Designing for complexity: Customised drive systems

Everything around us is in motion — from devices and machinery to assembly lines and sliding doors. This constant motion requires sophisticated, reliable solutions to ensure smooth and efficient operation across different applications. Sander van Vliet, a Mechanical Engineer in the Precision Motion & Control department, provides insight into how ERIKS develops these cutting-edge solutions. Additionally, he illustrates with several case studies how this department collaborates with clients to develop and implement drive systems that set machines and devices in motion.

Electric drive systems are found in nearly every application. A combination of mechanics and software completes these systems. Controlling the drive is often an interplay between electronics, mechanics, and software. In nearly all projects undertaken by the Precision Motion & Control department, these disciplines converge. Therefore, the engineering segment of Precision Motion & Control comprises dedicated teams for electronics, mechanics, and software, each with their own engineers.

“While the electronics engineers develop and test the control systems—consider PCB design and electronic simulations—the mechanical engineers focus on designing the moving components, such as gearboxes, timing belts, and casings,” says Sander. “The software engineers then complete the process by programming the appropriate control logic.”

Precision Motion & Control offers a wide range of products and services, from supplying standard components and customisation to co-engineering complete solutions. In the first case, standard products are selected to best meet the required specifications. For customisation, standard products are adapted to additional customer requirements. In co-engineering tailored solutions, ERIKS engineers guide the customer from A to Z through the development process, including design, iterations, and the final implementation of the jointly engineered solution.

Engineering is always based on customer needs. “Almost every request for a drive system is unique,” explains Sander. “Sometimes the machine already exists, and the customer wants to integrate the current or a new drive system. Other times, the machine doesn’t exist yet, and a drive system design is needed for later implementation. Besides the drive itself, there may be numerous additional requirements depending on the industrial sector, specific production environment, or industry standards.” To maximise the chances of project success for all parties, ERIKS follows a structured engineering process.

The first step in the engineering process is evaluating the complexity and feasibility of the customer’s request. The engineering team also assesses whether they have enough capacity to execute the project on time.

Sander explains: “Is there a standard solution available, or does the project require customisation? Often, a standard product from our suppliers is sufficient. For instance, if a motor-gearbox combination exists that meets the client’s requirements, it is often the most efficient option. Based on customer specifications, we conduct analyses and calculations to determine the necessary product specifications. While this may sound simple, it requires significant technical knowledge, particularly for motor selection: What power is required? What couplings and connections are involved? How will the selected product be applied by the customer?”

For larger projects, we always visit the site to see where the drive will be used. “A feasibility analysis determines whether the project can be done. Is the customer’s request achievable? We first check for common unachievable problems, such as excessive power requirements in a small space, or environmental factors that complicate the project. For instance, the food industry has strict design rules and material requirements to prevent bacterial growth. These factors can significantly increase costs, which we inform customers about early in the process.”

“In some applications, water and dust resistance are crucial. While solutions exist, the options with standard products are often limited. Our engineering team adds value by developing custom waterproof housings, taking the burden off the customer. Another key question is how to minimise the Total Cost of Ownership (TCO) for the customer. For example, can higher development costs reduce energy use, simplify installation, or extend the product’s lifespan?”

If the project is technically feasible and can be executed successfully according to applicable standards and quality requirements, we present a project proposal. This includes a preliminary design and cost estimation, providing the customer with a clear overview. Important technical components are conceptually developed, and a budget for components, development, and assembly costs is prepared. We also compile a shortlist of potential suppliers to explore various solutions for the customer.

Once the customer approves the proposal, a kick-off meeting takes place. The engineering team then begins developing concepts for the desired drive system.

“The central element in the drive system is often the motor type,” says Sander. “We design the required components around it. Sometimes multiple solutions are possible, and we develop several concepts so the customer can choose the best option with our guidance. For instance, we might consider stepper motors, which deliver high torque at low speeds, or brushed motors, which deliver high power at high speeds. Depending on the application, we might also incorporate gear reduction for higher torque at lower speeds.”

"After optimising and combining all necessary components, development begins. Today, we often use 3D drawings, which customers can directly integrate into their existing systems to check for compatibility. This approach reduces errors, accelerates adjustments, and ensures a faster, more cost-effective development process.”

For large-scale production, prototypes and a pilot series are created for small-scale testing. Once the customer approves the pilot series, mass production begins.

Innovation drives ERIKS’ products and services. By developing unique, cost-effective, and cutting-edge solutions tailored to current or future challenges, ERIKS distinguishes itself in industrial services. Co-engineering is the foundation of every successful project, guiding customers step-by-step from design to delivery.

An international client manufacturing interior doors for luxury yachts wanted to improve an existing drive system and asked ERIKS for input. “To test feasibility, we first determined the strict specifications and requirements for the drive system,” Sander explains. “Luxury yachts often involve complex technology, but space is limited. A compact drive system was crucial.”

“The drive system also had to avoid being self-locking, which is common in compact drives with high gear ratios. On yachts, doors must be manually operable in emergencies, such as power outages. Additionally, the system needed to operate quietly — a must for luxury yachts. These requirements made for a sophisticated design.”

After exploring several solutions with the customer, ERIKS iteratively refined the best concept. “We ran numerous calculations to create a compact, non-self-locking system with the necessary power. Material choice was a critical factor. While metal is typically used for gears, it generates significant noise. Collaborating with our plastics experts, we selected a material with similar strength but much lower noise levels. The final solution is truly unique in the market, and we’re proud of it!”

Many ERIKS customers use drive systems in harsh environments, where conditions significantly affect performance and lifespan. “For example, in agricultural settings, manure can corrode components. We design sealed systems to protect gears, motors, and electronics from such damage,” Sander explains. “In other cases, cleaning is the challenge. We developed solutions with multiple seals to ensure water resistance, enabling cleaning with high-pressure water jets.”

“Designing an effective casing and seal is complex. The right shape and material are crucial for its proper functioning. We possess all this expertise and are eager to share this knowledge with the customer to arrive at the most optimal solution.”

Finding the right drive system for a specific application can present significant challenges. “Translating customer needs and requirements into a final product is difficult,” says Sander. “This is especially true when seemingly simple requirements necessitate complex technology. It is essential to work closely with the customer to clearly identify which requirements are critical and which may be less significant. Good customer communication is crucial to the outcome. Regular meetings to discuss progress and any necessary adjustments are a must. We achieve effective co-engineering by involving the customer throughout the entire process and including them in regular meetings where our engineering team provides updates.”

“In my opinion, the added value of ERIKS truly lies in our extensive knowledge of materials, technologies, and their suitable applications. Our ability to develop, test, and even produce solutions in-house makes us a leading provider of all types of drive system solutions. This unique combination enables us to involve our customers fully in the development process. This way, we always succeed in bringing complex technology to life and applying it successfully together with our customers!”