Client Requirement
A Tier-1 automotive parts supplier needed a high-torque, precision gearbox to drive a circular indexing track used in their brake disc machining line. The system moves large workpieces (up to 250 kg) at exact intervals and requires both high torque transmission and low backlash to ensure consistent positioning and machining precision.
Technical Challenges
- Peak torque demand exceeding 450 Nm
- Positional accuracy within ±0.05°
- Continuous operation 24/7 with heavy-duty cycle
- Compact design to integrate with ring-shaped drive system
- Low backlash < 3 arcmin, vibration-free motion
Our Engineering Solution
We provided a custom planetary gearbox with the following features:
- High-torque helical gear design with reinforced output shaft
- Dual support bearing system for radial load stability
- Integrated absolute encoder support for closed-loop control
- Hardened gear profiles with fine-ground teeth
- Low-noise, anti-backlash internal structure
- Enclosure with IP65 protection for factory floor robustness
Outcome
- Achieved 470 Nm peak torque with < 2.5 arcmin backlash
- Maintained accuracy over 18,000+ hours of runtime
- Improved line indexing accuracy by 35%
- Reduced vibration-related maintenance downtime by 50%
