• • • ELECTRICAL EQUIPMENT• • • HOW SERVO GEARBOXES ARE


ADVANCING COMPLEX AUTOMATION AND ELECTRONIC APPLICATIONS


BY MIKE GULLIFORD, MANAGING DIRECTOR, APEX DYNAMICS UK


odern electronic and automated systems are advancing rapidly, and the mechanical components supporting them must develop at the same pace. Robots, semiconductor equipment, and other precision applications increasingly depend on compact gearboxes capable of delivering exceptional accuracy and torque. To meet these requirements, manufacturers are exploring new materials and production methods that enable lighter, more efficient, and increasingly complex designs. In doing so, they are transforming gearbox performance while creating new opportunities across both established industrial sectors and emerging high-precision applications.


M Driving greater performance


from smaller gearboxes With robotics, medical equipment, semiconductor manufacturing, and electronics assembly pushing the boundaries of precision, there is increasing demand for gearboxes with greater torque density; delivering more torque from a smaller gearbox. These industries require extremely compact motion systems without sacrificing accuracy or reliability. In response, gearbox manufacturers are employing advances in high-strength materials,


precision machining, and optimised gear-tooth geometry to unlock reductions in gearbox size and weight, while still maintaining a high load capacity. Low backlash is also becoming increasingly important, as semiconductor handling, high-speed robotics, and other advanced positioning applications require levels of repeatability and precision that would previously have been associated with much larger and more expensive motion systems. With the rapid growth of semiconductor and other robotics-based production, gearbox manufacturers are increasingly looking to deliver ultra-low-level backlash in footprints that are smaller and lighter than ever before.


Additive manufacturing opens


up new design possibilities Additive manufacturing, or industrial 3D printing, could also change what constitutes a practical gearbox design. Traditional machining inevitably places restrictions on component geometry, whereas additive manufacturing can create complex internal structures, such as lattice designs, which reduce weight without compromising strength, and integrated features that would otherwise be difficult or impossible to manufacture.


Through the use of additive manufacturing, cooling channels, sensor housings, and other features could be incorporated directly into components, and new gearbox variants prototyped rapidly without significant investment in tooling. Gearboxes may also be tailored for specific loads, speeds or environmental conditions, with minimal changes to tooling.


22 ELECTRICAL ENGINEERING • OCTOBER 2026


Initially, the greatest opportunities for additive manufacturing are likely to be found in medical robotics, aerospace and specialist automation, which are low-volume, high-value applications that have much to gain from the weight, customisation, and complexity benefits additive manufacturing offers.


As materials improve and costs decrease, additive manufacturing is also likely to become more popular in mainstream gearbox manufacturing. Overall, this process has the potential to transform gearbox production, offering lighter, more complex gearboxes with the same level of performance.


The rise of artificial intelligence Artificial intelligence is emerging as another new technology contributing to the manufacture of servo gearboxes. AI-based optimisation tools can analyse thousands of combinations of materials, gear geometries, operating speeds and load profiles, helping designers identify the best combination of performance, durability, size and cost.


Once the gearbox is operating, sensor information can be compared continuously with its digital model. This creates opportunities for predictive maintenance by identifying changes in vibration, temperature or other operating characteristics and catching problems before machine failure occurs.


Intelligent drive systems could also become increasingly self-optimising, automatically adjusting operating parameters according to changing machine conditions. Generative design may take this further, with algorithms developing


electricalengineeringmagazine.co.uk


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