An automotive Tier-1 supplier specializing in aluminum transmission housings contacted us for a custom reduction solution. Their horizontal machining center required extremely stable rotational output under intermittent peak loads during high-speed milling. The imported cycloidal drive previously used experienced increased backlash and heat buildup, which affected machining tolerance over long runs.
Key Requirements:
- Installation: Flange mount with shaft coupling
- Gear Ratio: 60:1
- Rated Torque: 150 Nm
- Backlash: ≤1 arcmin
- Load Fluctuation Tolerance: Capable of withstanding ±30% torque surge
- Precision Retention: ≤5 microns drift after 10,000 continuous cycles
- Protection: IP65; oil-mist compatible
Solution Delivered
We developed a heavy-duty, low-backlash planetary gearbox engineered for stability and precision:
- Helical planetary stages for smoother torque delivery
- Custom thermal balance housing with forced convection fins
- Active preload design using conical disc springs to eliminate micro-shift
- Hardened output flange with μm-level runout accuracy
- ISO VG68 synthetic lubrication for high-speed, long-hour operations
Our in-house testing simulated over 12,000 real machining cycles, confirming torque stability and minimal backlash drift.
Result & Feedback
The customer achieved:
- Improved part tolerance stability (±6 microns over 8-hour shifts)
- Reduced unplanned downtime by 18%
- Eliminated need for foreign replacement parts, improving cost control and supply chain reliability
The gearbox is now deployed across 4 machining cells for mass production of transmission covers.
