Innovative FAULHABER Drive System for Smart Logistics

Why It Matters

DualGear streamlines intralogistics architecture, cutting hardware complexity and cost while boosting performance, a critical advantage as warehouses push for higher automation density. Its compact, dual‑axis capability positions FAULHABER to capture a growing share of the smart‑logistics market.

Key Takeaways

• DualGear merges BX4 motor and GPT gearheads in one compact unit
• Enables two synchronous movements, cutting integration effort and system cost
• Offers flexible motor lengths (42 mm, 68 mm) for varied space constraints
• Planetary gearheads up to three stages allow precise speed‑torque matching
• Welded‑joint construction ensures durability without adhesives

Pulse Analysis

The rise of high‑density warehousing and autonomous material‑handling robots has intensified demand for drive solutions that combine power, precision, and minimal footprint. FAULHABER, a long‑standing specialist in miniature drives, addresses this need with DualGear, a hybrid unit that integrates its proven BX4 brushless motor family with robust GPT planetary gearheads. By delivering two synchronized axes from a single motor‑gear assembly, the system eliminates the need for separate drives, simplifying wiring, control logic, and mechanical layout—key factors for operators looking to scale automation without inflating floor space.

Technically, DualGear leverages the BX4 motor’s 32 mm diameter and offers two motor lengths—42 mm and 68 mm—to accommodate diverse installation constraints. Hall sensors with sine/cosine outputs provide high‑resolution rotor position data, enabling external motion controllers to achieve sub‑degree positioning accuracy. The GPT gearheads, available with up to three planetary stages, allow engineers to fine‑tune speed‑torque curves for specific conveyor or wheel‑drive requirements. All components are joined by welding rather than adhesives, ensuring a durable, maintenance‑friendly construction that can withstand the vibration and temperature swings typical of intralogistics environments.

From a market perspective, DualGear’s ability to consolidate two drives into one unit could reshape system architecture for conveyor manufacturers and robotics integrators. Reduced component count translates directly into lower capital expenditure and faster time‑to‑market, while the modular motor length options support retrofits in legacy equipment. As smart logistics ecosystems evolve toward tighter integration and higher throughput, FAULHABER’s DualGear positions the company to capitalize on the next wave of automation, challenging traditional drive suppliers and setting a new benchmark for compact, high‑performance motion solutions.