DS-AUG-PG46+47_Layout 1 07/07/2026 16:57 Page 1


FeatUre motion control


55thAnniversAry how Servo gearbox te


become a critical componen Mike Gulliford, managing director of Apex


Dynamics UK, looks into how servo gearbox technology has developed over the years to become a critical component in motion systems,


and looks ahead to a future of ‘smart gearboxes’, artificial intelligence and sustainable solutions


O


ver the last 50 years, servo gearbox technology has evolved from a relatively simple mechanical transmission device


into one of the most critical precision components within modern motion control systems. Few technologies within industrial automation have advanced as dramatically, driven by the rise of robotics, CNC machinery, renewable energy systems, medical devices, and increasingly sophisticated automation. In the early years, gearboxes were primarily


designed to multiply torque and reduce speed. Precision was limited, backlash was accepted as unavoidable, and manufacturing tolerances were far less refined than they are today. Traditional spur and worm gear systems served industry well, but they lacked the accuracy, efficiency, and dynamic response demanded by modern servo systems. The real turning point came with the rapid


development of servo motors and closed-loop control systems. Servo motors offered exceptional responsiveness and positioning capability, but they required gearboxes capable of matching that precision while


providing torque multiplication, inertia matching, and stability. This requirement fundamentally transformed gearbox design.


reducing backlaSh revolutioniSeS accuracy One of the greatest technological changes has been the reduction of backlash. Fifty years ago, backlash levels that would now be considered unacceptable were common throughout industry. As robotics and high-precision automation developed, manufacturers were forced to radically improve gearbox accuracy. Innovations such as preloaded gear


trains, precision grinding, advanced tooth geometries, and strain-wave technology, enabled the development of ultra-low backlash servo gearboxes, capable of achieving positioning accuracies measured in arc minutes or even arc seconds. Manufacturing technology itself has changed


enormously over the years. CNC machining, advanced heat treatment processes, high- strength alloy steels and modern surface finishing techniques have all improved gearbox reliability, stiffness and operational life. Today’s precision planetary gearboxes can deliver exceptional torque density within remarkably compact footprints, while operating quietly and efficiently for many years under continuous duty cycles.


gearboxeS and applicationS expand to meet induStry needS The types of servo gearbox technologies used across industry have also diversified significantly. Planetary gearboxes remain the dominant solution for many automation applications due to their compactness, high torque density and durability. Harmonic drives revolutionised


robotics by delivering near-zero backlash and very high reduction ratios within


lightweight packages, making them ideal for articulated robot joints. Cycloidal gearboxes introduced exceptional shock-load resistance and durability for demanding applications such as


4 DesiGn sOLUtiOns 1971-2026 JUly/aUgUSt 2026 6


how Servo gearbox technology iS likely to evolve Looking ahead, one of the most important developments is the rise of ‘smart gearboxes’


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heavy-duty robotics and machine tools. Applications of servo gearbox technology have


changed considerably over the decades. Early servo systems were largely confined to specialist industrial machinery and aerospace applications. Servo gearboxes are fundamental to almost every advanced manufacturing sector and have become integral to the following industries: • Robotics has probably experienced the greatest evolution. Industrial robots have become faster, lighter, and much more precise. Collaborative robots, or cobots, now work safely alongside humans and require extremely smooth motion, compact gearbox designs and high dynamic response. Servo gearboxes are critical not only for positioning accuracy but also for safety, efficiency, and energy consumption.


• CNC machinery has similarly evolved towards ever higher precision and faster throughput. Modern machine tools demand micron-level positioning accuracy combined with high rigidity and repeatability. Servo gearboxes play a crucial role in maintaining stiffness, while minimising vibration and backlash.


• Medical technology represents another rapidly expanding area. Surgical robots, laboratory automation systems, imaging equipment and prosthetics increasingly rely on miniature high-precision gearboxes capable of extremely smooth and accurate motion within very compact spaces.


• Renewable energy and electric mobility are also driving major change. Wind turbines use servo-controlled pitch and yaw systems, solar installations rely on precision tracking systems, and electric vehicles increasingly incorporate servo-assisted steering, braking, and motion systems. These industries demand high reliability, energy efficiency, and long operational life under challenging environmental conditions.


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