Press releases

Perfect duo – Nr. 1/2010

Baumüller and ZAE develop high-efficiency food-safe geared motor

Nuremberg. Drive manufacturers Baumüller and ZAE-AntriebsSysteme GmbH & Co. KG have jointly developed a two-stage bevel helical gear unit with integrated encoder-less permanent-magnet synchronous motor which achieves efficiencies of up to 90 per cent. The geared motor is designed as attachable version and its surface finish makes it suitable for sterile applications, for example in the food, beverages and pharmaceutical industries.

The drive system is based on a standard Baumüller DSC-series servo motor from which a motor/gearbox combination was derived. The motor was then electrically and mechanically optimised in the process. A special winding system permits the optimum system design, and a special bearing concept enables the two-stage bevel helical gear unit to be integrated. The gear unit was developed by ZAE and delivers efficiencies of up to 90 percent in combination with the integrated synchronous motor.

The robust construction and modern design simplify the fitting of the drive system which was developed as an attachable version. It is attached onto the machine shaft as a unit and is generally also braced by means of a torque support. The alignment of the drive is user-definable in 90° increments, enabling the motor/drive combination to be incorporated ideally in the machine. Furthermore, the drive is suitable for sterile applications. Thanks to the integrated connection system, its surface finish and the lack of “dirt traps” it is easy to clean and it is difficult for germs to collect. On request, the drive is also available with special coatings for the food industry.

Since the motor/gearbox combination achieves efficiencies of up to 90 per cent and the surface temperature does not exceed 75° Celsius even at full power, cooling fins and fans are superfluous. The drives are also practically maintenance-free. The lubricant used (the user can choose between H1 and H2) ensures that an oil change is only necessary after well over 20,000 operating hours. Since an encoder is not used, the system is considerably less susceptible to faults.

The technical innovations are reflected in the reduced life cycle costs. Lower energy consumption, low maintenance costs and minimal susceptibility to faults mean that the higher costs resulting from the slightly higher purchase price are quickly balanced out. Furthermore, savings can be achieved because the drive system has large usable operating ranges and the number of motor and transmission ratio variants needed is reduced.

The motor/gearbox solution was developed to series maturity by Baumüller and ZAE in just one year. If required, the motors are also available in the same design with an encoder or holding brake. Work is in progress on expanding the solution into a geared motor series

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About ZAE-AntriebsSysteme GmbH & Co. KG

Large spur gears for printing machines were being successfully manufactured as long ago as 1903 in a machine factory in Altona (now part of the city-state of Hamburg). After a period of strong economic growth this factory became Zahnradfabrik Altona Elbe GmbH in 1919. Over the years ZAE, now ZAE-AntriebsSysteme GmbH & Co. KG, has developed into an established and experienced provider of high-quality drive solutions with around 165 employees. The current product range encompasses standard gear units with and without modification, customised drive solutions for specific customer requirements, complete drive units, and technical services. Customers from around the world gain a competitive edge thanks to individual solutions which they are quickly and easily able to integrate in the relevant application.

About the Baumüller Group

More than 40 locations around the globe and collaboration with customers in every mechanical engineering and industrial sector make drive and automation manufacturer Baumüller the preferred technology partner in all major markets. Since 1930 the engineering expertise of its staff, currently numbering some 1500, has allowed the Nuremberg-based company group to develop innovative and market-compliant solutions which are used as individual components or complete systems. The emphasis is on achieving integrated one-stop automation solutions offering extreme flexibility at the greatest possible cost effectiveness. A complete engineering and service offer for all drive engineering applications ensures decisive market benefits for the customer – and better performance from the production lines, systems and machines.