Powerful drives today have to be ever more compact, robust and efficient, and developers are under pressure to integrate maximum performance into minimal housings. A leading manufacturer of battery-powered hand tools was faced with precisely this challenge. Its product was solid in itself, but there was a weak point. The ball screw from another supplier had served them well for years, but with increasing demands it was reaching its limits:
- Decreasing efficiency - small friction losses added up to a noticeable loss of power.
- Increasing wear and tear - Uneven load distribution led to material fatigue and drastically shortened the service life.
- Rising default rates - Complaints became more frequent, maintenance costs increased and warranty cases became an economic burden.
Every complaint cost time, money and trust - a problem that could not be ignored in production.
But the challenge had another dimension. More power was needed, but the limited installation space did not allow for larger components. A more powerful standard solution would not have solved the problem. A larger design did not fit into the design. A system change would have meant that many components would have had to be redeveloped - with immense costs and delays. The market would not allow this. A solution had to be found that would get maximum performance from exactly the available installation space. The manufacturer needed a real optimization - without having to redevelop the device.
What is a ball screw?
A ball screw, often used synonymously with a ball screw drive, is a key component for the precise conversion of rotary motion into linear motion. It uses recirculating balls between the screw and nut to enable particularly efficient power transmission with minimal friction loss.
Compared to trapezoidal screws, the ball screw offers significantly higher efficiency, a longer service life and high positioning accuracy - essential factors for high-performance drive systems. However, in this case it became clear that a standard solution was not sufficient to achieve the required performance.
Problem analysis of the existing drive
In such cases, detailed engineering skills are required. Our developers analyzed the mechanical load, the raceways and the energy loss of the previous solution. It quickly became clear that the problem did not lie in the performance of the ball screw itself - but in the way it worked under these specific conditions.
The existing deficits:
- The geometry of the track was not optimal. As a result, forces were distributed unevenly, causing wear at certain points.
- The efficiency was limited by friction losses. Small losses per revolution led to a significant loss of energy in the long term.
- The load peaks shortened the service life. The ball recirculation was not ideally adapted to the dynamic load profile, which placed unnecessary stress on the components.
Our developers recognized this: It was not simply a matter of using a more powerful ball screw - but of adapting the geometry to the application in such a way that the existing design could be used more efficiently.
The innovation: More performance through detailed work
That meant rethinking. The aim was to distribute the loads more evenly in order to eliminate wear peaks, minimize friction effects and maximize efficiency. By making specific adjustments to the details, the spindle was able to transmit more power without changing the external dimensions. At the same time, the material load was reduced, significantly extending the service life.
The result? Double the power, triple the service life and increased running smoothness - in exactly the same installation space. This solution not only allowed the handheld device to work more efficiently, but also significantly extended its maintenance intervals. The customer saved costs in the long term, while its end customers received a more robust, reliable product.
Pushing the boundaries of classic drive technology - live at the HMI
This targeted further development shows: Anyone working at the limits of classic ball screw technology does not need a stronger standard - but a well thought-out, customized solution.
How existing ball screw technology can be raised to a new level through customized optimizations is presented in our Masterclass at the Hannover Messe. Places are limited.
