Dunkermotoren Introduces New WG Combination Gearboxes for High Ratios, High Torque, and Precise Motion in Compact Spaces. Right-angle gearbox design combines worm and planetary stages to unlock new possibilities for demanding industrial and medical applications  Dunkermotoren, a global leader in precision drive solutions, announced the expansion of its gearbox portfolio with a new generation of WG combination gearboxes, engineered for applications that require very high reduction ratios, precise positioning, and a compact right-angle design - all in one integrated and economically efficient solution. The new WG series combines a worm gearbox with an integrated planetary gearbox, enabling reduction ratios that conventional right-angle or single-stage gearboxes cannot achieve. While right-angle gearboxes are already relatively compact by nature, the WG design offers an especially favorable ratio of reduction to installation size, making it possible to realize very high ratios without a disproportionate increase in gearbox dimensions. This clever combination of proven technologies delivers high torque transmission and excellent positioning accuracy, while helping OEMs simplify mechanical design and create more flexible machine layouts. Solving Space, Torque, and Precision Challenges - Simply and Efficiently Many modern machines - especially in automation, robotics, and medical technology - must balance tight installation spaces with increasing demands for torque, accuracy, and cost efficiency. The WG combination gearboxes are designed to address these challenges in a simple, robust and application-oriented way. Compared to single-stage bevel gearboxes, which are very compact but offer only a limited reduction range, the WG series enables significantly higher reduction ratios while remaining space-efficient. At the same time, spur gearboxes are typically more economical at low ratios, but are also limited in terms of achievable reduction. The WG combination gearbox closes this gap by offering a balanced solution in terms of reduction range, installation size, and overall system cost, especially for applications that exceed the limits of single-stage concepts. By transmitting power at a right angle while supporting multi-stage reduction in a compact form factor, the WG series enables: » Very high reduction ratios with an excellent ratio of reduction to gearbox size » High acceleration and peak torque capability for dynamic motion  » Accurate, repeatable positioning for sensitive adjustment and swivel movements This makes the WG gearboxes particularly well suited for swivel arms, positioning systems, lifting and adjustment axes, and other applications where simplicity, precision, and load capacity must go hand in hand. Proven Technology, Cleverly Combined The WG series is based on well-established gearbox technologies, intelligently combined to meet the rising requirements of industrial and medical applications. Each gearbox stage used in the WG combination is already proven in the field - both as a standalone solution and within combined configurations. This approach: » Reduces technical and integration risk » Ensures reliable performance across multiple stages » Supports long service life under demanding duty cycles » Enables a very attractive ratio of performance, reduction capability, and cost Designed for Demanding Industrial and Medical Use   Designed for Demanding Industrial and Medical Use Developed for industrial automation, medical technology, and mobile systems, the WG combination gearboxes deliver reliable performance even under high loads and dynamic operating conditions. Defined self-locking characteristics and low-noise operation further expand their suitability for sensitive environments, including operating tables, patient beds, and medical handling equipment. The robust mechanical design supports high acceleration torques and consistent performance, even where compact dimensions and economic efficiency are critical.  Multiple Sizes, Broad Motor Compatibility The new WG combination gearboxes are available in three sizes—WG 52, WG 63, and WG 75 - and can easily be adapted to a wide range of Dunkermotoren motor platforms. Thanks to their efficiency and compact design, the WG series is also well suited for battery-powered, mobile, and autonomous systems, where energy consumption, space, and system cost must be carefully balanced. Typical Applications » Conveyor and material handling systems » Robotics and automation equipment » Lifting, adjustment, and positioning drives » Medical devices and patient handling systems » Mobile and autonomous automation solutions “Instead of developing an entirely new concept, we deliberately combined proven gearbox technologies in a smart way,” said Benedict Hermann, Manager R&D Gearboxes at Dunkermotoren. “The WG combination gearboxes offer a very attractive ratio of reduction to size and cost, making them an efficient and reliable solution for the increasing demands in industrial and medical technology.” A Practical and Economic Solution Where Conventional Concepts Reach Their Limits With the introduction of the WG combination gearboxes, Dunkermotoren expands its portfolio with a simple, robust, and economically attractive right-angle solution for applications where conventional gearbox concepts no longer provide the required balance between reduction range, size, and cost. Downloads: Pressrelease_WG Combination Gearbox (PDF) Graphic (JPG) WG Combination Gearbox Datasheet

People look to Dunkermotoren for motion – but reliable stopping is just as critical. With the redesigned E90R LN spring-applied brake, Dunkermotoren expands its brake portfolio with a solution that delivers quieter operation, precise control and uncompromising safety, even in the most demanding applications.

The E90R LN is based on the proven fail-safe principle: when de-energized, the brake engages automatically and securely holds the load. When power is applied, a magnetic field pulls the armature plate, releasing the braking force. This ensures maximum operational safety, particularly in the event of power failure or emergency stop scenarios.

As part of the latest design update, Dunkermotoren placed a strong focus on acoustic performance. A newly optimized driver design significantly reduces play between the driver and the armature plate. This minimizes vibration and rattling, resulting in noticeably smoother and quieter operation. The improved acoustic behavior enhances not only user comfort, but also the perceived quality of the entire drive system.

“In many modern machines, noise has become a decisive quality criterion – especially in sensitive environments such as medical technology,” says Michael Burgert, Product Manager Brakes at Dunkermotoren. “With the E90R LN, we offer a spring-applied brake that combines proven safety and durability with a clearly perceptible reduction in operating noise.”

Thanks to its compact design, the E90R LN integrates easily into existing drive concepts. Typical applications include medical devices, automation and packaging machinery, conveyor systems and all applications where smooth motion, precision and acoustic comfort are essential.

With the noise-optimized E90R LN spring-applied brake, Dunkermotoren once again demonstrates how engineering precision, fail-safe functionality and user-oriented design come together to create reliable, high-quality drive solutions.

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Press Release (PDF)
Graphic (JPG)

Reliable Positioning for Demanding Applications When applications must stop safely, start accurately, and operate with long-term reliability, every pulse matters. The new AFS58 safety encoder combines functional safety, rugged engineering, and effortless integration into a dependable solution tailored for the BG66, BG75, and BG95 motor series. Featuring a Sin/Cos signal, 2,048 ppr incremental resolution, and a robust design, the AFS58 absolute encoder with a diameter of 58 mm only, is built for the toughest industrial environments. Standardized M12 connectors and a 5 volt supply simplify installation into existing systems. High Safety. Easy Integration. Maximum Confidence. The AFS58 expands the Dunkermotoren portfolio with a functionally safe Sin/Cos encoder certified up to SIL2 and Performance Level d. Its combination of high measurement quality, a clearly defined interface, and compact design ensures safe detection of position, speed, or direction - wherever reliable axis monitoring is essential. Your Key Benefits • Meets top-tier functional safety standards up to SIL2 and PL d • 2,048 ppr Sin/Cos signals for precise measurement data • High signal quality with finely interpolated position feedback • Plug-and-play thanks to standardized connectors • Rugged design withstands continuous industrial operation • Perfect fit for BG66, BG75, and BG95 motor series Company Profile  Dunkermotoren GmbH, headquartered in Bonndorf in the Black Forest, is a global leader in intelligent, integrated drive solutions. As part of AMETEK, the company develops and manufactures motors, gearboxes, encoders, and controllers for demanding applications across industrial automation, medical technology, robotics, and many other sectors. For more information, including technical drawings and a new product finder, please visit the Dunkermotoren website. Downloads: Press release (PDF) Graphic (JPG)

How Automated Storage and Retrieval Systems (ASRS) sustainably optimize processes The intralogistics industry is currently undergoing a profound transformation. Increasing demands for speed, flexibility, and cost efficiency are driving the development of modern automated storage and retrieval systems (ASRS). Technologies such as artificial intelligence (AI), IIoT, and advanced sensor technology form the foundation for new performance standards in warehouse and production environments. Modern providers of robotic and warehouse solutions emphasize system availability, reliability, and minimal manual intervention. Many systems today achieve over 99% uptime, enabling nearly uninterrupted material flow. A key factor is contactless charging technology, which efficiently manages the energy supply of autonomous vehicles and reduces downtime. Combined with AI‑based algorithms, vehicles can react to environmental changes in real time, optimize their routes, and make autonomous decisions. Increasing Requirements for Drive Technology As automation advances, expectations for motor technology continue to rise. Long service life, high availability, integrated safety, and intelligent data utilization have become essential. Dunkermotoren addresses these needs with its new motor controller platform. All integrated and external control electronics are fitted as standard with a certified STO safety interface to ensure safe operation in challenging conditions. New Safety Functions for Maximum Machine and Process Safety Higher safety – lower integration effort – proven functionality With the introduction of dSafe, Dunkermotoren is offering comprehensive Safe Motion functions for the first time. These include: • SS1 – Safe Stop 1 • SLS – Safely Limited Speed • SLP – Safe Limited Position • SBC – Safe Brake Control • FSoE interface (Fail Safe over EtherCAT) These features simplify safety concepts, reduce the need for external hardware, and help implement standards-compliant applications more quickly. Flexibly Configurable Motor Controller Platform  Maximum adaptability – simple integration – reduced system costs The platform allows users to configure the control electronics precisely according to application requirements. Bus and Ethernet interfaces such as: • CANopen • PROFINET (PROFIdrive AK 1 & 4) • EtherCAT (Distributed Clocks) • EtherNet/IP are integrated directly into the motor. This often eliminates the need for an external controller, saving installation space and significantly simplifying commissioning via the Drive Assistant Tool.  Additional features such as an electronic nameplate, operating hours counter, clock synchronization, and freely programmable logic increase transparency and flexibility. Improved voltage resistance also protects the electronics from high battery charging voltages - an especially important advantage in mobile robotics systems. IIoT‑Integration with nexofox Data-driven efficiency – predictive maintenance – lower downtime costs In combination with the digital brand nexofox, high-frequency process data can be collected directly within the customer application and transferred to the cloud via a gateway-independent of the higher-level PLC. The analysis enables: • Real-time insights into motor status • Visual dashboards • Derivation of maintenance needs • For the first time: precise statements about motor lifetime This forms the basis for predictive maintenance, reduces failure risks, and improves planning reliability.  Expansion of the Motor Portfolio Higher load capacity – compact designs – robust mechanics In parallel with electronic developments, the motor portfolio has been expanded with new hub gearboxes. The NG 250, NG 500, and NG 1000 w/o series are specifically designed for drive wheels in mobile intralogistics systems. Their robust design supports loads up to 1,000 kg without additional bearing support, saving space and simplifying mechanical integration. Application Areas in Modern Logistics Environments Dunkermotoren’s intelligent motors are used in numerous systems, including shuttles and high-speed storage systems, AGVs and AMRs, cube robotics solutions, and sorting and picking systems. Real-world examples highlight the versatility of the portfolio: BG 95 dPro is used in robots for online supermarket operations, while BG 75 supports parcel sorting processes in logistics centers. Conclusion The combination of high-performance motor technology, integrated safety functions, IIoT capabilities, and robust mechanical design makes Dunkermotoren’s solutions an essential building block for the smart warehouse of the future. Companies benefit from higher system availability, reduced operating costs, increased safety, and data-based process optimization. These solutions make a significant contribution to improving efficiency and competitiveness in modern intralogistics. Downloads: Professional Article (PDF)