ABB 3HAC057549-003 Motor incl Pinion – High-Performance Robot Axis Drive for Demanding Automation

The ABB 3HAC057549-003 motor incl pinion is a dedicated industrial robot drive unit designed to deliver precise, repeatable motion on heavy-duty robot axes. Used widely as a spare part in ABB robot systems such as the IRB 6600 series, this motor combines robust mechanical design with optimized torque and speed characteristics for continuous operation in harsh industrial environments. 

Engineered as a “motor incl pinion” assembly, it comes with an integrated pinion gear, simplifying mechanical integration into the robot gearbox and reducing installation time. This package is ideal for users who need to restore robot performance quickly after a failure, or for those performing preventive maintenance on critical lines.

Key Technical Specifications

All electrical data should be verified against the robot controller manual and ABB documentation before commissioning.

Product Overview

The ABB 3HAC057549-003 is not a generic motor; it is a robot-specific servo/drive motor with an integrated pinion tailored to the mechanical and electronic ecosystem of ABB industrial robots. Its purpose is to provide:

• High positioning accuracy

• Smooth, vibration-controlled motion

• Reliable torque delivery for heavy payloads and high-inertia moves

By integrating the pinion directly on the shaft, ABB reduces the number of mechanical interfaces, which can lower backlash, improve repeatability, and shorten installation steps compared to a separate motor + gear solution. 

Key Features and Benefits

1. Optimized for ABB Robot Axes

This motor is part of ABB’s official spare-parts family for robotics. It is designed to match the dynamic requirements, torque curve, and thermal behavior expected by ABB robot controllers, minimizing the risk of incompatibility or performance loss when replacing older motors such as the 3HAC15991-x series. 

2. Integrated Pinion for Faster Installation

Because the pinion gear is included and pre-fitted at the factory, maintenance engineers avoid:

• Press-fitting a gear onto the shaft

• Aligning a separate gear with the robot’s internal gearing

• Extra balancing or run-out checks

This helps reduce downtime during critical maintenance windows, especially in 24/7 production environments.

3. High Torque Density in a Compact Package

With around 4 Nm of rated torque and a mechanical output close to 2.2 kW, packaged in a 285 mm long and 9.16 kg body, the 3HAC057549-003 provides a strong torque-to-size ratio. This is valuable on articulated robots where space is limited and every kilogram affects payload and inertia. 

4. Designed for Industrial Harsh Conditions

ABB motors in this family are specified for continuous operation under demanding conditions—high duty cycles, frequent starts/stops, and exposure to elevated ambient temperatures. The Foundry+ designation indicates suitability for applications such as foundries and heavy manufacturing where dust, heat, and contaminants are common. 

Typical Applications

The ABB 3HAC057549-003 motor incl pinion is commonly used as:

• A replacement axis motor in ABB IRB 6600 or similar heavy-duty industrial robots in automotive, metal processing, and general manufacturing. 

• A spare part held in stock by maintenance teams to minimize downtime in critical robot cells.

• A component in retrofit or upgrade projects, where older motor variants (3HAC15991-x, 3HAC033234-001, etc.) are phased out in favor of the newer design. 

Typical tasks supported by robots using this motor include:

• Spot and arc welding

• Material handling and palletizing

• Machine tending and press loading

• Casting, forging, and other foundry operations

Design and Construction Highlights

1. Motor incl pinion concept

   • The pinion is firmly mounted to the motor shaft at the factory, improving concentricity and reducing assembly variation.

   • Fewer bolted interfaces mean fewer potential points of mechanical looseness over time.

2. Industrial-grade housing

   • The housing and sealing concept are designed for industrial environments, with robust surface finishes and mechanical protection appropriate to ABB’s robotics portfolio. 

3. Compatibility with ABB control systems

   • Electrical characteristics (voltage, feedback, speed) are coordinated with ABB robot controllers, allowing plug-and-play replacement when the correct part number is used.

Installation and Integration Guidelines (High-Level)

When installing a 3HAC057549-003 in an ABB robot:

1. Verify part number and compatibility

   • Cross-check with the robot’s spare-parts list or ABB documentation to confirm that 3HAC057549-003 is the correct replacement for the given axis and robot variant.

2. Follow ABB mechanical alignment procedures

   • Ensure correct meshing of the pinion with the robot’s internal gear or gearbox.

   • Check backlash and play according to ABB’s service manual; many robots include factory markings to simplify alignment.

3. Observe torque-down procedures

   • Use specified tightening torques for mounting bolts.

   • After installation, run the axis slowly to listen for abnormal noise or vibration.

4. Commission through the controller

   • After mechanical installation, perform calibration and mastering procedures using the robot controller, so that position feedback aligns correctly with physical joint positions.

Maintenance and Service Considerations

The 3HAC057549-003 is designed for long life, but predictive maintenance is still crucial:

• Thermal monitoring: Check for abnormal heating during intensive cycles, which may indicate overload, misalignment, or gearbox problems.

• Noise and vibration: New noises after installation often point to pinion/gear issues, improper mounting, or internal damage elsewhere in the drive train.

• Regular inspection intervals: During scheduled robot service windows, visually inspect cable connections, seals, and the mounting area for contamination or oil ingress.

• Spare part strategy: Many plants keep at least one unit in stock due to its critical role in keeping large robot cells online.

Because this motor replaces several older ABB part numbers, consolidating spare-part inventory around 3HAC057549-003 can simplify stock management.

Why Choose the ABB 3HAC057549-003 Motor incl Pinion?

• Genuine ABB design – Developed specifically for ABB robot platforms, ensuring tight integration with mechanics, drives, and control firmware. 

• Backwards compatibility – Serves as the newer replacement for multiple legacy part numbers, which simplifies upgrades and repairs. 

• Compact yet powerful – Delivers robust torque and power in a relatively small footprint, supporting high-performance motion on large robots.

• Reduced downtime – Integrated pinion and ABB-specific design reduce installation complexity and configuration time.

For any facility relying on ABB heavy-duty robots, keeping a 3HAC057549-003 motor incl pinion on the shelf is a practical way to protect productivity and avoid costly, unplanned stops in the production line.