Custom Gearbox Manufacturer | Industrial Drive System Design

Design

EMS custom drive system design

EMS isn’t only known for its supply of small DC motors and actuation systems from some of industry’s best known manufacturers. As well as our robust distribution offering, EMS manufactures custom industrial gearbox and precision drive systems for a range of applications.

Our manufacturing capabilities have grown year-on-year since 1991. Today, supporting customers with bespoke drive solutions is a strategic part of our portfolio.

These systems include custom gearbox design, but we can work closely with customers to develop many other bespoke alternatives depending on your needs.

EMS can design and manufacture bespoke drive solutions for a wide range of applications. With an experienced UK based design team, advanced tools and in house research and development and testing facilities, we ensure precision and reliability in our custom design offerings.

Why invest in a custom industrial gearbox?

While standard drive products can often provide a suitable answer to your application’s needs, sometimes the optimisation that comes with a custom design can result in a better overall solution both technically and economically.

You may want to consider a custom option if:

Your component needs to be smaller, but with the same power requirements
You’re working with a very particular space envelope, in shape and/ or in size
The solution requires an optimised system that can reach a specific output performance

If any of these tick the boxes, then it could be time to consider consulting a custom gearbox manufacturer like EMS.

You may also need a bespoke option without even realising yet. Talking through your requirements with EMS means we can recommend the best route for your application, whether that’s an off-the-shelf drive system or an optimised custom alternative.

Design specification and application requirements

Our design process begins with understanding your application’s specification requirements. What we need to know includes:

Required force or torque
Desired speed, whether linear or rotary
Available electrical parameters, including voltage and maximum current
Space constraints and design limitations
Product lifespan expectations
Any statutory or regulatory compliance needs

Concept design and proposal

Once the application requirements are established, our design engineers conduct feasibility assessments to ensure we can deliver the right solution.

At this stage, we determine whether the best solution is a linear actuator, providing controlled linear movement, or a rotary actuator, delivering rotational movement with specified torque and speed. With output performance in mind, we select the appropriate small DC motor and gearing technology, considering space constraints, performance goals and commercial feasibility.

Concept design and proposal prototype

By combining an extensive catalogue of drive motors from our trusted partners and our in-house capability to manufacture spur, helical, worm gears and other gearing types, we tailor solutions to meet exact requirements.

Once verification calculations are complete, we’ll provide a concept proposal that includes a computer aided design (CAD) model, budget cost estimations and technical details for your consideration. Depending on the complexity of the project, this phase can be completed in as little as two weeks.

Prototypes

Prototype development is an essential step in the process, allowing you to fully validate a production representative sample in application representative conditions.

All EMS prototypes are manufactured in house in the UK using our production manufacturing capability to ensure full control of process and product quality to deliver samples in a timely manner.

Optimised tools for optimised drive systems

Our manufacturing facility boasts a wealth of equipment and manufacturing techniques to bring your custom drive design to life. On site, we have 27 CNC machining centres and lathes, as well as 55 gear cutting machines for producing spur, helical, worm and other gearing types as designs require.

To provide customers with computer aided design models of their custom gearbox and other precision drive systems, EMS uses the latest 3D solid modelling and 2D design tools to craft clear, effective component and product designs. This ensures that, long before the metal is cut, the customer can assess the fit and function of the custom design and be assured the end product will function as they envisioned.

Our capabilities include:

SolidWorks — advanced 3D design, modelling and simulation software
Gear modelling and design software — precision tools for designing and optimising gear systems
Research and development equipment — includes torque and force testing, environmental testing and sound measurement to support customer validation
Test equipment — used for verification, characterisation and reverse engineering of existing solutions
FDM Additive Manufacture (3D Printing) — enables rapid prototyping for space samples and proof-of-concept manufacturing

We're also ISO9001:2015 accredited as part of our continuous dedication towards delivering the utmost quality to our customers.

Product types

EMS has extensive experience in drive system design for both linear and rotary applications. We manufacture and assemble bespoke gearboxes with gears typically ranging from 0.2 to 2 module. This allows us to design miniature solutions as well as systems in excess of 100Nm to specifically suit your requirements in high power, space constrained applications.

In addition to fully customised solutions EMS can offer custom modification to catalogue products where a full bespoke solution isn’t required. These modifications can include addition of output pinion, wiring looms, shaft modifications and other changes to provide a cost-effective solution.

Industries and applications

Our broad expertise enables us to design solutions for a wide range of industries and applications. Some of our successful projects include:

Powered prosthetics — custom drive design solutions for advanced prosthetic limbs
Laboratory equipment — precision motion solutions for scientific instruments
Home healthcare — including stairlifts and patient hoists
Automotive — custom actuators for performance vehicles and specialised automotive applications

Looking for an experienced custom gearbox manufacturer to deliver bespoke results for your application? Visit the contact page to get in touch with a member of the team today.