FAULHABER DualGear: Redefining Synchronous Movement in Smart Logistics
As the demand for efficiency in automated warehousing and intralogistics grows, the hardware powering these systems must become smaller, faster, and more precise. FAULHABER is addressing these challenges with the introduction of the DualGear drive system, a high-performance solution specifically engineered for modern conveying systems and autonomous logistics.
The DualGear system represents a shift toward more integrated drive technology. By combining a powerful motor with dual gearheads in a single unit, it allows engineers to achieve two synchronous movements using only one drive. This innovation significantly reduces the integration effort, optimizes installation space, and lowers overall system costs.
A Unified Approach to Drive Technology
The core of the DualGear system is the integration of two proven technologies: the BX4 brushless DC-motor and GPT metal planetary gearheads. This combination is housed in a compact, diameter-compliant design that ensures the system fits into the tight constraints often found in intralogistics environments.
The system utilizes a 32 mm brushless motor from the BX4 family, which is available in two different lengths—42 mm and 68 mm. This flexibility allows developers to adapt the drive system to specific performance requirements and space limitations without needing to redesign the entire housing.
Precision Engineering: The BX4 and GPT Synergy
To achieve high dynamics and robustness, the DualGear system mounts robust metal planetary gearheads from the GPT series at both ends of the motor. These gearheads are available with up to three stages, enabling precise calibration of speed and torque based on the application’s needs.
Accuracy is further enhanced through the use of Hall sensors with sine/cosine output signals. These sensors allow for the precise detection of the rotor position, which is critical for exact commutation and positioning. When paired with an external motion controller, the system delivers a combination of high torque and maximum accuracy, making it ideal for applications where millimetric precision is non-negotiable.
Applications in Modern Intralogistics
The versatility of the DualGear system makes it particularly effective in two primary areas of smart logistics:
- Conveyor Belts: The ability to drive two synchronous movements with one motor simplifies the mechanical layout of conveyor systems, reducing the number of components and potential points of failure.
- Autonomous Logistics Systems: The compact design is optimized for wheel drives in autonomous mobile robots (AMRs) and other automated guided vehicles, where space is at a premium but high performance is required.
- Synchronous Control: Enables two movements from a single drive, reducing complexity.
- Compact Components: Combines a 32 mm BX4 brushless motor with GPT planetary gearheads.
- Flexible Sizing: Motor lengths available in 42 mm and 68 mm to fit various installation spaces.
- High Precision: Employs Hall sensors with sine/cosine outputs for exact rotor positioning.
- Industrial Robustness: Specifically designed for the high demands of conveyor belts and autonomous wheel drives.
Frequently Asked Questions
What makes the DualGear system different from standard drive systems?
Unlike standard drives that typically power a single output, the DualGear system integrates gearheads at both ends of the motor. This allows one motor to power two synchronous movements, which reduces the amount of hardware required and saves valuable installation space.
How does the system ensure precise positioning?
The system uses Hall sensors that provide sine/cosine output signals. These signals allow an external motion controller to detect the exact position of the rotor, ensuring the drive moves with high accuracy and precise commutation.
Can the torque and speed be customized?
Yes. The GPT planetary gearheads used in the DualGear system are available with up to three stages, allowing engineers to dimension the system specifically to meet their torque and speed requirements.
The Future of Logistics Hardware
The move toward integrated, multi-functional drive systems like the DualGear reflects a broader trend in robotics and logistics: the pursuit of “more with less.” By reducing the component count while increasing precision and power density, FAULHABER is providing the hardware foundation necessary for the next generation of autonomous, high-speed intralogistics. As warehouses become more crowded and autonomous systems more complex, these compact, high-performance drive solutions will be essential for maintaining operational throughput.