In today's age of digitalization, the successful interaction of hardware and software is increasingly becoming a decisive competitive factor. Intelligent components, smart sensor technology, digitally networked systems and automated production processes are dominating innovation and setting the course for success. No digitalization, no future. “The digital transformation is one of the key challenges of our time. Anyone who misses the boat here will sooner or later fall by the wayside. Modern IIoT technologies and data-based solutions support companies in optimizing their processes and make them fit for the future”, says Daniel Obladen, Director Sales & Marketing at Nabtesco Precision Europe GmbH, and makes it clear: "Precision gearboxes such as the cycloidal gears and strain wave gears from Nabtesco Precision Europe make a valuable contribution. They are an essential component in the drive train of robots and production machines and make a significant contribution to increasing productivity and efficiency in digital automation environments, improving machine and system availability, reducing downtimes and cutting costs."
Focus on the digitalization of gearboxes
Nabtesco, one of the leading specialists for precision gearboxes and world market leader in the field of robotic gearboxes, brings together a unique combination of outstanding gearbox expertise, innovative electronics and software development, many years of experience and mechatronic system competence within the corporate family. This concentrated know-how forms the basis for new innovations and for ward-looking solutions. One of the current main points is the digitalization of gearboxes. Hybridization, digital gear twins, machine learning, big data and artificial intelligence (AI) are the buzzwords.
Analyzing data
Data is the fuel of digital transformation and opens the door to new possibilities such as condition monitoring and predictive maintenance. Operating and process parameters can be recorded directly via real sensors or indirectly via virtual sensors. The art lies in analyzing and processing the data. Experience, expertise and an understanding of the application-specific characteristics are essential for this, as a high quality of the underlying data and a well-founded, detailed and high-quality evaluation are of immense importance for the quality of the results. Nabtesco Precision Europe is a decisive step ahead here. Whether digital gearbox models, sensorized strain wave gearboxes or hybridized cycloidal gears: the technology leader's solutions combine know-how and expertise from more than 35 years and provide convincing answers to current questions.
No additional space required
The digital strain wave gear developed and produced in Limburg an der Lahn (Ovalo GmbH site) integrates smart sensor technology with the same dimensions as a standard gearbox and therefore offers a space-neutral solution for intelligent automation. This is unique on the market and a major advantage for users. Sensors determine torque, temperature and vibration. Together with empirical values from practical experience, reliable conclusions can be drawn about the condition of the gearbox. The integrated Electronic Evaluation Unit (EEU) evaluates the data and sends it directly to the higher-level control system via the bus system. The operator receives recommendations for action and can react to changing parameters at an early stage and initiate appropriate measures. “With our sensorized strain wave gear, we are expanding our range of digital solutions and taking drive technology into the future. Our plug-and-play product combines high-precision, backlash-free technology with smart sensor technology and artificial intelligence without any change in size. This solves key problems for our customers and helps to increase efficiency, optimize performance, conserve resources and improve cost-effectiveness”, says Daniel Obladen, summing up the benefits.
Cycloidal gears and the digital gear twin Nabtesco is taking a different, equally innovative approach to cycloidal gears. The company is the first gearbox manufacturer in robotics to open up the black box gearbox and provide robot manufacturers with gearbox-specific data and characteristics using a Nabtesco add-on for the robot controller. The goal: a digital replica of the haptic gearbox with its relevant properties. The digital gearbox twin becomes reality. It will work with values that are already available. The speed and torque curve, combined with a pool of statistical data from over 35 years of transmission development, allows detailed conclusions to be drawn about the condition of the transmission and thus its remaining service life. “Not all data can be recorded using external sensors. This applies, for example, to rigidity and, of course, the empirical values from development. We carry out extensive tests before a gearbox is launched on the market and therefore know exactly how the gearbox behaves when it wears out or what influence temperature and lubricant have. All these parameters are incorporated into the robot control system”, explains Daniel Obladen.
Seizing opportunities, exploiting potential
Digitalization requires a radical rethink. Technologies, products, processes - everything has to be put to the test. At the same time, it opens up incredible opportunities. Whether calculating the real gearbox service life, determining the gearbox fault or detecting overload, wear, loss of efficiency, unsuitable operating points and cases of misuse: Digital gearbox solutions make it possible to track the real operating behavior and the specific load on each individual axis of machines and robots in real time. This allows immediate countermeasures to be taken in the event of irregularities or signs of wear. The result: reduced maintenance costs, predictable service calls, less downtime, maximized machine, system and robot availability, significant increases in efficiency and performance and lower overall operating costs. All in all, this results in potential savings in the double-digit percentage range.
The gearbox of the future is digital
And digitalization can do much more. It revolutionizes production processes, opens up growth potential and paves the way for completely new business models, applications and services. Gearboxes are the heart of machines and robots and are therefore an important cornerstone of digitalization in the manufacturing industry. They transmit and convert torques, speeds, directions of rotation and forces and set the pace or the beat. If precision is required, cycloidal gears and strain wave gears from Nabtesco Precision Europe are the first choice. The technologies cover a torque range from 7 to 70,000 Nm, meet the highest requirements in terms of precision, torque capacity and torque density and are ready for the digital age thanks to technological innovations. “In order to always be at the cutting edge of technology, we are continuously developing our products and services with the requirements of the digital factory in mind”, emphasizes Daniel Obladen.
