Among other things, the aim was to achieve even higher positioning rigidity as well as more stiffness at alternating load, faster positioning times, lower energy consumption with identical dynamics and tangible cost savings – with comparable functionality – by reducing the number of parts. Not only that but the new rotary tilt table also needed to have exactly the same mechanical and electrical interfaces as the direct-driven ZASD 400 series. In other words, customers should be free to choose between these two alternatives or, if necessary, upgrade to the newer technology of the ZASG 400.

Peiseler opted for the Galaxie^® GS215 as the hollow-shaft gearbox – and this is what the GS stands for – with the highest precision in the market.

From a technical point of view, the Galaxie^® GS215 meets the precision machining specialist’s requirements in every respect – not surprising really when you remember that the Galaxie^® is superior on principle. Dynamic teeth instead of a rigid gear ring, tangential tooth contact over the full surface rather than the much smaller surface that is achievable with linear contact and a new type of bearing with a segmented outer race ring are its decisive features. Thanks to these characteristics, it is clearly superior to other known gearbox technologies in all key disciplines.

Moreover, the hydrodynamic lubrication that is built up during contact by the multiple teeth over the full surface means mechanical abrasion and wear are virtually eliminated with Galaxie^® compared to involute gear trains. Finally, very high rigidity is maintained at alternating load, even at the zero crossing, without any reduction in the maximum transmittable torques.

The Galaxie^® Drive System is a compact mechatronic unit comprised of a special permanent magnet, high performance synchronous motor, a Galaxie^® gearbox, water cooling, an encoder system and an optional holding brake. However, this innovative gearbox technology is also offered simply as a hollow-shaft gearbox, into which customers can integrate their own motor concept. The Galaxie^® GS215 is mounted in Peiseler’s new two-axis rotary tilt table in combination with an integrated direct drive, including water cooling and a direct measurement system. A second motor working in gantry mode is no longer required with the ZASG 400 – which cuts the cost not only by doing away with this component but also on the control side. 

A developmental advance was necessary in order to maximize the drive’s efficiency: the reduction ratio was then modified such that a more compact gearbox could be integrated and power consumption significantly lowered. Furthermore, as a result of downsizing, the safety brake coupled to the drive train could be much more compact design. In the event of a power failure or an emergency stop, it fixes the drive, preventing uncontrolled movements of the swivel axis. The fact that no hydraulic clamping is required is yet another advantage; this speeds up positioning, leading to shorter times per piece as well as lower unit costs for tilted machining.

The two companies’ many years of experience in their respective segments – precision machining and mechatronic drive technology – proved crucial here. They are currently investigating ways to open up more new applications for Galaxie^® based drive technology in the field of simultaneous five-axis machining. Other future joint developments will concern the digitalization of drive trains as a requirement for additional efficiency improvements, for instance by integrating monitoring and performance enhancing sensors. As just one example, operating data could in the future be transmitted to an IIoT cloud throughout the entire life cycle of the drive and then used to optimize processes or for condition monitoring in connection with the drive train and the rotary tilt table.