Equipment & Technology

Flender unveils next generation gear units

Flender has introduced a new, single-stage helical gear unit with reduced power loss and significantly lower operating costs.

Flender has introduced a new, single-stage helical gear unit with reduced power loss and significantly lower operating costs.

The Flender One gear unit is a complete redesign, featuring a revised housing design and gear set optimisation to make the most efficient use of resources possible.

With a 35 per cent larger housing surface and distinct cooling ribs, the Flender One has increased its thermal capacity significantly.

Depending on the application the need for additional external cooling is eliminated, cutting down on energy usage.

Optimised gearing also reduced power loss by up to 50 per cent when compared with previous solutions. This was made possible by improve rolling behaviour and uniform contact surfaces of the gearing.

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Flender engineers have developed one of the world’s narrowest gear ratio ranges, with 103 steps between one and 7.1 per size. This allows the ratio to be optimised for maximum efficiency. The deviation between the desired speed and the available, technical solution is 1.5 per cent at most.

Flender Group CEO Andreas Evertz said the company’s goal is to make the world more sustainable together with its customers and partners.

“This is what our products stand for,” Evertz said. “With Flender One, our customers receive a completely new type of gear unit solution, precisely tailored to their application, exactly according to their requirements and preventing waste while utilising the smallest drive concept possible.”

“The reduced energy requirement during operation also helps to protect resources.”

Flender One also includes the company’s new gear unit intelligence, AIQ. It provides plant operators with valuable information about the gear unit during operation, thanks to integrated sensor technology and extensive analysis functions.

Operating states can be easily monitored via an app and online portal if desired. Potential failures can be predicted with detailed condition monitoring of individual components.

Operators can control and optimise the drivetrain and processes, often resulting in reduced wear at constant performance and increases the availability.

A new product configurator, which was developed in cooperation with Flender’s digitalisation partner adesso, will allow customers to configure their custom gear units online.

Flender One project manager Jan Reimann said the company offers to take the time-consuming preliminary considerations off its customers’ hands.

“We no longer ask for the specifications and features of the gear unit, but only for the desired benefits,” Reimann said.

“Customers tell us how and where they want to use the gear unit, and we guide them which gear unit with which functions they need for this.”

Flender president of industrial gears Rouven Daniel said Flender One is a step towards a completely new customer experience in drive technology.

“We are convinced that Flender One is not only a milestone, but also a worthy successor to the previous single-stage gear unit,” Daniel said.

“We have understood the customer’s wish to be able to obtain a suitable gear unit solution easily and at the same time with maximum precision.

“The customer can look forward not only to a new gear unit, but also to a faster ordering process and optimized operation throughout the entire life cycle thanks to AIQ. This is a unique gear unit solution in the market.”

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