FLENDER gear units selection – precision without compromise
Traditional gear unit selection often leads to oversizing, which results in higher energy consumption and unnecessarily elevated total cost of ownership (TCO). FLENDER ONE utilizes a configurator that enables unit selection based on actual operating parameters, including:
- required torque ranging from 1,300 Nm to over 1,000,000 Nm,
- optimal gear ratio selection – from 1:1 to 450:1, depending on the configuration (single-, two-, three-, or four-stage helical and bevel-helical designs),
- acceptable thermal and mechanical loads,
- space constraints and mounting position (horizontal/vertical).
Based on decades of experience with the FZG gearbox series—of which over 500,000 units have been deployed across various industries—the modern FLENDER ONE gearbox line was developed. This extensive reference base allows for precise parameter matching, even in non-standard applications.
Lower energy consumption, higher efficiency
The new FLENDER ONE series has been optimized through several key innovations:
- use of METAPERFORM® gear teeth, which increase contact surface area and reduce resistance,
- new types of rolling bearings with reduced friction coefficients,
- enhanced cooling – made possible by a revolutionary ribbed housing design that significantly improves airflow and delays heat buildup. Additional cooling can be implemented later, resulting in real cost savings.
Thanks to these improvements, power losses are on average 20% lower compared to previous-generation gearboxes. This translates into:
- lower operating temperatures,
- extended oil service life,
- longer maintenance intervals.
Gear units with wonitoring – FLENDER ONE with AIQ Core sensor
FLENDER ONE can optionally be equipped with AIQ Core – an integrated condition monitoring module. The FLENDER sensor’s functionality includes:
- recording and analysis of vibrations, oscillations, temperature, and oil level,
- logging operating history and load variations,
- communication via OPC UA, MQTT, Bluetooth, or locally via USB,
- integration with SCADA, MES, and CMMS platforms.
Efficiency beyond the paper
In a world where the reliability and predictability of a drive system are just as crucial as its nominal performance parameters, FLENDER ONE brings both aspects together. Thanks to precise adaptation to process conditions, an optimized mechanical design, and continuous condition monitoring, this gearbox series offers tangible support for modern industrial operations.
In summary, FLENDER ONE offers:
- tailored fit to specific application requirements – without oversizing,
- actual energy savings and reduced power losses,
- readiness for integration with diagnostic and automation systems,
- a design focused on serviceability and extended lifespan.
This is a solution that supports not only energy efficiency and digital transformation goals but also meets the everyday challenges of technical teams – from maintenance planning to minimizing unplanned downtime.
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