Industrial Automation Magazine India

Industrial Gear Units, Single Helical

Published on : Thursday 16-03-2023

Flender introduces the gear unit of the future

New, single-stage helical gear unit with reduced power loss and significant savings in operating costs.

The requirements placed on industrial gear units are as varied as the applications in which they are used. In almost all sectors and industrial processes, machines are driven and torques are transmitted. In most cases, different performance requirements, ambient conditions and installation positions make an individual gear unit solution necessary. It must be both cost- and energy-efficient, and quickly available. So far, this combination of customised design, efficiency and delivery time always left plant manufacturers and operators with the answer: not possible.

With Flender One, drive specialist Flender now introduces a gear unit solution that combines all this in one product. Flender One is the completely redesigned version of the single-stage helical gear unit that has long been the global benchmark in the paper industry and other industrial applications. Thanks to a revised housing design and optimised gear set, the new generation of these gear units lowers operating costs while making the most efficient use of resources possible. In addition, users benefit from fast and smart configuration options that greatly simplify the selection process. Thus, the gear unit delivery is accelerated.
Lower operating costs and energy consumption

The new iF Award-winning Flender One product design features a 35 percent larger housing surface. Thanks to the distinct cooling ribs, the thermal capacity increases significantly. Depending on the application the need for additional, external cooling of the gear unit is eliminated. This saves valuable energy and thus costs in operation. The optimised Metaperform® gearing also reduces power loss by up to 50 percent compared with previous solutions. This is made possible by improved rolling behavior and the even more uniform contact surfaces of the gearing.

Flender One lives up to this as it is designed and dimensioned precisely for the application, not wasting unnecessary raw materials and resources. Flender engineers have succeeded in developing the world's narrowest gear ratio range with 103 steps between 1 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 percent at most. 

Flender One is unique in linking product design and digital services throughout the entire life cycle - from ordering to operation in the plant. Flender's new gear unit intelligence AIQ® is included by default in Flender One for the first time and 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 app and online portal if desired.

Flender International GmbH. Email: [email protected]