Power transmission systems in logistics automation: Insights from logistics & automation Madrid 2025

Accelerated Transformation of Intralogistics

We are at IFEMA Madrid on October 15 and 16, participating in Logistics & Automation, the main event in the logistics sector in Spain. Conversations with manufacturers of automated systems reveal a clear trend: power transmission represents a critical factor in the performance and reliability of advanced intralogistics solutions.

Automated storage systems, autonomous mobile robots (AMR), high-cadence conveyors and industrial handling equipment face increasing technical requirements. The density of operations, intensive duty cycles and millimeter accuracy requirements demand transmission components specifically designed for these applications.

For more than four decades, we have developed competencies in the design and manufacture of gearmotors for industrial applications where the fault involves line stoppage. The logistics automation sector has particular operational characteristics that require differentiated technical solutions.

Planetary Gear Motors: Analysis of Technical Advantages in Automation

Planetary systems offer the highest torque/volume ratio available in mechanical reduction technologies. This feature is critical in applications where spatial constraints limit design options.

Distributed Gear Architecture

While conventional parallel axis systems transmit charge through a single point of contact, the planetary configuration distributes forces between 3-4 satellite gears that orbit the central solar gear. This distribution generates multiple technical benefits:

High power density: A 52 mm diameter planetary provides torques equivalent to 80-90 mm parallel-shaft reducers. In mobile robot or integrated actuator applications, this compactness represents a significant competitive advantage.

Angular accuracy: Planetary systems achieve backlash values of less than 3 arc minutes. This precision is essential in automated positioning applications: picking robots, high-cadence sorting systems, lifting platforms with exact stop requirements.

Mechanical Efficiency: With mechanical efficiency of 95-97%, energy losses are minimized. In installations with multiple automated systems operating simultaneously, this factor translates into a measurable reduction in total energy consumption.

Uniform load distribution: The mechanical load is distributed between multiple contact points, reducing localized stresses on individual components. This factor significantly increases operational lifespan and reduces the likelihood of premature failure.

Reduced acoustic emission: The operation of optimized planetary configurations generates lower noise levels than parallel axis systems of equivalent capacity. Relevant in environments where people and equipment operate simultaneously.

Planetary Gear Motor Range: Technical Specifications

We manufacture three diameter configurations, each optimized for different application ranges:

D42 - Compact configuration
Nominal diameter 42 mm. Typical applications: light-medium load mobile robots, compact linear actuators, automatic adjustment systems, orientation mechanisms. Optimal balance between small dimensions and torque capacity for medium precision applications.

D52 - Versatile configuration
Nominal diameter 52 mm. It represents the optimal balance between load capacity and dimensions. Typical applications: medium load conveyors, lifting systems, robotic arms, rotating platforms, standard capacity AGVs. Greater application versatility in the range.

D63 - High Capacity Configuration
Nominal diameter 63 mm. Maximum torque capacity in a planetary configuration. Typical applications: heavy-duty AGVs, palletizing systems, industrial elevators, high-capacity shuttles. Increased robustness while maintaining planetary compactness advantages.

All configurations support customization of reduction rates, motor integration, mounting options and specific features based on application requirements.

IGS Series: Industrial Solutions for High Loads

When torque requirements exceed the capabilities of planetary systems, or when the application requires extreme robustness for sustained loads, the IGS (Industrial Gear Solutions) series provides the right technical answer.

They are parallel-shaft gearmotors specifically designed for heavy industrial applications where long-term reliability is a critical factor. High-capacity conveyors, high-tonnage elevators, industrial handling systems, high-density automated storage platforms.

Differentiated Technical Characteristics

Reinforced industrial construction: Machined castings with high structural strength. Gears made of forged steel with specialized heat treatments. Bearings designed to absorb high radial and axial loads during continuous operating cycles.

Industrial torque capacity: Torque ranges from 200 Nm to values greater than 600 Nm depending on the model (CLR200, CLR400, CLR600). Demonstrated capacity to withstand peak loads and starts with high inertia without premature component degradation.

Optimized efficiency: Maintaining mechanical efficiencies greater than 90% despite the robust construction. Minimization of energy losses in continuous operation for full shifts.

Versatile configuration: Modular design that supports multiple installation positions. It facilitates integration into machines with spatial restrictions or specific assembly configurations.

Adaptability ratio: Wide range of reduction ratios available. From high angle/low speed configurations for to low speed/high torque systems. Adaptability to different operating profiles without redesigning base components.

Preparation for control systems: Integration options with absolute/incremental encoders, position sensors, electromagnetic brakes. Compatibility with modern industrial communication protocols (CANopen, EtherCAT, Profinet).

Typical Applications in Logistics Automation

High-capacity industrial conveyors:Systems for the movement of pallets, containers or heavyweight loading units. Requirements: high torque, continuous operation for full shifts, absolute reliability without unforeseen stops.

Automated elevators and stacker cranes:Vertical movement of loads in high-rise warehouses. Requirements: positioning accuracy on multiple levels, controlled braking capacity, operation with low acoustic levels.

Industrial classification systems: Product diversion, orientation or distribution equipment Requirements: high frequency starts and stops, capacity to absorb variable inertia, durability against repetitive cycles of high cadence.

Automated storage platforms: Shuttle systems, shuttles or mobile platforms that transport merchandise within high-density storage structures. Combination of positioning accuracy, mechanical robustness and energy efficiency.

Palletizing and depalletizing machinery:Automated handling of complete pallets. High loads, continuous operating cycles, synchronization requirements with other production line equipment.

Critical Factors in Selecting Transmission Systems for Intralogistics

In automated systems, the gear motor represents a critical component whose failure can paralyze an entire production line. It is not a periodic replacement element, but a component designed for thousands of hours of operation with minimal maintenance.

Determining Technical Parameters

Operational Reliability: Automated storage facilities that process thousands of daily orders do not allow for unexpected shutdowns. Every hour of inactivity generates a direct cost in productivity and commitment to delivery times. Gear motors must guarantee MTBF (Mean Time Between Failures) in accordance with the operating requirements of the complete system.

Energy Efficiency: In installations with multiple motorized systems operating simultaneously, the individual efficiency of each component generates cumulative impact. A gear motor with 5% additional efficiency can represent significant energy savings when scaled to a complete installation level with dozens of operating units.

Positioning accuracy: Robots that position products on shelves, systems that classify packages by destination, elevators that must stop in exact multiple positions. The backlash and repeatability of the gear motor directly affect the accuracy of the entire system. Cumulative positioning errors can lead to operational failures.

Operation with controlled acoustic emission: Warehouses where people and machines operate simultaneously. Accumulated noise from multiple equipment can create problematic work environments if individual components are not designed for quiet operation. Occupational safety regulations establish maximum exposure limits.

Ability to integrate with monitoring systems:The integration of sensors in gearmotors allows monitoring critical operating parameters (working temperature, characteristic vibrations, energy consumption). This enables predictive maintenance strategies that prevent failures before they occur, reducing unplanned downtime.

Collaborative Development Methodology with manufacturers/OEMs

Our experience collaborating with automation system manufacturers has shown us that each project has unique requirements. There are no universal solutions, but there are proven methodologies that guarantee optimal results.

Applied Engineering Process

Requirements analysis phase: Full understanding of the application. Load parameters (nominal torque, peak loads, service factors), environmental conditions (temperature, humidity, contaminants), integration requirements (limit dimensions, mechanical interfaces, positioning), expected lifespan, applicable regulations (CE directives, industry-specific certifications).

Selection or development of a technical solution: In many cases, our standard series (planetary or IGS) meet requirements through specific configuration of ratio, motor and mounting options. In applications with particular requirements, we develop customized variants that optimize performance, dimensions or specific operational characteristics.

Prototyping and experimental validation: Fabrication of functional prototypes using internal CNC machining and precision assembly capabilities. Test bench tests with measurement of efficiency, operating temperature, vibrations and noise level. Critical validation in the final machine, under real conditions of use, where behaviors are revealed that no simulation fully predicts.

Scaled up to mass production: Once the solution has been validated, production begins with full batch traceability. Registration of materials, applied heat treatments and dimensional controls. Operational flexibility from short series (100-200 units/year for highly specialized products) to high volumes (tens of thousands of units for manufacturers with multiple product lines).

Ongoing post-sales technical support: Maintaining contact with customers to understand real behavior in the field. Detection of opportunities for continuous improvement or new needs generated by the evolution of their products.

Objectives at Logistics & Automation Madrid 2025

The event brings together manufacturers of automation systems, integrators of complete solutions, specialized engineers and end users who are transforming logistics through advanced technology. It represents an opportunity to establish contact with:

OEM manufacturers of automated systems: Companies that develop mobile robots, conveyors, elevators, classifiers, AGVs and require transmission components with different technical specifications.

Logistics system integrators: Companies that design complete solutions for end users and need technological partners in critical components of their facilities.

Engineers specialized in automation: Technical teams that develop customized machinery for specific intralogistics applications and require transmission solutions adapted to particular requirements.

End users with internal engineering capabilities:Companies with technical departments that develop their own automation solutions and are looking for components that provide differentiated competitive advantages.

We currently export to more than 30 countries and collaborate with leading manufacturers of European automated systems. Each new project provides knowledge that we apply in subsequent developments.

Active Research and Development Lines

Investment in R&D allows us to explore emerging technical directions:

Integration of IoT monitoring systems:Gear motors capable of transmitting operational data in real time. Early detection of operational anomalies, algorithmic prediction of maintenance needs, optimization of work cycle profiles through data analysis.

Research in advanced materials: State-of-the-art surface treatments, high-performance lubricants with improved tribological properties, special alloys that increase durability and reduce specific weight.

Advanced computer simulation: Intensive use of FEM (Finite Element Method) and CFD (Computational Fluid Dynamics) software for geometry optimization, useful life prediction through fatigue analysis, reduction of acoustic emissions and vibrations before manufacturing physical prototypes.

Operational Sustainability: Designs that minimize energy consumption during the entire life cycle, materials with a higher percentage of recyclable content, manufacturing processes with a reduced carbon footprint.

We collaborate with technology centers and university research departments because real technical innovation comes from combining knowledge from multiple specialized sources.

Contact Information and Technical Monitoring

For manufacturers of logistics automation systems that require technical analysis of specific applications, we have detailed technical documentation for planetariums and IGS Series, capacity to organize technical requirements analysis meetings, and accumulated experience in multiple industrial automation sectors.

In case of mutual interest, we prepare technical proposals adapted to the real needs of the project, with flexibility to develop customized solutions when the standard series do not fully cover specific requirements.

What we provide is applied mechanical engineering backed by more than 40 years of experience solving power transmission problems in demanding industrial applications. That accumulated experience makes the difference between a component that works and one that maintains optimal performance for years without causing operational problems.

About CLR

More than 40 years of experience in designing and manufacturing custom gearmotors for industrial applications. Direct collaboration with engineering teams from OEM manufacturers, from the initial concept phase to series production and ongoing technical support. The ability to adapt to the specific needs of each industrial sector represents our differentiating competence.

Logistics & Automation Madrid 2025
15-16 October 2025
IFEMA Madrid - Hall 10
Additional Information: www.logisticsautomationmadrid.com

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