Custom Precision Gears for Automated Guided Vehicles | DD Gear

Features & Benefits

• Designed for AGV & AMR duty cycles:
  AGV Gear is engineered for low-speed, high-torque operation with frequent start/stop, reversing and slow-speed maneuvering, supporting long operating hours and short charging cycles in warehouse and factory environments.

• Small-module precision for smooth, controlled motion:
  Tight control of tooth profile, pitch, backlash and runout allows smooth wheel rotation, accurate speed control and precise docking or pallet positioning, which is essential for safe interaction with racks, pallets and operators.

• Support for wheel drives, steering and lifting systems:
  DD Gear can supply gears and shafts for drive wheels, steer wheels, bogies, jackshafts and lifting/lowering mechanisms, helping OEMs use a consistent gear partner across different AGV platforms and load classes.

• Spur, helical and planetary gear capability:
  Spur gears provide compact, efficient torque transfer in many wheel and intermediate stages; helical gears help reduce noise and increase load capacity; planetary gear sets enable high reduction ratios and torque density in tight wheel housings.

• Material & heat-treatment options for long life and reliability:
  Case-hardened and nitrided steels are selected to provide high contact fatigue and bending strength; surface treatments and corrosion-control options help resist humidity, condensation and occasional outdoor exposure in loading areas.

• Efficiency and NVH-focused manufacturing:
  Small-module precision machining, tooth finishing and controlled heat treatment help minimize friction losses and gear whine, which is critical because AGVs and AMRs operate close to people in quiet indoor environments where noise is easily perceived.

• Prototype-to-series production support:
  DD Gear can provide prototype sets for new AGV platforms or wheel modules, then stabilize processes and inspection plans for series production, supporting volume ramp-up and platform updates over time.

Technical Specifications

Final data will be defined according to the customer’s drawing and sample.

Applications

AGV Gears from DD Gear can be tailored to many types of automated vehicles and mobile robots, for example:

• Warehouse AGVs & AMRs – Wheel-drive and steering gears for pallet movers, tow tractors and small AMRs handling totes or racks in intralogistics applications.

• AGV forklifts & stackers – Drive-wheel reductions and lifting-system gears for automated pallet stackers and counterbalanced AGV forklifts working in aisles and loading bays.

• Tugger and train AGVs – High-torque wheel gear sets for tugger trains pulling multiple trailers over long distances within factories and distribution centers.

• Assembly and line-feeding AGVs – Compact wheel-drive gears for low-profile vehicles carrying car bodies, subassemblies or kitting racks to assembly stations.

• Custom mobile robots – Gears and shafts for special-purpose AMRs in manufacturing, healthcare, electronics or semiconductor fabs where clean operation and precise positioning are critical.

Gear Manufacturing Process

Every AGV gear is produced under a controlled gear manufacturing route designed for precision and durability. A typical process flow is:

1. Forging or bar cutting of shaft blanks

2. Lathe machining of shaft diameters and reference surfaces

3. Hobbing or shaping of gear teeth

4. Drilling, milling, and other CNC machining operations

5. Heat treatment (such as carburizing, quenching, tempering, nitriding)

6. Shot blasting and stress relief as required

7. Finish machining and grinding of journals and critical surfaces

8. Gear grinding (profile or worm grinding) where accuracy demands it

9. Cleaning and rust prevention treatment

10. Final inspection and packaging for shipment

Precision Gear Customization Process

To support custom AGV gear projects, DD Gear follows a clear, eight-step customization process:

Step 1 – Requirement Collection
Customers provide design requirements, 2D drawings, 3D models, or physical samples, together with basic duty cycle information (torque, speed, life, installation).

Step 2 – Drawing Design & Optimization
Based on the provided drawings or samples, DD Gear prepares or optimizes detailed manufacturing drawings and shares them with the customer for confirmation.

Step 3 – Quotation
After the drawings and technical points are confirmed, we issue a precise quotation covering tooling, piece price, lead time, and quality requirements.

Step 4 – Tooling & Fixture Preparation
Once the price is confirmed, we arrange tooling and fixture production. Any tooling cost is agreed with the customer in advance and can be offset or refunded after mass orders, according to the commercial agreement.

Step 5 – First Sample Approval
After tooling and fixtures are ready, we manufacture the first sample batch—typically within about 30 days—and ship it to the customer for testing.The customer inspects and validates the samples in their gearbox or test bench and provides feedback on dimensions, performance, and any required adjustments.

Step 6 – Mass Production
When the sample is approved, we start mass production according to the agreed production plan and quality standards.

Step 7 – Finished Product Inspection
After production, we inspect hardness, dimensions, runout, tooth accuracy, and other critical characteristics to ensure full compliance with the drawing and standards.

Step 8 – Shipping Arrangement
Once inspection is passed and shipment is approved by the customer, we arrange booking, packaging, and delivery to the specified destination.

Quality Assurance & Inspection

DD Gear applies the same quality philosophy to AGV gear and all precision gears:

• Quality management systems based on ISO 9001 and IATF 16949

• Process control from incoming material to final inspection, including:

  • Material certification and chemical composition checks

  • Hardness and case depth verification after heat treatment

  • Gear measurement for profile, lead, pitch, and runout

  • Surface roughness testing on gear flanks and journals

  • Dimensional inspection with calibrated gauges and CMMs

• Traceability for each batch with inspection records and reports

• Optional documentation such as PPAP/FAIR packs on request

Packaging

Usage & Installation Notes

• Ensure wheel-drive gearboxes, steering modules and lift mechanisms are assembled with the shaft alignment, fits and preload specified on the drawings; misalignment and incorrect fits will increase noise and accelerate wear.

• Use the recommended lubricant type, viscosity and fill level; AGVs often rely on sealed gearboxes with limited lubricant volume, so cleanliness and correct filling are essential.

• Avoid mixing gears from different sets unless they are explicitly designed to be interchangeable; planetary gear sets in particular depend on matched geometry and controlled clearances.

• Monitor noise, vibration, temperature and backlash during commissioning and maintenance; abnormal changes should trigger inspection of tooth contact patterns, lubrication condition and bearing health.

• Protect gears from corrosion and contamination during storage, shipping and vehicle assembly, especially if vehicles will be used in refrigerated warehouses, outdoor loading areas or environments with strong temperature fluctuations.

Company Strength – DD Gear

• Specialized in small module, high-precision gears and shafts for EVs, humanoid robots, AGVs, and intelligent automation.

• Integrated manufacturing from forging and machining to heat treatment and gear grinding.

• Quality systems aligned with automotive standards, with experience supporting OEM and Tier 1 projects.

• Engineering support covering concept feasibility, DFM reviews, and failure analysis feedback.

• Global export capability with experience serving customers in multiple countries.

Q1: What information do you need to quote AGV Gears?
We typically need: vehicle type and load class (e.g. pallet AGV, tugger, AGV forklift, AMR), drivetrain layout (hub motor, wheel-side gearbox, central motor + shaft, etc.), 2D drawings and preferably 3D models, gear types (spur/helical/planetary/gear shafts), materials and heat-treatment requirements, motor power and speed, wheel size, maximum load and slope, duty cycle, lubrication concept and annual volume.

Q2: Are AGV transmissions usually single-speed or multi-speed?
Most AGV and AMR drivetrains are single-speed, using one or two gear stages (often with planetary or spur/helical gears) to provide the necessary wheel torque and travel speed. Multi-speed transmissions are less common and usually reserved for special performance requirements.

Q3: Should we choose spur, helical or planetary gears for AGV drives?
Spur gears are simple and efficient and can work well for many wheel and intermediate stages. Helical gears offer smoother, quieter operation and higher load capacity, but introduce axial thrust that must be handled in the bearing design. Planetary gear sets are ideal when you need high reduction ratios and torque in a compact wheel hub or wheel-side gearbox. The best solution depends on your packaging, NVH, efficiency and cost targets.

Q4: Can DD Gear supply complete AGV drive units or vehicles?
No. DD Gear acts as a precision gear and shaft supplier. We manufacture gears, gear shafts and related components according to your drawings. Complete gearboxes, wheel modules and vehicles are designed and assembled by the AGV/AMR OEM or system integrators.

Q5: How can we control gear noise in quiet warehouse environments?
Gear noise can be addressed through appropriate tooth geometry, accuracy levels, surface finish, lubrication and housing stiffness. DD Gear can support with manufacturability-focused feedback on tooth modifications, tolerances and surface treatments, but final NVH performance must be verified in the complete drive module and vehicle.