Bespoke gearbox engineering for a world-first shutter system
At Brown GearTech we’ve spent over 50 years supporting OEMs with bespoke gearbox design, geared motors, and precision gearbox solutions built to perform under pressure.
When Bolton Gate Company, a leading manufacturer of industrial doors, fire and security shutters, approached us, the project required more than a standard gearbox. They needed a drive system for a ContraRoll Marine Rolling Shutter which would be required to operate in extreme offshore conditions, a completely unique product requiring precise engineering and collaborative problem-solving.
The challenge
The ContraRoll was a conceptual design proposed for installation above and below a new walk-to-work gangway lift system, integrated onto the decks of service vessels built for offshore windfarm maintenance and repair. Mounted on the front face of the lift tower, up to 25 metres above deck level, the system would enable engineers to safely access turbines across European offshore wind farms, often in sub-zero temperatures and extreme marine conditions. Key requirements included:
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1.
Drive System
High IP-rated drive system resistant to water and dust ingress
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2.
Torque
Continuous torque to maintain tension on the barrel system
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3.
Precise
Encoders for precise speed and position control
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4.
Seamless
Seamless integration with a third-party control system
With multiple partners involved, including the control panel manufacturer, collaboration was essential. Complex calculations and detailed torque analysis were needed to ensure reliability and safety in extreme conditions.
The solution
We approached the project as co-designers and problem-solvers, working closely with Bolton Gate Company and their partners. Key elements of the solution included:
- Developing and supplying a brake motor with an IP66 rating for harsh marine conditions
- An IP66 encoder system providing accurate speed and position monitoring
- Gearbox assembly securely fastened to the auxiliary shaft for reliable load handling
- Transparent communication on performance criteria and lead times
During development, we refined torque specifications and upgraded the encoder system to ensure consistent tension and safe operation.
As Nichola Adshead, Sales Director at Brown GearTech, explains
Our goal was to ensure the gearbox didn’t just fit the system, but performed flawlessly under conditions nobody else had tested. Collaboration at every stage was key to that success.
– Nichola Adshead, Sales Director at Brown Europe
Impact
The first three systems, including the prototype, are now fully operational. The IP66-rated drive system continues to perform reliably offshore, and the upgraded encoders minimise performance discrepancies.
Andrew Marsh from Bolton Gate Company said:
“Great quality. When we needed compliant motors, Brown were the only supplier who could deliver what we needed. Brown were professional, collaborative, with a can-do attitude, and always clear and concise. We value their engagement, collaboration and responsiveness. Equipment is robust, delivered on time and they’re reliable, and we’ve not had a single client complaint.”
“Equipment is robust, delivered on time and they’re reliable…”
Partnering with a uk gearbox supplier
Projects like this showcase how technical expertise combined with collaborative design delivers gearbox systems OEMs can trust. By focusing on precision, reliability, and clear communication, complex systems can operate in even the most challenging environments.
If you’re an OEM seeking a UK gearbox partner for bespoke designs and mission-critical applications, our engineering team is ready to work with you to deliver solutions that perform where it matters most. Contact the team to learn more.
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