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Case Studies

Engineering problems solved.
Results documented.

Real OEM challenges. Custom motion control solutions. Measurable outcomes.

Robotics & AGVBrushless DC MotorsGearmotors

Autonomous Transport Drive System for High-Value Medical Analysis Equipment

Medical Robotics OEM (Confidential)

The Challenge

A robotics OEM developing an autonomous transport platform for high-value medical analysis systems faced a drive system engineering challenge that no catalog solution could solve off the shelf. The application: an indoor autonomous mobile robot designed to transport laboratory analyzers valued at $80,000 to $300,000 per unit between laboratory stations in hospital and clinical lab environments. T

The Solution

TelcoMotion's engineering team modeled the full operating envelope before specifying any components: traction force requirements at each floor transition, ramp-climb current profiles, steady-state corridor navigation torque, and the back-drive force requirement for a single-operator push-override. Drive Motor Selection: A custom-wound Kyneks BLDC motor with a 2-stage helical inline gearbox was sp

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Results

62 to 38 dBA
Acoustic Level
In-motion acoustic level reduced from 62 dBA to 38 dBA, below clinical environment threshold
<80 N
Back-Drive Force
Single-operator push-override requires less than 80N, within ergonomic manual handling guidelines
+/- 1.8 cm
Positioning Accuracy
Differential drive system delivers +/-1.8cm autonomous positioning accuracy in narrow corridor navigation
5 deg at 400 kg
Ramp Capability
Full payload ramp climbing validated on physical test rig with zero controller limiting events

More engineering programs

Building Automation

IP-Rated Gearmotor Program for Loading Dock Equipment OEM

Loading Dock Equipment Manufacturer (Confidential)

A leading manufacturer of commercial loading dock levelers and vehicle restraint systems was experiencing field failures at an unacceptable rate in the electromechanical actuator systems that raise an

44% to 8%Warranty Calls
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HVAC-R

Safety-Rated EC Motor Retrofit for Cast Iron Range and Heater Manufacturer

Cast Iron Heating Equipment Manufacturer (Confidential)

A manufacturer of commercial cast iron ranges and radiant heaters for the foodservice market was facing convergent regulatory and operational pressure on their blower motor subsystem. The existing sh

-31%Production Cost
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Food Equipment

Extended-Life Gearmotor Solution for Commercial Rotisserie Equipment OEM

Commercial Food Equipment Manufacturer (Confidential)

A manufacturer of commercial rotisserie and heated display equipment was experiencing premature gearmotor failures in their flagship product line, generating warranty replacement costs that were erodi

14 mo to 48 mo+Component Life
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Medical & Laboratory

Low-Noise BLDC Motor Platform for High-Cycle Medical Imaging Device

Medical Device Manufacturer (Confidential)

A medical device manufacturer developing a next-generation patient positioning system for diagnostic imaging needed a drive motor that existing catalog offerings could not satisfy across all required

-43%System Weight
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Specialty Vehicles

Low-EMI BLDC Wiper Drive System for Specialty Vehicle OEM

Specialty Vehicle Manufacturer (Confidential)

A manufacturer of specialty electric vehicles for airport ground support operations needed to replace the brushed DC wiper motor in their next-generation platform, and the requirements went significan

600k cycles validatedService Life
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Valve & Pump

Sensorless EC Motor Pump Solution with Integrated Efficiency Control

Industrial Pump OEM (Confidential)

An industrial pump OEM manufacturing circulation pumps for HVAC and industrial process applications was under simultaneous pressure from two directions: energy efficiency mandates that their existing

+34%Efficiency
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Robotics & AGV

AGV Drive Program Consolidation: From 14 Suppliers to One

AGV Manufacturer (Confidential)

A leading North American manufacturer of autonomous guided vehicles (AGVs) for warehouse and logistics applications came to TelcoMotion with a sourcing problem that was undermining their cost structur

14 → 1Vendor Consolidation
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