The Value of a Single-Supplier Powertrain Partner for Modern OEMs

Every powertrain decision OEMs make for their equipment greatly impacts the functionality and longevity of their equipment. But before any of these choices can be made, an OEM must define their Critical to Quality (CTQ) requirements to ensure component selections and assembly meets the application’s needs.

Requirements such as power, torque, shock absorption, daily operating time or duty cycles, environmental variables, lifecycle, maintenance and energy efficiency all play a role in selecting the right components for a system. To meet these needs, selected components must work together as a system rather than individual contributors.

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When OEMs select components that do not meet their various application requirements, the likelihood of unplanned downtime occurring skyrockets. This can be very costly depending on the application and duration of the downtime, with some applications ranging from $100,000 to even more than $1 million in lost revenue per day.

Balancing performance, cost and reliability when making these equipment decisions can be challenging. OEMs can use high safety factors to maintain performance and reliability, but this comes at increased cost. Technologies such as current limits in variable frequency drives (VFDs) to limit motor torque, torque limiters and predictive maintenance with condition monitoring equipment can protect components to maintain performance and reliability at a more attractive price point.

However, making these decisions on your own can be difficult. Ensuring selection of components that work together cohesively within budget and application requirements is made easier by partnering with a supplier and manufacturer whose engineers can create an integrated system that is more than just a collection of parts.

Understanding Today’s OEM Reality

Most OEM engineers understand the basic equipment fundamentals, such as bearings, motors, gearboxes and couplings. They have knowledge of how components function and how they connect with each other. Still, there is a knowledge gap when it comes to keeping up with the ongoing innovation seen in manufacturing today resulting in unintentionally selecting outdated or unoptimized solutions.

There have been rapid advancements in component technology, ranging from high efficiency motors and VFDs to monitoring equipment and changing efficiency standards. Similarly, predictive maintenance and failure prevention has matured with condition monitoring solutions, such as Regal Rexnord Perceptiv Intelligent Reliability Solutions, that can monitor vibration, temperature, pressure and oil cleanliness providing industry-leading capabilities.

The Value of Partnering with a Single Supplier

Single suppliers who design and manufacture these systems fill that knowledge gap. Working with the engineers who develop the components gives assurance that the components chosen will work together while representing today’s optimal configuration, not legacy assumptions. These experts keep up to date with the current industry innovations and can recommend the right solutions for specific application and equipment needs.

Integrated system expertise gives these suppliers the ability to design the entire powertrain as a cohesive system. This leads to improved efficiency, reliability and a perfect application fit. Purchasing the entire assembly from one manufacturer also typically results in a lower price as opposed to going through multiple sources and having to assemble on site or through a third party.

Receiving the powertrain as one assembly also ensures proper alignment and installation of the components by trained experts, which reduces installation time and risk for the end user. 

In addition, partnering with a single supplier provides streamlined troubleshooting and support. If problems do arise, OEMs have one point of contact for diagnosing issues or replacing components.

Real-World Application: Custom Rotary Calciner Drum Drive Assembly Saves OEM $13,000 Per Project

An OEM producing biocarbon solutions, a renewable alternative to fossil fuel-based carbon sources, needed support and partnership in designing the full power transmission system for their rotary calciner drum drive application. A rotary calciner drum drive is a mechanism used to rotate the drum of a rotary calciner, which is a type of industrial furnace used for high-temperature processing of materials.

The drive system typically includes a motor, a gear reducer and a pinion or chain drive that wraps around the drum. It allows the drum to rotate at a specific speed, ensuring uniform heating of the material inside. Rotary calciners are often used in applications where precise temperature control and minimal exhaust gases are required. The drive system is crucial for maintaining the consistent rotation needed for effective calcination.

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This OEM wanted product selection guidance and engineering expertise to optimize their system. Utilizing a broad portfolio and industry and application knowledge, the Regal Rexnord team provided a custom, turnkey, intelligent solution comprised of Falk V-Class and Ultramite reducers; industrial motors; Falk Steelflex input and output couplings; and Rexnord mounted bearings and speed sensors, all assembled on a custom base plate.

From design and product selection to full assembly, Regal Rexnord fabricated the complete solution and shipped out the full unit to the end-user directly. Serving in an advisory role to the OEM, the team drew on its technical expertise to refine the system, so it aligned with the application requirements and the end-user’s objectives.  

By delivering the system fully assembled, the project helped the end-user reduce costs and complexity of installation on-site. With design teams based overseas and additional resources based in the U.S., they also benefited from working with Regal Rexnord’s local representatives.

Additionally, Regal Rexnord assumed responsibility for both sourcing and assembly, significantly cutting down on project management costs and eliminating the need for outsourced assembly. This approach saved the customer an estimated six hours and $11,000.

 The efficiency of its engineering solutions and the ease of collaboration facilitated by Regal Rexnord’s Powertrain Solutions team reduced the overall project completion time by 25%, contributing to an additional $2,000 in savings. In the end, the end user saved about $13,000 in costs and an estimated 14 hours of sourcing and project oversight. The rotary calciner drum drive developed for this project is now becoming a standard design for this end-user.

Additional Benefits of Working with a Unified Powertrain Supplier

A partnership with a single supplier brings value beyond just bridging knowledge gaps and troubleshooting support. For example, by utilizing components engineered to work together, OEMs can reduce risk and minimize interoperability issues. This also ensures consistent service factors are applied to all components, resulting in a robust and reliable system.

Working with a single supplier also simplifies the supply chain through reduced vendor management. One supplier means one purchase, eliminating the challenge of coordinating multiple suppliers, systems and shipments.

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Outside of simply providing troubleshooting support down the line, partnering with a single supplier delivers ongoing support from conception through commissioning. From the start, OEMs receive application-focused engineering guidance from experts with decades of industry and application experience.

Gaining a true partner that understands both the mechanics and the end-user environment creates solutions that function as intended. Over the entire lifetime of the solution, Regal Rexnord Field Services also provides installation and maintenance support inside your facility.

From Single-Supplier to Trusted Partner

As technology is rapidly evolving, modern equipment demands modern component expertise. Keeping up with the pace of innovation is highly demanding and requires a partner who can help bridge the gap. Partnering with a supplier that designs, integrates and stands behind the entire solution provides a clear advantage to ensure your powertrain systems are both functional and reliable.