~ How custom gearboxes enable specialist automation for heavy industry ~
In Odense, Denmark, construction of a new Large Structure Production (LSP) Centre is underway. The new facility will be dedicated to developing specialised automated equipment for heavy industry, an industry which, until now, has remained largely manual. This is due to 
its harsh environments and demand for tools that must endure extreme conditions while performing complex, high-force tasks. Here, Dave Walsha, sales and marketing director at industrial gearbox manufacturer Electro Mechanical Systems, explains why enabling the shift to automation starts with the right components.
From enabling faster production cycles to improving product consistency and lowering operational costs, automation has transformed how industries operate. However, these benefits remain mostly out of reach for heavy industries, such as construction, shipbuilding and metal casting.
Where other sectors have easily adopted standard robots, CNC machines and Automated guided vehicles (AGVs) to optimise workflows, heavy industries still rely on manual labour. This reduces productivity and exposes workers to potentially avoidable risks.
A 2018 McKinsey survey about industrial automation found that 88 per cent of heavy industry respondents were planning to start automating operations. However, this is yet to be seen. A 2024 Siemens thought leadership piece suggested that the reason isn’t changing priorities, but rather the complexity of developing specialised equipment capable of operating in harsh environments.
Heavy industrial environments are fundamentally different from controlled factory floors. Machines must operate in conditions filled with dust, heat and moisture, and are exposed to shock and vibration. In these settings, automated equipment can quickly degrade, resulting in potential system failure.
Therefore, automated machinery used in heavy industries must be specialised, starting at the component level.
Custom components, specialised equipment
Gearboxes translate motion, torque and speed within automated systems. These components are inherently fundamental to automation’s function but are particularly vulnerable to harsh environmental and mechanical stresses.
Exposed to thermal fluctuation, corrosive particulates and misalignment to vibration, an off-the-shelf gearbox will likely fail, subsequently causing the equipment to fail. To avoid this, they must be designed with the operating environment in mind.
The design process begins with a comprehensive analysis of the application’s desired requirements for torque, speed ranges, motion type, whether rotary or linear, and electrical parameters. Once established, environmental and physical constraints are assessed. In heavy industry, this step is vital as it dictates the success of the final specialised product. This stage includes outlining the operating temperatures, potential exposure to dust or moisture and the space the gearbox must fit within an application.
With these specifications in mind, it’s possible to identify lifespan expectations and select materials with the necessary strength and wear resistance. They can further tailor gear tooth profiles for smooth, efficient power transmission and design robust sealing systems to prevent contaminants from getting inside.
After the design is established, advanced computer-aided design (CAD) tools, specialised gear modelling and thermal simulation software allow engineers to virtually prototype the design. If needed, the gearbox design can then be refined, ensuring that the final product can withstand shock loads, minimise backlash for accurate positioning and deliver stable long-term operation.
Unlocking automation
By addressing specific load, space and durability challenges, a custom industrial gearbox turns standard automated machinery into a specialist piece of equipment. Not only enabling its use but unlocking its benefits for an entire sector.
For example, robotic gripper arms can struggle in heavy industrial environments, as they must lift large, irregular and often hot components. These conditions make stable, precise movement difficult, in an environment where even the slightest instability can cause product damage or injury.
With a custom gearbox, features like reinforced output shafts, oversized bearings and low-backlash helical gears can be added to absorb shock and ensure precise motion. This results in safer, more accurate handling and continuous, reliable operations.
AGVs are increasingly used across industrial sectors to streamline material handling and improve efficiency. However, they traditionally face difficulties operating in heavy industrial environments due to heavy loads, uneven surfaces and the need to navigate around large machinery.
To allow AGVs to manoeuvre tight spaces, operate on ramps and stop precisely when fully loaded, gearboxes must be compact enough to fit low-profile chassis without sacrificing strength. A custom solution can be configured with high torque density and planetary reduction stages, opening the door for greater automation of internal logistics on construction sites and beyond.
Meanwhile, CNC machines must cut through hard metals with extreme precision despite constant vibration, abrasive debris and temperature fluctuations. These conditions can quickly undermine cutting accuracy and tool life. A custom gearbox, built using low thermal expansion materials and multi-stage gearing, can withstand this intensity. This stabilises torque delivery and fixes spindle speeds, ensuring component quality and dimensional accuracy, even across extended production runs.
The new Large Structure Production Centre in Denmark marks a pivotal step in implementing automation across heavy industry. But progress starts at component level. A customised gearbox enables specialist automated machinery, unlocking the full benefits of automation even in the harshest environments.
