A drive system must not only achieve the required performance values during startup. It is crucial that it functions reliably throughout its intended service life. Recurring load peaks, long operating times, and high temperatures can place varying stresses on individual components. To ensure the longest possible service life, therefore, it is not only the quality of the components that matters, but also how well the entire drive solution is tailored to its operating conditions. This makes durability, as a guiding principle, a relevant aspect of the responsible use of resources.
Durability in Drive Technology as a Guiding Principle
Operating conditions determine the requirements
Torque alone says little about how heavily a drive is stressed during operation. Other decisive factors include how frequently load peaks occur, how long the motor runs, and what temperatures are generated in the process. High thermal stress, for example, can accelerate the aging of electrical insulation materials. At the same time, speed and mechanical stress affect the wear on the bearings.
The motor design also plays a role. In brushed DC motors, the brushes and commutator are among the potential wear points. In BLDC motors, this mechanical commutation wear is eliminated, while other components, such as the bearings, continue to be subjected to stress. These different wear mechanisms must be taken into account when selecting and designing a motor with regard to the respective load profile and the intended service life.
Durability starts with the design phase
The foundation for a reliable drive solution is laid as early as the technical requirements definition phase. A specification document outlines, among other things, the required performance values, operating times, and environmental conditions. This allows the design process to account for expected loads and, where applicable, the target service life.
At Kern Antriebstechnik, the collaborative development of the specifications incorporates not only technical requirements but also manufacturing capabilities, resource conservation, and cost optimization. The company supports the development of customer-specific drive solutions from the initial concept through to series production. Technical calculations and simulations support the design process, while CAD-aided design forms the basis for prototype construction. Subsequent testing allows the selected design to be verified under defined conditions and adjusted as needed.
Quality must stand the test under stress
Whether a drive solution meets the specified requirements cannot be determined solely on the basis of its design data. Systematic testing helps to evaluate electrical and mechanical properties under defined conditions.
Kern Antriebstechnik uses test benches developed in-house for this purpose, which are tailored to the respective products. Measurements of torque and speed enable the evaluation of the motor’s mechanical performance. Insulation tests are used to verify electrical safety. Endurance and load tests also allow us to examine how a drive behaves under sustained or high stress.
The test results support quality assurance. If deviations or weaknesses are identified, these can be specifically investigated during further development, and design adjustments can be made.
Durability and Resource Use
Every newly manufactured drive component requires materials and energy for its production. If premature replacement is avoided through longer, reliable use, the additional material and manufacturing requirements can be reduced. Therefore, the length of time a component is actually used and how often it needs to be replaced are also crucial factors.
However, whether this results in an overall environmental benefit cannot be assessed based on service life alone. For a comprehensive environmental assessment, energy consumption and efficiency during operation, as well as manufacturing costs, must also be taken into account.
Customized Solutions for Long-Term Needs
In addition to developing new drive solutions, Kern Antriebstechnik helps companies optimize their existing products in a targeted manner. Our range of services also includes reengineering and the development of alternatives for discontinued components.
Are you looking to develop a drive solution for long-term requirements or to specifically optimize existing components? Kern Antriebstechnik supports you with customized design and development. Learn more about our customer-specific solutions or talk to us about your project.