ABM Drives Offers Gearmotors for Intralogistics

Figure 1: ABM powerful angular geared motors from the KG series with motor mounted IoT capable INVEOR inverter.

Complete Package from a Single Source 

In times of e-commerce and same-day delivery expectations, fast movement of goods in warehouses is becoming ever more important. In this context, stock picking and loading plays a key role. Line powered fully and partially automated logistics facilities with material handling equipment, lifting equipment as well as forklifts and automated guided vehicles (AGVs) are deployed. ABM offers suitable system solutions for all – alternatively for line or battery power supply. For line powered conveying, loading and lifting devices they include motors, gearboxes, brakes and inverters. The latter can be networked and are gaining in importance with regard to Industry 4.0 (IoT).
Line powered systems are perfectly suited for container, box and pallet handling equipment including truck trailer loading and unloading conveyors. The range of products includes energy-efficient asynchronous and Sinochron® motors and apart from helical, parallel shaft and angular gearboxes, centralized and decentralized inverters.
Intralogistics system OEM require compact, powerful and energy efficient drive units. Integration flexibility and reliability with a long service life expectancy are a must. ABM motors and geared motors have been designed with these goals in mind and customization to make life easy for the OEM is always possible even preferred.
Systems Supplier: ONE Partner for Intralogistics
ABM DRIVES INC. is a systems supplier for both stationary and mobile applications. Customers are comprehensively supported from development to series production and receive everything from a single source. Users can select from an extensive modular system. We provide cost-efficiently and quickly application-specific adaptations. ABM assumes system responsibility and provides support in system integration for demanding and individual projects. Focus is on maximum customer benefit and intensive development activities. This results in reliable, durable and safe products that are characterized by high dynamics, smooth running and reliability and are of compact design for easy installation. With a global team of application specialists, ABM is ready to assist you in finding the perfect drive solution for your unique needs wherever your operation is located.

 

Figure 1: ABM powerful angular geared motors from the KG series with motor mounted IoT capable INVEOR inverter.
Figure 1: ABM powerful angular geared motors from the KG series with motor mounted IoT capable INVEOR inverter.
Figure 2: Compact and energy efficient parallel shaft gearbox (type FGA 172/173 shown) available in 2- and 3-stage versions.
Figure 2: Compact and energy efficient parallel shaft gearbox (type FGA 172/173 shown) available in 2- and 3-stage versions.
Figure 3: ABM Sinochron® Motors excel with outstanding efficiency and exceed even the highest efficiency standards.
Figure 3: ABM Sinochron® Motors excel with outstanding efficiency and exceed even the highest efficiency standards.

Choosing a Gearbox Drive and Electric Motor Supplier

When choosing manufacturing partners during a machine build, remember that there are two methods for choosing a gearbox and electric motor supplier. One is selecting a pre-engineered unit and the other is choosing a gearbox-motor combination and integrating them into the equipment.

Pre-engineered gearmotor solutions are suitable if a design engineer doesn’t have the time or engineering resources to build a gearmotor in-house — or if the design needs a quick setup. New modular approaches to support OEMs (and enable new machine tools, automation, and design software) now let engineers get reasonably priced gearmotors even in modest volumes.

It’s true that one benefit to selecting a separate motor and gearbox and then combining them can less expensive than choosing a pre-engineered gearmotor. Another benefit to this approach is that one may be able to design the most optimized gearmotor for the application at hand … because this approach also gives the design engineer the most control over the final configuration and cost.

No matter the approach to gearmotor selection, be sure to continually improve the design by comparing predictions of performance with measurements. Then use the result of the analysis to improve next gearmotor iteration.

Contact: Gabriel Venzin, President, ABM DRIVES INC, +1-513-576-1300, [email protected].

Improved Crane and Hoist Safety With New GH and GHX Hoist Drives

Improved Crane and Hoist Safety With New GH and GHX Lines of Hoist Drive Units and Motors

ABM DRIVES INC. introduces its latest line of GH and GHX hoist drive units and motors to manage precise and safe lifting of loads ranging from 3.2 to 40.1 tons. These hoist and crane drives deliver safe handling for both the operator and the load by managing precise loads; implementing soft acceleration; integrating smooth, low-wear and dual-surface safety brakes; braking safely without swinging the load; automatically braking during a power loss; and offering aluminum housings with high corrosion resistance.

Additional product highlights include: light weight units for reduced shipping costs and easy mounting; compact designs for small space requirements; increased axle distance for favorable mounting conditions; dynamic speed torque curve for high start and break-down torque; and bearing support of drum integrated into hoist drive gearbox.

ABM DRIVES INC.’s specially designed product program for demanding hoist technology offers a single source for hoist drive units, hoist motors all the way to travel drive units and frequency inverters.


Choosing a Gearbox Drive and Electric Motor Supplier

When choosing manufacturing partners during a machine build, remember that there are two methods for choosing a gearbox and electric motor supplier. One is selecting a pre-engineered unit and the other is choosing a gearbox-motor combination and integrating them into the equipment.

Pre-engineered gearmotor solutions are suitable if a design engineer doesn’t have the time or engineering resources to build a gearmotor in-house — or if the design needs a quick setup. New modular approaches to support OEMs (and enable new machine tools, automation, and design software) now let engineers get reasonably priced gearmotors even in modest volumes.

It’s true that one benefit to selecting a separate motor and gearbox and then combining them can less expensive than choosing a pre-engineered gearmotor. Another benefit to this approach is that one may be able to design the most optimized gearmotor for the application at hand … because this approach also gives the design engineer the most control over the final configuration and cost.

No matter the approach to gearmotor selection, be sure to continually improve the design by comparing predictions of performance with measurements. Then use the result of the analysis to improve next gearmotor iteration.

Contact: Gabriel Venzin, President, ABM DRIVES INC, +1-513-576-1300, [email protected].

New, Chain Hoist Drive Units with Integrated Electric Contols

Drives for reliable and energy-efficient chain hoists with integrated electronic control.

ABM DRIVES INC. offers new chain hoist drive units with integrated electric controls.

These chain hoists provide overload protection through friction clutches. The basic version for lifting and lowering is easily expanded to integrate the travel function with plug-and-play connection to another board. Brake controls allow for safe operation. ABM’s solution also reduces the wear of contact points to extend the chain hoist’s life. The chain hoists are corrosion-resistant and operate in harsh environments. High-grade, helical-gearing teeth enable quiet operation and as a result reduce noise emissions. Customers can draw from ABM’s modular kit design to arrange their own application-specific solutions.

ABM DRIVES INC. offers ready-to-install, plug-and-play systems based on a modular platform concept for the mobile industry. Different motor technologies and gearbox designs in conjunction with brakes and sensors can be combined and integrated into different vehicle, crane, and lift types.

To see the new chain hoists in action, visit the ABM DRIVES INC. booth B15 at LogiMAT 2020 in Stuttgart March 10-12, 2020.

Drives for reliable and energy-efficient chain hoists with integrated electronic control.
Drives for reliable and energy-efficient chain hoists with integrated electronic control.

Choosing a Gearbox Drive and Electric Motor Supplier

When choosing manufacturing partners during a machine build, remember that there are two methods for choosing a gearbox and electric motor supplier. One is selecting a pre-engineered unit and the other is choosing a gearbox-motor combination and integrating them into the equipment.

Pre-engineered gearmotor solutions are suitable if a design engineer doesn’t have the time or engineering resources to build a gearmotor in-house — or if the design needs a quick setup. New modular approaches to support OEMs (and enable new machine tools, automation, and design software) now let engineers get reasonably priced gearmotors even in modest volumes.

It’s true that one benefit to selecting a separate motor and gearbox and then combining them can less expensive than choosing a pre-engineered gearmotor. Another benefit to this approach is that one may be able to design the most optimized gearmotor for the application at hand … because this approach also gives the design engineer the most control over the final configuration and cost.

No matter the approach to gearmotor selection, be sure to continually improve the design by comparing predictions of performance with measurements. Then use the result of the analysis to improve next gearmotor iteration.

Contact: Gabriel Venzin, President, ABM DRIVES INC, +1-513-576-1300, [email protected].

Top Ten Electric Motor Selection Tips

Electric Motor Selection 1

Electric Motor Selection 2

10. Consider PMAC for same torque as AC Induction in a smaller, lighter motor.

Electric Motor Selection 3

Permanent Magnet AC (PMAC) motors are a growing alternative to AC Induction motors, which for decades have been the workhorse of almost any electrical motor application.

PMAC motors preserve the reliability and simplicity of the ac induction motor while offering higher efficiency, synchronous operation, and the opportunity to use a smaller frame size.

Electric Motor Selection 4
9. Use the best lamination bath impregnation process for optimum thermal management.

Electric Motor Selection 5

Impregnating stators strengthens stator winding electrical insulation, protects against chemicals or harsh environments, and enhances thermal dissipation.

Driving out air pockets from the electric winding enhances the thermal conductivityof the winding.

Electric Motor Selection 6

8. Balance at operational speeds using high standards.

Electric Motor Selection 7

Bearing vibration readings are normally taken on three planes. Vertical vibration may indicate a mounting problem. Horizontal vibration may mean a balance problem, whereas axial vibration may indicate a bearing problem.

Unbalance can also be caused by centripetal forces at the bearings.

Electric Motor Selection 8

7. Select low-friction bearings suited for application speeds.

Electric Motor Selection 9

Ball bearings are more suitable for high-speed applications than roller bearings.

Consider additional forces such as unsymmetrical air gaps causing magnetic pull, out-of-balance forces, pitch errors in gears, and thrust loads.

Electric Motor Selection 11

6. Consider rare earth versus ferrite (ceramic) magnets.

Electric Motor Selection 12

Neodymium rare earth, samarium cobalt magnets or ferrite (ceramic) magnets are used in PMAC electric motors.

Rare earth magnets are two to three times stronger than ferrite or ceramic permanent magnets but are more expensive.

Samarium cobalt magnets are optimal for high-temperature applications because of their high energy density.

Electric Motor Selection 13

5. Optimize design of rotor/stator laminations to show a sinusoidal magnetic field.

Electric Motor Selection 13

ABM synchronous motors with high-performance permanent magnets come with a sinusoidal flux distribution as well as Electro-Motive-Force.

Stator windings for distributed windings are identical to asynchronous motor windings. It results in lowered vibration, noise and maintenance cost as well as increased overall performance.

Electric Motor Selection 14

4. Select an inverter to provide sensorlessoperation & optimize programing.

Electric Motor Selection 15

PMAC drives can “self-detect” and track the rotor’s permanent magnet position. Critical for a smooth motor start and also allows for optimum torque production.

Programming the controller settings to attain optimum efficiency is becoming more and more important with the ever-increasing efficiency regulations.

Electric Motor Selection 16

3. Use high grade copper for more conductive windings and to optimize density.

Electric Motor Selection 17

Use of more copper by optimizing the stator lamination slot design increases the cross-sectional area of stator windings. This lowers resistance of the windings and reduces losses due to current flow.

A high-efficiency electric motor can have up to 20 percent more copper in the stator winding.

Electric Motor Selection 18

2. Optimize cooling fan for minimum power, while providing adequate cooling.

Electric Motor Selection 19

A cool motor runs more efficiently. To obtain the best airflow, optimize the cooling fan and fan shroud design. Assuring a tight bond between the stator and motor housing provides the best cooling performance.

Electric Motor Selection 20

  1. Select duty cycle for peaks/shocks in a specific time period.

Electric Motor Selection 21

What torque and speed is needed when and how often?

What are the ambient conditions such as temperature, humidity and elevation?

Even the most efficient motor will not perform to its utmost efficiency if used for the wrong application.

Electric Motor Selection 22

Choosing a Gearbox Drive and Electric Motor Supplier

When choosing manufacturing partners during a machine build, remember that there are two methods for choosing a gearbox and electric motor supplier. One is selecting a pre-engineered unit and the other is choosing a gearbox-motor combination and integrating them into the equipment.

Pre-engineered gearmotor solutions are suitable if a design engineer doesn’t have the time or engineering resources to build a gearmotor in-house — or if the design needs a quick setup. New modular approaches to support OEMs (and enable new machine tools, automation, and design software) now let engineers get reasonably priced gearmotors even in modest volumes.

Contact: Gabriel Venzin, President, ABM DRIVES INC, +1-513-576-1300, [email protected].

Electric Motor Selection 23

New, efficient INVEOR Drive Controllers for all Motors

INVEOR MP Drive Controller

New, efficient INVEOR Drive Controllers for all Motors

ABM now offers INVEOR MP and MP Modular motor-mounted drive controllers. They feature impressively fast system integration, energy-efficient operation and easy handling.

The new controllers can be easily combined with asynchronous and SINOCHRON® motors as well as with all gearboxes from ABM Greiffenberger. The exclusive technology enables a speed control range of 1:200. A significant advantage here is the unique mode of operation: a sensorless, large control range. This extended range saves the user costs and greatly increases equipment availability.

The drive system offers numerous advantages in warehouse logistics. It can be configured so external connections, as well as supply or control lines, are all plug-in. Therefore, installation can be accomplished quickly and smoothly, saving the user money: no costly experts are needed. The system is particularly beneficial for applications such as modular warehouse logistics systems that are rearranged regularly.

Smart features simplify handling, such as a Bluetooth interface that enables easy start-up and control via an app. This makes the drive system an optimal solution for applications in tight spaces where a cable connection for parameterization is not feasible. The app also allows smooth transfer of settings to other devices. The solution from ABM Greiffenberger is of modular design so customer-specific configurations can occur at any time. Optional fieldbus systems are also available. They assure the connectivity and prepare the drive system to meet Industry 4.0 requirements.

The sensorless motor control and expanded speed control range of the INVEOR MP ensure optimal efficiency with minimal energy consumption in every application. It meets protection class IP 65 and also works reliably under harsh conditions. The unique feature of the MP Modular version is its smart power section that contains all essential control characteristics in the power electronics. This lowers the costs for the user: no application board is needed. This version can be equipped and configured with various modules. The module carrier even offers the possibility of mechanically integrating customer supplied electronics. It can also be used for factory-provided options such as I/O modules or main disconnects. More installation space for additional components is also available.

System Integration with Added Value
The drive system from ABM Greiffenberger ensures perfect performance in numerous applications. It is powerful, energy-efficient and conserves resources. From specification to production, the company assumes full system responsibility and integration. This makes optimal facility availability possible for the user. The drive specialist is a complete supplier with a high level of consultation and development expertise. All products are offered from a single source. With additive manufacturing, even complex prototypes can be quickly produced. Modern testing technologies, motor dynos and a laboratory for materials analysis ensure high quality in design and engineering already at the development stage. ABM Greiffenberger has always maintained close customer relationships and conducts intense market monitoring. Based on its extensive and modular portfolio, tailored space and cost-optimized systems, the user gains maximum benefits.

INVEOR MP Drive Controller
ABM Greiffenberger’s portfolio includes energy-efficient and powerful INVEOR MP series drive controllers.
ABM Gearboxes and Motors
The new INVEOR drive controllers can be combined with all motors and gearboxes from ABM Greiffenberger.

Choosing a Gearbox Drive and Electric Motor Supplier

When choosing manufacturing partners during a machine build, remember that there are two methods for choosing a gearbox and electric motor supplier. One is selecting a pre-engineered unit and the other is choosing a gearbox-motor combination and integrating them into the equipment.

Pre-engineered gearmotor solutions are suitable if a design engineer doesn’t have the time or engineering resources to build a gearmotor in-house — or if the design needs a quick setup. New modular approaches to support OEMs (and enable new machine tools, automation, and design software) now let engineers get reasonably priced gearmotors even in modest volumes.

It’s true that one benefit to selecting a separate motor and gearbox and then combining them can less expensive than choosing a pre-engineered gearmotor. Another benefit to this approach is that one may be able to design the most optimized gearmotor for the application at hand … because this approach also gives the design engineer the most control over the final configuration and cost.

No matter the approach to gearmotor selection, be sure to continually improve the design by comparing predictions of performance with measurements. Then use the result of the analysis to improve next gearmotor iteration.

Contact: Gabriel Venzin, President, ABM DRIVES INC, +1-513-576-1300, [email protected].

Compact Gearboxes: All Clear for Automated Guided Vehicles

Compact Gearboxes: All Clear for Automated Guided Vehicles

Automated guided vehicle (AGV) systems can increase efficiency in production and logistics. To do so, however, they have to be powerful, safe and flexible. ABM Greiffenberger presented a series of extremely compact and space-saving gearboxes designed specifically for use in automated guided vehicles. They enable reliable and energy-efficient operation on factory floors and in warehouses.

ABM offers efficient gearboxes for various vehicle concepts. These include towing vehicles, undercarriages, upgraded forklifts and assembly platforms. ABM  developed particularly compact parallel shaft and angular gearboxes, which can be easily integrated into the often tight spaces of automated guided vehicles.

The two- and three-stage units are available with high reductions, low backlash and high encoder resolution. They are designed for low speeds and enable exact vehicle positioning. Different steering versions are used depending on the drive unit design, e.g., via electronic differential control of two motors for curved paths. For complex driving maneuvers, forward and backward motion, lateral travel or rotation when stationary, one or more drive wheels can be steered electrically.

KG series bevel gears with output torques of 60 to 800 Nm are included among the versions that are particularly well suited to use in AGVs. FG series parallel shaft gearboxes range from 50 to 2,000 Nm. ABM also has helical gearboxes in its portfolio with output torques ranging from 30 to 2,080 Nm. High wheel loads of up to 25,000 N are provided by hub wheel drives (TDH series) offered in four versions with output torques from 360 to 2,000 Nm and of robust design. Through the integration of the components into the drive wheel, the ABM designs excel as traction drives with particularly efficient, space-saving force transmission. Bevel gear drives type TDB can be supplied with electric steering upon request. They are available with static wheel loads of up to 16,000 N and in the different versions cover a range from 435 to 2,000 Nm. Type TDF parallel shaft gearboxes with a performance range of 435 to 1,400 Nm reach static wheel loads of up to 17,000 N.

The high wheel torques at low rotational speeds facilitate traveling on slight inclines and enable precise maneuvering. Additionally, users save costs: Thanks to the high wheel loads, there is no need for separate support of the wheel axle.

SINOCHRON® Motors for Long Battery Life
Compared with forklift drives, automated guided vehicles do not require high starting torques for inclines because they are usually used on level factory floors. Autonomous operation batteries with 48 or 24 volts are frequently used. Permanent-magnet synchronous motors have proven themselves in low-voltage applications and are recommended for use here. ABM offers the SINOCHRON® series with a continuous output of up to 13 kilowatts for this use. This series is characterized by its compactness and high efficiency. SINOCHRON® Motors are environmentally friendly. They surpass the requirements of Super Premium Efficiency class IE4. Users can meet future legal regulations with these advanced standards. The drives possess a high power density and provide for long battery life in daily use. In addition, the series is compact and can easily be integrated into transport systems.

Permanent focus on customer benefit
ABM Greiffenberger is present in the AGV sector as a system supplier who offers a high-level of customer support, development expertise and turnkey solutions: all products are designed in-house, and even complex prototypes can be quickly produced via additive manufacturing. Modern testing technologies and a laboratory for materials analysis and motor dynos ensure consistent high quality. The parts are produced on state-of-the-art machines and machining centers; robot-controlled manufacturing cells guarantee consistent series quality. Innovative products arise out of close customer relationships and intense market monitoring. ABM uses its modular and extensive portfolio to develop application-tailored, space- and cost-optimized systems.

Angular Gear with a Low-Voltage Motor
Angular gear with low-voltage motor from ABM Greiffenberger for efficient use in automated guided vehicles.
TDH 230 Wheel Hub drive from ABM
Type TDH 230 wheel hub drive from ABM Greiffenberger with high wheel loads of up to 25,000 N.
Towing Vehicle with angular motor
In this towing vehicle angular gears with low-voltage motors are used to ensure powerful and precise driving performance.

Choosing a Gearbox Drive and Electric Motor Supplier

When choosing manufacturing partners during a machine build, remember that there are two methods for choosing a gearbox and electric motor supplier. One is selecting a pre-engineered unit and the other is choosing a gearbox-motor combination and integrating them into the equipment.

Pre-engineered gearmotor solutions are suitable if a design engineer doesn’t have the time or engineering resources to build a gearmotor in-house — or if the design needs a quick setup. New modular approaches to support OEMs (and enable new machine tools, automation, and design software) now let engineers get reasonably priced gearmotors even in modest volumes.

It’s true that one benefit to selecting a separate motor and gearbox and then combining them can less expensive than choosing a pre-engineered gearmotor. Another benefit to this approach is that one may be able to design the most optimized gearmotor for the application at hand … because this approach also gives the design engineer the most control over the final configuration and cost.

No matter the approach to gearmotor selection, be sure to continually improve the design by comparing predictions of performance with measurements. Then use the result of the analysis to improve next gearmotor iteration.

Contact: Gabriel Venzin, President, ABM DRIVES INC, +1-513-576-1300, [email protected].

ABM Offers Energy-Efficient, Liquid-Cooled Motors for Long Operation

Liquid-Cooled, Energy-Efficient Gearbox Motors

Efficient Drives for Various Industries

ABM DRIVES INC. added liquid-cooled motors to their comprehensive program of efficient drive technologies for various industries. This motor excels with high power density at minimal space requirement, energy efficiency and long operating time.

Liquid-Cooled, Energy-Efficient Gearbox Motors
The liquid-cooled motors are suitable for a variety of industrial applications as well as mobile applications.

Users can reliably operate this motor over a long period with high output devoid of overheating. ABM DRIVES INC. offers these motors in IEC frame sizes 80 to 160. Outputs up to 100 kW are feasible and if required they can be easily controlled with ABM inverters. Additionally, it is possible to set a constant operating temperature resulting in uniform elongation. This means the motor can be fitted in µ-accuracy in its application – an advantage that considers the ever-increasing demand for smaller space requirements.

Depending on the application or customer needs, cooling can be accomplished by water, oil or refrigerant. Radial cooling results in an extremely efficient motor but axial cooling is simpler in design. Liquid-cooled motors can be combined with ABM straight shaft, parallel shaft and right-angle shaft helical gearboxes. The user can pick flexibly from the complete ABM drive portfolio. The motor lends itself for industrial applications such as textile machinery but also for mobile uses such as construction machinery. In addition, they impress in powerful electro vehicles and watercraft.

ABM presents itself as a systems supplier that can deliver complete drive solutions from a single source. The company takes over full systems responsibility from specification to manufacturing. In addition, the specialists from the town of Marktredwitz deal with the systems integration, so customers receive solutions with additional benefits. ABM makes sustainability an important consideration in the strategic direction through an emphasis on the protection of resources, high energy efficiency and minimal emissions during operation.

Straight shaft, parallel shaft and right-angle shaft helical gearboxes combined with ABM motors can also be supplied industry and application-specific with inverters. They are equipped optimally with different bus systems and guarantee network interconnectedness. This prepares the ABM drives system for the Industry 4.0 requirements.


Choosing a Gearbox Drive and Electric Motor Supplier

When choosing manufacturing partners during a machine build, remember that there are two methods for choosing a gearbox and electric motor supplier. One is selecting a pre-engineered unit and the other is choosing a gearbox-motor combination and integrating them into the equipment.

Pre-engineered gearmotor solutions are suitable if a design engineer doesn’t have the time or engineering resources to build a gearmotor in-house — or if the design needs a quick setup. New modular approaches to support OEMs (and enable new machine tools, automation, and design software) now let engineers get reasonably priced gearmotors even in modest volumes.

It’s true that one benefit to selecting a separate motor and gearbox and then combining them can less expensive than choosing a pre-engineered gearmotor. Another benefit to this approach is that one may be able to design the most optimized gearmotor for the application at hand … because this approach also gives the design engineer the most control over the final configuration and cost.

No matter the approach to gearmotor selection, be sure to continually improve the design by comparing predictions of performance with measurements. Then use the result of the analysis to improve next gearmotor iteration.

Contact: Gabriel Venzin, President, ABM DRIVES INC, +1-513-576-1300, [email protected].

What is Droop Control in the Context of AC Motors & Drives

AC Gear Motor Droop Control Conveyor

What is Droop Control in the Context of AC Motors & Drives

One of the fundamental characteristics of an AC induction motor is that the rotor spins at a slower rate than that of the stator’s rotating magnetic field. This difference in speed between the rotor and the stator’s magnetic field is known as slip.

Slip allows the motor to produce torque — the higher the slip, the higher the torque production, but also, the lower the motor’s efficiency (in most cases). But in load-sharing applications, motor slip can be used to prevent one motor from taking a disproportionate share of the load.

Slip = (Ns – N)/Ns

Ns = synchronous speed (rpm)

N = rotor speed (rpm)

Load-sharing, in this context, refers to two or more AC motors connected to and driving the same load. Read More.

Natural Load Balancing

Because slip is inherent in AC motors, when two or more motors are connected to one drive, their natural slip will work to achieve balanced load sharing. As one motor experiences increased load, its speed (i.e., rotor speed) slows down, increasing slip between the rotor and stator. Read More.

Droop Control

For applications where load-sharing needs to be precise and controllable, some AC drives include a function — typically referred to as droop control — that manipulates motor slip to better ensure equal load-sharing. Read More.

AC Gear Motor Droop Control Conveyor

Droop control is often used to increase slip in an overloaded motor, allowing other motors connected to the same load to take a higher share of the load. One application where droop control is useful is a conveyor with multiple driven rolls. If one section of the conveyor (and, therefore, one motor) sees an increase in load, droop control prevents the motor from sustaining this disproportionate share of the load, preventing damage to the motor and, potentially, to the system.
Image credit: Rockwell International Corporation

For additional gearmotor content, go to MotionControlTips.com


Choosing a Gearbox Drive and Electric Motor Supplier

When choosing manufacturing partners during a machine build, remember that there are two methods for choosing a gearbox and electric motor supplier. One is selecting a pre-engineered unit and the other is choosing a gearbox-motor combination and integrating them into the equipment.

Pre-engineered gearmotor solutions are suitable if a design engineer doesn’t have the time or engineering resources to build a gearmotor in-house — or if the design needs a quick setup. New modular approaches to support OEMs (and enable new machine tools, automation, and design software) now let engineers get reasonably priced gearmotors even in modest volumes.

It’s true that one benefit to selecting a separate motor and gearbox and then combining them can less expensive than choosing a pre-engineered gearmotor. Another benefit to this approach is that one may be able to design the most optimized gearmotor for the application at hand … because this approach also gives the design engineer the most control over the final configuration and cost.

No matter the approach to gearmotor selection, be sure to continually improve the design by comparing predictions of performance with measurements. Then use the result of the analysis to improve next gearmotor iteration.

Contact: Gabriel Venzin, President, ABM DRIVES INC, +1-513-576-1300, [email protected].

Stable & Streamlined Gear Drives

The special design of ABM’s Sinochron motor rotor with internal magnets leads to an almost ideal sine distribution of the magnetic flux. It’s designed for sensor-less control mode, making it an alternative to servo drives.

Gear Drives Focus on Longevity, Quality and Customization

Is it the product itself? Is it the engineering team behind the latest technology? Is it simply listening to the customer and determining what needs to be tweaked and modified to work more effectively? These are all acceptable answers, particularly when discussing gear drives.

Whether it’s a marine, aerospace, mining, aggregate, packing or food and beverage application, manufacturers are focusing on areas like efficiency, flexibility, power-loss reduction and performance to enhance their product offerings in the power transmission industry. Read more.

Efficiency on Demand

Customers require gearing products that are long-lasting, provide documented cost savings and give additional options for reducing stockroom inventories. “Efficiency is key,” says Alton Vilhauer, product/marketing specialist at Regal. “As the cost of energy continues to climb, producing a product that saves or reduces energy consumption—not only for our customers, but also in the way  we manufacture it—is the direction we are going in our facilities.”

Enhanced service and support create this efficiency. Offering support and education help with product selection, installation, monitoring and repair. Also, speed to customer is vital for success and repeat business. Read more.

Application Flexibility

Gear drives need to be more flexible than in the past. Having robust gear drives that can be applied for a variety of industries, sizes, uses, optimized construction and broad torque ranges allow for high efficiency and reliability. Read more.

Power Loss Reduction

High pitch line velocities of up to 200 m/s, oil swirling and oil squeezing in the gear mesh account for a substantial part of the power loos of high-speed turbo gears units. By separating lubrication and cooling, power loss is reduced. Read more.

Meeting Performance Demands

Meeting the performance requirements is important, but often larger gear units are selected forces at the output shaft exceed the gear unit capacities. In cases like these, selection of oversized bearing to accommodate requirements of applications like pumps or agitators for the chemical, pharmaceutical, food and water treatment sectors are used to absorb high axial and radial forces. Read more.

Don’t Forget the Lubrication

One of the leading causes of gearbox failure is improper lubrication. Viscosity, additives, and oil-levels must be monitored to get the most out of your equipment. Factors in lubrication include type of gearing, speed, materials used, temperature fluctuations and loading considerations. Read more.

For additional gearmotor content, go to PowerTransmission.com


Choosing a Gearbox Drive and Electric Motor Supplier

When choosing manufacturing partners during a machine build, remember that there are two methods for choosing a gearbox and electric motor supplier. One is selecting a pre-engineered unit and the other is choosing a gearbox-motor combination and integrating them into the equipment.

Pre-engineered gearmotor solutions are suitable if a design engineer doesn’t have the time or engineering resources to build a gearmotor in-house — or if the design needs a quick setup. New modular approaches to support OEMs (and enable new machine tools, automation, and design software) now let engineers get reasonably priced gearmotors even in modest volumes.

It’s true that one benefit to selecting a separate motor and gearbox and then combining them can less expensive than choosing a pre-engineered gearmotor. Another benefit to this approach is that one may be able to design the most optimized gearmotor for the application at hand … because this approach also gives the design engineer the most control over the final configuration and cost.

No matter the approach to gearmotor selection, be sure to continually improve the design by comparing predictions of performance with measurements. Then use the result of the analysis to improve next gearmotor iteration.

Contact: Gabriel Venzin, President, ABM DRIVES INC, +1-513-576-1300, [email protected].

Gearmotors Pulling, Pushing-and Controlling-Their Weight

abm gearmotors icon

Industrial mainstay adapts to remain relevant in a 4.0 world

As manufacturers wend their way through what is now the increasingly vertical 4.0 world of industry, more of what were once-essential manufacturing components and processes find themselves on the endangered species list.

But not gearmotors. In some industries, they’re becoming more relevant than ever. For example, as more hydraulics-driven applications transition to electronic actuators, gearmotors are taking over. In addition, national defense and automotive are just two major sectors where geared actuators are specified, especially for custom applications. Indeed, if high force is required, gear or ball screw actuators remain the way to go.

This is not to say that gearmotor makers don’t have concerns and conditions to deal with; some very real ones include:

  • Growing gearmotor manufacturer and customer cost concerns in light of the escalating China trade war, which will directly affect magnet prices (brush and brushless DC, as well as IPM AC) and commutators (brush DC) — not to mention tariff-related rising steel and aluminum prices.

Looking for more insight, we asked some industry experts for their views on gearmotor usage and continued relevancy.

For instance: what is the relevancy of gearmotors relative to hydraulics used in electronic actuators? Is the needle pointing up or down? What would be their most common industrial application? It depends — as almost always — on the application. Is brute force needed — or motion-controlled finesse?

“Just about every OEM application you can think of is trying to accomplish greater flexibility, precision and efficiency, says John Morehead, principal consultant for Motion Mechatronics. “That’s why there’s a strong move to replace hydraulic actuators with electric motor-driven actuators. Rather than the brute force of a hydraulic motor driving various linkages, the move today is toward distributed motion with individual smaller, more efficient electric gearmotors. A notable example is agricultural precision planting to increase yields and reduce costs for farmers. Not only can the maintenance of a complex system of jackshafts, sprockets and chains be replaced with individual gearmotors; each one can be controlled individually to maximize yield for each row planted, which is important when the multi-row planter turns corners or follows curves. The elimination of hydraulic fluid leaks and contamination is a bonus.

“A wide range (of relevancy), says George Holling, CTO, Rocky Mountain Technologies and Power Transmission Engineering motors blogger. “We are working on missile actuators where size, volume and weight are the prime concerns, and gearmotors do well. Gearmotors now start to match the power density of hydraulic systems on an overall system comparison. The distributed system and the independence between actuators vs. a single hydraulic reservoir add a high level of redundancy and potentially also lower overall system and installation cost, as wires are lighter and cheaper to install than hydraulic lines.”

Looking for more, we asked about the efficacy of gearmotors/actuators in, for example, fly-by-wire and drive-by-wire applications requiring high power densities.

Holling responds that “The total efficiency is the actuator efficiency * gear efficiency. As motor speed increases, the motor efficiency will increase — especially p to 2KRPM-3KRPM at higher speeds it will drop again. Gear efficiency is approximately 90%; most gear ratios are 3:1 to 6:1.”

Morehead believes that “High-power density brushless DC gearmotors, combined with optimized efficiency gearing, is becoming the standard in autonomous warehouse robots. Brushless DC is not only more responsive but also more efficient and compact, with virtually limitless lifetime expectations compared to conventional brush DC gearmotors.”

Returning to automotive applications, is it relevant to wonder what, if any, part gearmotors play in electric vehicles? To what extent do potentially deal-breaking things like size, weight and gear cost apply?

“EV motors typically have a fixed reduction gear to reduce the motor size,” Holling states. “Increasingly, OEMs are looking to increase the motor speed to 12KRPM or more to save motor cost. There will be an optimal point where the total cost of motor + gear is minimized.”

And what of any advances of note in plastic-geared gearmotors/drive systems? Available information is a bit sketchy, but Holling reports that he’s “seen a durable, plastic-based gear system out of China: lightweight, low cost and somewhat durable. And we know of at least one Chinese manufacturer that integrated a plastic gear into a traction motor for small 3-wheel delivery trucks. I do not know if this panned out though.”

China’s mention returns us to the tariffs/trade war issue. Sure, it is all very political and perhaps uniquely Trumpian, but this is a “guns-and-butter,” all-hands-on-deck issue for certain manufacturers — like those of gearmotors.

Morehead allows that “Unexpected tariff burdens are a fact of life today, where gearmotors possess content sourced from China and has prompted U.S. gearmotor manufacturers to look toward other low-labor-cost APAC (Asian-Pacific) countries for component or motor sourcing. Of course, the warning signs have been there for years and basic global economics foretell that the advantages of low labor and material costs are fleeting as economies develop. If all you make today is a standard-design gearmotor, you’ve set yourself up for global commoditization.

“While it’s more important today than ever to provide the best application and design engineering support, along with highest quality and shortest lead times, it is becoming evident that customers are looking for more than just a gearmotor. Those gearmotor manufacturers who can also provide motor controls, cabling, brakes, encoders, brackets, shielding, enclosures and anything else customers will find advantageous to purchase as a sub-assembly will be rewarded with a stronger customer relationship and increased insulation from competition.”

For Holling, in much the same vein, “These motors are becoming a commodity item with shrinking margins and strong price competition from China and others, which makes them less attractive to U.S. producers,” says Holling. “Unless the supplier can offer a value-added which commands better margins, the U.S. is not competitive.”

Meanwhile, seemingly, everything is a moving target in today’s automated, bot-driven world. And highly sophisticated, software-driven motion control is now manufacturing’s meat du jour. So where do, say, brushless DC motors fit in?

“Integrating the control required to make the brushless motor turn with the motor only makes sense in terms of eliminating costs of cabling and enclosures, while simultaneously eliminating electrical interference issues,” says Morehead. “In addition, the OEM’s installation time and cost are reduced and field servicing, which is always a burden, is greatly simplified. The OEM’s greatest source of frustration is when a motor-and-drive problem arises and they’re faced with finger-pointing from two separate sources. Simple speed controls are just the first step and the gearmotor manufacturer’s controls capability needs to eventually expand to positioning and networking to ensure being able to offer the highest-value, differentiated gearmotor solutions.”

Holling explains that “Integrated controls can simplify the machine design, wiring costs etc. Thus, an integrated controller is a prime example of a value-added service that customers value and pay for. An integrated controller can also reduce design time and cost for equipment. Allow for future upgrades and field replacements (repair with different or generic components), and the reduced wiring and connections can potentially improve reliability.”

“These motors are becoming a commodity item with shrinking margins and strong price competition from China and others, which makes them less attractive to U.S. producers,” Holling says. “Unless the supplier can offer a value-added which commands better margins, the U.S. is not competitive.”

For additional gearmotor content, go to PowerTransmission.com


Choosing a Gearbox Drive and Electric Motor Supplier

When choosing manufacturing partners during a machine build, remember that there are two methods for choosing a gearbox and electric motor supplier. One is selecting a pre-engineered unit and the other is choosing a gearbox-motor combination and integrating them into the equipment.

Pre-engineered gearmotor solutions are suitable if a design engineer doesn’t have the time or engineering resources to build a gearmotor in-house — or if the design needs a quick setup. New modular approaches to support OEMs (and enable new machine tools, automation, and design software) now let engineers get reasonably priced gearmotors even in modest volumes.

It’s true that one benefit to selecting a separate motor and gearbox and then combining them can less expensive than choosing a pre-engineered gearmotor. Another benefit to this approach is that one may be able to design the most optimized gearmotor for the application at hand … because this approach also gives the design engineer the most control over the final configuration and cost.

No matter the approach to gearmotor selection, be sure to continually improve the design by comparing predictions of performance with measurements. Then use the result of the analysis to improve next gearmotor iteration.

Contact: Gabriel Venzin, President, ABM DRIVES INC, +1-513-576-1300, [email protected].