From a motor inquiry to a complete spindle unit: Case study of the BSD 120 spindle
In technical practice, it is common for an initial customer concept to encounter the physical limits of standard components. This was exactly the case with the BSD 120 spindle project, which quickly evolved from a standard inquiry into a complex engineering challenge.
Instead of simply supplying the requested motor, we identified critical risks related to the expected load and proposed a technically sustainable alternative.
Read the full story of how the BSD 120 spindle evolved from the initial idea to the final solution.
BSD 120 Spindle: When a Standard Motor Is Not Enough
The original inquiry was focused on a standard HSD motor based on the customer’s initial specification. However, after a detailed analysis of the application and expected load, we identified that directly mounting the load onto the motor would be technically unsuitable and potentially risky.
Instead of simply supplying a component, we developed the request into a more advanced project. We offered the customer a complete solution, including the design of a full spindle unit with an integrated drive tailored to the specific application.
The result is the BSD 120 spindle.
Engineering Approach and FEM Analysis
The key to success was not only our long-term experience, but above all precise calculation methods. The project was based on:
- Analytical calculations for initial dimensioning
- Advanced FEM analysis, eliminating the need for a trial-and-error approach
- Housing optimization: four variants of an aluminum housing were developed, with the most efficient solution selected
- Shaft and bearing design: the entire assembly was engineered to safely operate at 13,000 rpm in an overhung configuration without additional support
“It’s not about taking a shot in the dark. The result is built on our extensive know-how and precise calculations, ensuring system stability even at extreme speeds.”
Vladislav Čítek
managing director
End-to-End Implementation
Our role did not end with design documentation. We delivered a complete turnkey solution, including:
- Design and engineering calculations (including technical documentation)
- Manufacturing and assembly of the spindle unit
- Testing and commissioning: as the customer did not have the required equipment, we also supplied and configured a frequency inverter
- Implementation: the unit is now successfully installed in the machine and undergoing final testing in real operating conditions
Conclusion: The BSD 120 Spindle
The BSD 120 project demonstrates our ability to take full responsibility for a technical solution—from initial analysis to final assembly and on-site testing at the customer’s facility.
It confirms that our greatest added value lies in combining precise engineering calculations with practical manufacturing expertise.
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