear boxes offer advantages in numerous industries, including the machine and plant engineering for high-dynamic movements that robotics and automation for the highest precision, that renewable energies for reliability under extreme conditions as well as the food and medical technology, where special materials and hygiene requirements exist.
How does ATEK ensure the quality and performance of its special gear boxes?
ATEK ensures quality through a partnership-based development process, the use of CAD and FEM tools for design optimization, precise CNC manufacturing and a strict quality assurance according to DIN ISO 9001.. Every special gear box undergoes a comprehensive final inspection, which checks, among other things, operating noise and backlash.
What advantage does ATEK’s modular system offer for special gear boxes?
ATEK’s modular system with nearly 500,000 individual parts enables a quick and efficient configuration of special gear boxes. It allows the combination of proven components into new, customized solutions, which can shorten development times by up to 30% while simultaneously ensuring proven reliability. What are the decisive factors in the costs of an industrial special gear box?
Was sind die entscheidenden Faktoren bei den Kosten eines industriellen Sondergetriebes?
The costs of an industrial special gear box depend on several factors: the complexity of the design, the materials used (e.g. stainless steel, special alloys), the required precision and tolerances, the quantity (single piece vs. small series) and the necessary tests and certifications (e.g. ATEX).
Special gear boxes ATEK’s are custom drive solutions, used where standard gear boxes reach their limits, thus enabling technical excellence in specific applications.
Through a collaborative development process and a modular system , ATEK efficiently realizes special gear boxes that shorten development times by up to 30% and ensure an optimal system integration. ATEK special gear boxes offer not only technical superiority but also
ATEK Sondergetriebe bieten nicht nur technische Überlegenheit, sondern auch long-term economic value through higher efficiency, longevity, and reduced downtime, leading to TCO savings of over 20% can be achieved.Discover the world of special gear boxes: From conception to manufacturing – ATEK provides you with innovative solutions for your specific requirements. Learn more about our expertise and our modular system.
Standard is not enough for you? ATEK Drive Solutions develops special gear boxes that are perfectly tailored to your individual needs. Our experts support you from the first idea to the final implementation. Contact us now Contact us!
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Understanding what Special gear boxes they can do and when they are indispensable
When standard drives reach their limits, specialized gear boxes offer expanded technical possibilities. ATEK Drive Solutions develops customized drive solutions for specific challenges. erweiterte technische Möglichkeiten. ATEK Drive Solutions entwickelt maßgeschneiderte Antriebslösungen für spezifische Herausforderungen. These gear boxes are precisely tailored drive elements to individual customer needs, unlike series products.
Definition and distinction from standard solutions
Standard gear boxes often do not suffice in limited installation space or unusual output geometry. A precision of less than 5 angular seconds of play often requires a Special gear boxes.
demand for customized solutions.
A custom gear box solution is necessary when extreme environmental conditions (e.g. -40°C), special materials, or high power density are required. Example: Beispiel: Stainless steel gear boxes (IP69K) for the food industry.
Importance of system competence
System competence is important, as a special gear box is part of a complex drive train (motor, brake, control). ATEK enables integrated coordination as a system provider, e.g. of high-performance servo motors with planetary gears, which can increase overall efficiency by up to 10%.Open new application fields with customized special gear boxes.
machine and plant engineering
In machine and plant engineering, special designs enable high-dynamic movements and precise positioning, e.g. for packaging machines (120 cycles/min). ATEK develops compact angular gear boxes for handling systems in tight spaces with high torque.
robotics and automation
For precision and dynamics in robotics, individual gear box solutions with play under 1 arcmin are necessary, (e.g. weld seam accuracy 0.1 mm). ATEK provides specialized bevel gear boxes, tailored to the axle kinematics.
Renewable energies and demanding environments
Special gear boxes for renewable energies or ATEX zones require high reliability and certifications (e.g. offshore wind power). For solar trackers, a worm gear box with special coating for >25 years of maintenance-free operation was developed.Realize your perfect Special gear boxes through collaborative development
Analysis of specific requirements
When catalog products do not fit, the development of your customized gear box solution at ATEK begins with the analysis of the application: torques up to 50,000 Nm, speeds, installation spaces, environmental conditions. Example medical technology: quiet gear box (< 45 dB) through special tooth geometries.
- Detailed analysis of specific application requirements as a starting point.
- Collaborative development and design using CAD and FEM tools for optimization.
- Use of a modular system to increase efficiency and shorten development time by up to 30%.
- Precise manufacturing through CNC technology for the highest quality.
- Strict quality assurance according to DIN ISO 9001.
- Conducting a comprehensive final inspection for every gear box, including operating noise and backlash.
Collaborative development and design
A partnership process with CAD and FEM tools optimizes design and material selection. Das modular system of ATEK, based on proven components, can shorten development times for your expanded technical possibilities. ATEK Drive Solutions develops customized drive solutions for specific challenges. by up to 30%.
Precise manufacturing and quality assurance
Precise CNC manufacturing and quality assurance (DIN ISO 9001) are crucial for performance and reliability. Each Special gear boxes undergoes a final inspection (operating noise, backlash).Identify the crucial criteria for your optimal Special gear boxes
power density and installation space optimization.
In case of space constraints and high loads, installation space optimization is central. Customized gear boxes aim for high performance in a small installation space. For logistics, a gear box was developed that provided double torque capacity at half the size.
Lifespan, reliability, and low maintenance
Long lifespan (e.g. 20,000 operating hours) is important. The design of bearings, gears, and seals focuses on reliability and low maintenance. In mining, a expanded technical possibilities. ATEK Drive Solutions develops customized drive solutions for specific challenges. with special lubrication extended maintenance intervals from 6 months to 2 years.
Integration into the overall system
Harmonization with motor, brake, and control is important. An optimal special gear box is integrated into the drive train, which ATEK supports as a system provider. A gear box with an integrated servo motor reduced complexity and assembly effort by 25%.Create sustainable value through a precise ATEK Special gear boxes-partnership
development partnership
ATEK acts as a development partner, accompanying customers from the idea to the series maturity of their individual drive solution.. This collaboration can enable improvements, such as 15% higher positioning accuracy in machine tool construction.
- Dedicated development partnership from the first idea to final series maturity.
- Utilization of the ATEK modular system with approximately 500,000 individual parts for quick and efficient configuration.
- Rapid realization of complex special requests based on proven, modular components.
- Focus on total cost of ownership (TCO) for comprehensive economic considerations.
- Proven TCO savings (e.g. >20% over 5 years) through higher efficiency and durability.
- Creating sustainable added value through customized, reliable drive solutions.
The ATEK modular system for efficiency
Customized expanded technical possibilities. ATEK Drive Solutions develops customized drive solutions for specific challenges. do not necessarily require long delivery times or high costs. Das modular system from ATEK (approximately 500,000 individual parts) enables quick configuration and implementation of complex requests based on proven modules. Ein ATEX Gear Boxes for the packaging industry was delivered in 4 weeks.
Long-term value and total cost of ownership (TCO)
The TCO is relevant, not just the purchase price. An ATEK special gear box can be more economical due to efficiency, durability, and low downtime. A TCO analysis in food production showed >20% savings over 5 years compared to a standard solution.
ATEK Special gear boxes provides solutions for demanding drive applications. Our expertise and modular system enable tailored solutions. Contact us for a quote.
