The Role and Importance of Gear Reducers in the Robotics Industry
A gear reducer is a critical mechanical component that decreases a motor’s rotational speed while generating greater output torque (force). It is an essential part of various industries, from industrial machinery and construction equipment to the rapidly evolving artificial intelligence robotics sector. In simple terms, a gear reducer functions like the joints in the human body.
Imagine carrying a heavy object with weak joints—what would happen? You wouldn’t be able to support the weight properly, increasing the risk of injury or damage to the object. While muscles play a crucial role in movement, joints provide the necessary structural support. If the joints fail to function correctly, the weight you can carry will be significantly limited.
Robots used in industrial settings are also designed according to their specific applications and purposes. For instance, automated equipment used in semiconductor manufacturing requires extremely precise movements. On the other hand, machines like palletizers, which stack large and heavy products, need high torque output and strong durability.
From manufacturing and healthcare to service and logistics, machines and equipment are used in diverse industries, each with unique operational requirements. One of the key components that ensure these machines meet their specific demands is the gear reducer.
What Is Gear Reducer Design Service?
As previously mentioned, a gear reducer must be designed with specifications that align with the intended purpose of the product being developed. Gear reducer design service is a specialized technical service that ensures the reducer meets the required performance and conditions specified by the customer. This includes gear selection, optimization of reduction ratio and motor compatibility, and customized structural design to achieve the best possible performance.
Why Did We Develop This Service?
To better illustrate the necessity of our service, let’s revisit the example of AMRs (Autonomous Mobile Robots) mentioned in our previous discussion on “Why Is the Demand for Heavy-Duty Transport Robots Increasing?“
With advancements in automation technology, the use of Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) is rapidly expanding across various industries. Traditional AGVs, which operate by following predetermined paths, have been widely used in logistics and manufacturing. However, as industrial environments become increasingly complex and demand for efficiency grows, AMRs, which offer more flexible and autonomous operations, are gaining attention.
An AMR’s structure consists of four main components: frame, drive unit, control system, and power system. Among these, battery capacity, charging speed, and energy efficiency directly impact the productivity of logistics transport systems.
If the battery capacity is small, its charge will quickly deplete during repetitive logistics operations, leading to an increased number of visits to charging stations. To address this issue, battery performance must be improved, or a charging system capable of storing a larger capacity must be established. However, these solutions may introduce another challenge. If the battery size increases, it will occupy more space within the AMR.
For example, if interference between components limits the driving radius of the wheels, the robot’s movement will not be smooth, posing a critical obstacle in logistics operations. Additionally, various issues, such as increased structural complexity, may arise.
When such issues arise, solutions require expanding the frame structure or reducing the size of the drive unit. However, these measures further complicate the product’s design, leading not only to maintenance difficulties but also to increased production processes, ultimately raising costs. In the end, these challenges hinder the product’s ability to secure market competitiveness.
Many of you reading this article are likely engineers or industry professionals, so you can probably relate to these challenges. In product design, developing every component from scratch is rarely feasible. Instead, most companies rely on off-the-shelf components, which often come with significant design constraints.
Using standard components for product development is ideal, but what if a specific battery must be used in the system? If expanding the frame is not an option, then reducing the size of internal components and simplifying the design becomes essential.
Among all components, the gear reducer presents the greatest challenge in this process. Since it is a core component that significantly impacts product size and design constraints, it is essential to develop a space-efficient gear reducer that is also optimized for performance.
In transport robots, speed and payload capacity are critical factors. A high reduction ratio increases payload capacity but reduces speed, while a low reduction ratio enhances speed but decreases payload capacity. However, the complexity of gear reducers extends beyond this simple trade-off.
For example, planetary gear reducers have limited reduction ratios per stage, meaning that achieving a high reduction ratio requires a multi-stage design. This increases the size of the reducer and complicates the overall design.
Meanwhile, one of the key technologies driving the Fourth Industrial Revolution—artificial intelligence (AI)—has evolved far beyond initial expectations. However, in contrast, the development of robot hardware has struggled to keep pace.
One major reason for this gap is the lack of a custom gear reducer design system capable of meeting the diverse specifications demanded by the market. To address this issue, we sought a technology that could be widely applied across industries while fulfilling customer requirements. The solution was the cycloidal gear-based reduction technology.
Key Features of Our Gear Reducer Design Service
Our service is built upon five core elements, ensuring optimal performance and customization for our clients.
1) Application of Cycloidal Gears
Cycloidal gears differ from traditional involute gears, which have sharp, toothed edges. Instead, cycloidal gears feature a smooth, curved profile, reducing wear and ensuring greater durability and stability in operation.
Additionally, cycloidal gears offer the advantage of achieving various reduction ratios within the same gear size. This means that without increasing the physical size of the reducer, both low and high reduction ratios can be accommodated. This flexibility is a key solution for preventing component interference issues during product design.
2) Fully Customized Gear Reducer Design
At Bon Systems, we provide 100% custom-designed gear reducers. By specifying desired torque, payload capacity, speed, and other requirements, customers receive optimally designed solutions tailored to their needs.
However, this level of customization is not just due to the application of cycloidal gears. Our gear reduction technology incorporates a unique tooth profile, structural innovations, and proprietary design techniques that set it apart from conventional cycloidal reducers. This allows us to precisely tailor reducers for various industrial applications, ensuring unmatched customization and performance.
3) Simplified Structural Design and Innovative Engineering
The ability to achieve multiple reduction ratios within the same size provides a significant advantage during the product design phase.
- Minimized Component Interference: Enhances design flexibility by reducing spatial constraints between internal parts.
- Simplified Structural Design: Improves manufacturing efficiency while making maintenance and operation more convenient.
- Optimized Internal Space: Allows for a more compact and lightweight product design without compromising performance.
This design flexibility opens the door to innovative engineering solutions that differentiate our reducers from conventional products.
4) High Torque Output Even with a Slim Design
The ability to implement various reduction ratios goes beyond mere design optimization. When combined with a frameless outer motor (or inner motor), our technology enables the development of actuators that deliver high torque even within an ultra-thin structure.
This configuration is particularly beneficial for robots and automation equipment operating in space-constrained environments where high torque is required. It serves as a powerful solution that enhances both design simplicity and structural scalability. By maximizing internal space efficiency while maintaining high torque output, our technology increases applicability across multiple industries.
5) Smart Actuator Solution with Integrated Control System
A smart actuator is an all-in-one solution that integrates a gear reducer, motor, and control system (including an inverter, brake, etc.). This fully integrated system enables precise individual control of each drive unit, while also supporting real-time data collection and analysis.
By combining smart actuator technology with cycloidal gear reducer design, Bon Systems offers a highly optimized drive system tailored to customer specifications—BCSA (Bon Systems Cycloidal Smart Actuator).
This next-generation robotic drive system streamlines design complexity and enhances innovation, making it an ideal solution for advanced robotic applications.
How to Use Our Gear Reducer Design Service
For inquiries regarding our gear reducer design service, you can submit a request through the Bon Systems website.
By clicking the link below, you will be directed to a development inquiry form. To ensure the most accurate consultation, please review the following requirements before submitting your request. Our team will then provide a customized gear reducer design consultation based on the provided details.
1) Provide Basic Specifications
- Specify the required torque, speed, and reduction ratio for your application.
- Include the model and specifications of the motor currently in use or planned for integration.
2) Provide Information About the Application or Industry
- Gear reducer designs must be optimized for the intended product and industry.
- By providing details about your application, we can offer even better alternatives beyond your initial specifications.
By sharing precise specifications and product details, we can deliver a more efficient and tailored service. Our custom gear reducer solutions are already utilized across logistics automation, collaborative robotics, and the defense industry, offering highly optimized solutions that meet the specific needs of our clients.
Get in touch today to experience Bon Systems’ custom gear reducer solutions!
