Whenever there’s a need for electro-mechanical power, you’ll find a DC motor. When used in conjunction with a gearbox, higher torques are achievable and speed can be reduced to usable levels depending on the needs of the application.
However, standard gearboxes may be too large for customers dealing with strict shape and size limitations. In these situations, it may be worth opting for a custom actuation design. With an extensive portfolio of motor and gearbox options, working on a custom design with EMS means that the in-house expertise is there to provide a consultative and supportive experience to the customer.
A collaborative approach between design engineers is key when outlining the specification that the final product needs to meet.
These criteria include the desired speed and torque, duty cycle and the environment in which the drive system will need to operate. Limitations such as the customer’s power supply, current draw and space available will also need to be considered.
Once the specification has been agreed upon, design work can begin. A concept is formulated applying motor theory knowledge, background material strength calculations and 3D modelling software. Where necessary 3D printed prototype parts can be provided as the next step, giving an ideal opportunity to provide simple visualisation of the final design and to check size and fit into a customer’s existing space envelope.
Sharing of the CAD data from both sides is encouraged so that verifying the fit and integration can be done easily and any issues quickly identified in advance of cutting metal. Each design is by nature unique to that customer, thereby granting the customer a competitive edge in the market.
The manufacture of spur, helical and worm gears is done using dedicated gear cutting machines or driven tool CNC lathes and the addition of CNC gear cutting further enhances capability. High precision, complex shapes can be achieved in a single operation, increasing productivity and ensuring high mechanical integrityof the component.
Following product approval and the start of production, the relationship formed between the customer and the manufacturer remains strong through the life cycle of the product; investing in a custom drive system is also about investing in a long-term partnership that will last the life of the product, and beyond.
