Challenges:
- Multi-station machining platforms require frequent station switching, while traditional gear systems suffer from response delays, insufficient positioning accuracy, and complex wiring.
- Dynamic load fluctuations during switching cause equipment wear, and traditional modular designs struggle with compact layout requirements.
Waimica Solution:
- Three-in-One Integration: Integrates motor, gear reducer, and controller into one unit, enabling plug-and-play operation and reducing external wiring by 70%.
- High-Precision Dynamic Response: Combines helical and planetary gears with backlash control of ±5 arcmin and supports 1200 Nm high-torque output.
- Smart Control Integration: Built-in PLC control module with Modbus/TCP industrial protocol support for remote monitoring and fault diagnosis.
- Modular Mounting: Offers flange/bottom foot/hollow shaft mounting options to adapt to different device structures.
Case Details:
An automotive parts manufacturer needed to upgrade its multi-station machining platform with requirements: 8:1 gear ratio, ±3 arcmin backlash, and 0.1° positioning accuracy within limited space.
Waimica Implementation Strategy:
- Structural Optimization:采用了 K-series hardened helical gears, reducing volume by 40% to fit narrow spaces.
- Material Upgrade: Used nitrided steel gears and corrosion-resistant coatings, extending service life to 10,000 hours.
- Control Integration: Integrated IP67-rated controller with PWM closed-loop speed control, achieving positioning repeatability of ±0.05°.
- Fast Delivery: Delivered 200 units within 3 weeks using a modular platform, shortening customer debugging cycles.
Outcomes and Value:
- Customer equipment switching efficiency improved by 35%, reducing scrap rate by 90% due to positioning errors.
- Waimica solution cost is 50% lower than international brands, with 65% shorter lead time.
- This solution is now used in 5 production lines, increasing annual capacity by 1.5 million units.
Technical Parameters Example:
- Model: K37-8-1200
- Input Power: 7.5 kW
- Reduction Ratio: 8:1
- Backlash: ±3 arcmin
- Output Torque: 1200 Nm
- Flange Type: ISO 952 B5/B14
- Protection Rating: IP67
- Control Interface: Modbus/TCP
Summary:
Waimica’s customized three-in-one gear motor provides high integration, precision, and reliability for multi-station machining platforms, enabling customers to achieve smart manufacturing upgrades.
