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In batch production, identical or equivalent products are manufactured using standardised, automated processes. The result is high productivity combined with low costs per item, as well as consistently high product quality. Mass production is long established as standard in the automotive industry, electronics manufacturing, the metal industry or furniture making, to name just a few. In the precision gear sector, however, the situation is different. Customers who require large quantities – for example in the field of robotics – would do better to rely on the experience and expertise of established, experienced manufacturers like Nabtesco.

Advantages of batch production:

• Standardised, automated production processes
• Large quantities with short turnaround times
• Excellent product quality
• Low manufacturing costs per gearbox
• High availability
• Use of scaling effects

Specialising in batch production of precision gears

We have more than 35 years of experience in the manufacture of large batches, which means we possess the necessary expertise for the efficient, cost-optimised production of cycloidal gears and strain wave gears (at the Ovalo GmbH location in Limburg (Lahn)). The product design of our precision gears, which is compatible with batch production, and a high level of modularity combine to form the basis for economical batch production. That guarantees high availability together with shorter delivery times. The production process is highly automated and optimised for maximum efficiency and consistently high quality. Prior to delivery, the gears are subjected to a 100% inspection: Each individual gear unit is put through its paces.

Expertise and experience make the difference:

• More than 35 years of experience in batch production
• High level of automation in production
• Consistently high quality
• High production capacity
• Mass customisation
• Effective quality management
• Reliable delivery times
• Project support: from the idea to after sales
• Comprehensive engineering services, including gear design, feasibility study and prototype construction
• Standardisation of custom solutions in batch production

Individualisation through mass customisation

Batch production does not necessarily mean lack of individuality. On the contrary. Strategies such as mass customisation combine the advantages of individualisation with those of mass production. The result: tailor-made solutions with maximum performance, cost-effectiveness and availability. We have long adopted this innovative production concept so we can deliver high-performance precision gears that are custom tailored to your application, while offering the advantages of large-scale batch production.

Economical batch production for the highest standards

More than 13 million cycloidal gears are in use around the world. More than a million leave our production facilities every year – at the last count. With the construction of a third production site in Hamamatsu, Japan, we will double our production output to two million precision cycloidal gears by 2030 – an ideal scenario to meet the surging demand for automation solutions.

We are likewise taking an innovative approach with respect to strain wave gears. All strain wave gears are developed to exact customer requirements and the individual application. The production of our custom-tailored, zero backlash precision gears is compliant with automotive standards, to guarantee you the highest quality, large volumes, short development times, seamless traceability, and a high level of cost-effectiveness.

Series precision: Custom solutions as standard products

We also expressly pursue the standardisation of our custom solutions in batch production. The best example of this is the RV-2800N. The RV-2800N delivers a rated torque of 28,000 Nm, as well as acceleration and braking moments of 70,000 Nm – and it is the largest precision gearbox in the world. But even the biggest started out small – namely as a customising project for a renowned international robot manufacturer. Thanks to the development expertise of our engineers, we were able to manufacture the extra-large gearbox on a large scale. To achieve this, we developed new assembly lines and production methods, which are also used by our suppliers.

You see: Our focus is fully on your requirements, to give you the optimal precision gear solution with the best service – whether in one-off, small-, medium- or large-scale batch production. Would you like to learn more about our mass-produced precision gears, or do you have questions about a particular product? Then don’t hesitate to contact our experts.