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Tag: Bonfiglioli

New AGV Hero in the Warehouse

Posted on by David Priestman

In the pursuit of more efficient, productive and safe operations, a growing number of warehouses are implementing automated guided vehicles (AGVs).

“Companies continue to invest in automation, and in many cases AGVs present the most feasible investment, resolving a number of business challenge, such as labour shortages, worker safety, the need for a flexible factory layout, space saving as well as meeting the demands for more productive and efficient operations,” says Martin Broglia, MD of Bonfiglioli Australia and New Zealand. “As the AGV sector matures, we’re seeing a trend towards solutions that are customisable, modular and deliver precision and high performance. To meet this need, Bonfiglioli has developed the specialised BlueRoll gearbox”.

The BlueRoll is a wheel-mounted gearbox, specifically developed to meet the requirements of the AGV sector, delivering excellent position accuracy and high energy efficiency for long operating cycles. This gearbox is almost completely enclosed by the wheel and can be fitted directly to the chassis of the vehicle, making installation easy. The integrated wheel is supported directly by reinforced gearbox bearings, which permit ultra-high radial forces. It’s available in various sizes to meet load requirements, and reaches a speed of up to 2 m/s. With its compact axles and flat design, the BlueRoll is a space-saving solution.

“This is a gearbox that is built to handle heavy loads. It’s also a durable solution, using high-quality precision planetary gears. It comes with a range of feedback systems including safety encoders,” says Broglia (pictured). “It’s ideal for use in a wide range of warehousing and materials handling applications.”

Martin Broglia

The BlueRoll is currently available in three models:

1. BlueRoll BASIC: Achieves max speed of up to 2m/s, it can handle loads from 360 – 1020 kg. It’s available in three sizes – the 1.7kg TQW 060; the 5.5 kg TQW 070 or 10.9 kg TQW 090.

2. BlueRoll ADVANCED: Delivers low inertia and features a holding and safety brake. Available in three gearbox sizes – with four motor frame options, and a wide range of encoders for easy system integration. The ADVANCED is available in a range of sizes, from the 1.3 kg BMD 65, right up to the 7.7. kg BMD 118.

3. BlueRoll COMPACT: It’s 25% more compact than a standard motor-gearbox solution and is highly customisable. It also offers high energy efficiency thanks to its optimised mechanical design.

“Selecting the right gearmotor is critical. Our technical team ensure extensive consultation and collaboration with the customer, to deliver the solution that meets application requirements,” says Broglia.

Making its local debut

The BlueRoll will make its local debut at the 2025 Foodtech Packtech & MHL expo (taking place from 2-4 September 2025 at the Auckland Showgrounds, with free registration). Bonfiglioli will be exhibiting a number of innovations for the food processing and packaging sector. “The BlueRoll has a lot to offer the AGV brands and we can’t wait to introduce our customers to this smart product,” concludes Broglia.

Gearmotors for AMR Growth

Posted on by David Priestman

Bonfiglioli’s tailored drive solutions are at the heart of a smarter, more connected future for manufacturers of AGVs and AMRs, writes Editor Peter MacLeod.

As demand for autonomous mobile robots (AMRs) and automated guided vehicles (AGVs) surges across logistics and warehouse environments, Bonfiglioli, a long-established Italian manufacturer of gear motors and drive systems, is turning its attention to providing customised, compact, and connected solutions for OEMs. Cristiano Cattan, Global Key Account Manager, sat down with us at LogiMAT to discuss the company’s evolution and innovation trajectory.

“We’re seeing significant growth in the AMR space,” Cattan explains. “And what we’ve learned is that this is a very different business from traditional industrial markets. OEMs don’t want off-the-shelf components, they want tailored solutions.”

Bonfiglioli, known historically for industrial gearboxes, continues to expand its offering of integrated systems that combine motors, gear units, and drive controllers. This shift is more than a product evolution, it’s a strategic move to meet customer demands for turnkey solutions and to help them reduce their roster of component suppliers.

“Today, customers are coming to us not for a gearbox, but for a compact, all-in-one drive solution,” says Cattan. “They’re saying, ‘Here’s the performance spec and physical dimensions, can you build something that fits?’ And we’re answering yes, with a collaborative engineering approach between their R&D and ours.”

Valued Partner

This high-touch engagement has made Bonfiglioli a valued partner for OEMs building AMRs and AGVs, especially in space-constrained applications. It’s also pushing the company deeper into electronic integration. The 2023 acquisition of Selcom Group, an Italian electronics manufacturer, has bolstered Bonfiglioli’s in-house capabilities in drive control and edge computing, opening the door to smarter, IoT-enabled systems.

“We now offer solutions that include condition monitoring and predictive maintenance,” says Cattan. “Our gear motors can report live data on temperature, vibration and load. That means operators can identify wear or potential failures before they cause downtime.”

These insights are transmitted either through the customer’s PLC or via Bonfiglioli’s edge computing devices, enabling residual lifetime analysis of components like bearings and motors. “Customers don’t want to stop a line, even for a second,” Cattan (pictured below) adds. “So being able to plan maintenance before failure is a real value-add.”

Cristiano Cattan, Bonfiglioli

Broad Portfolio

Despite these advances, Bonfiglioli’s challenge remains market perception. “We’re still seen by many as just a gearbox supplier,” Cattan says. “But we have a broad portfolio and deep flexibility to go beyond it. We want the industry to know that Bonfiglioli offers full, intelligent drive solutions.”

Indeed, that flexibility has proven crucial, not only in AMRs but also in fixed logistics applications. While Bonfiglioli isn’t embedded in global giants such as Amazon or DHL, Cattan notes a rising interest in their smart conveyor solutions, especially for airport baggage handling and intralogistics systems.

As it evolves its product portfolio, Bonfiglioli is also positioned for a global customer base. “We have production and service locations in Europe, the US, China, and India,” says Cattan. “That global footprint is important for OEMs looking for consistent quality and local support in every major market.”

Looking ahead, Bonfiglioli is preparing to launch a new integrated AGV drive solution later this year. “It’s made entirely in Italy – motor, gear, controller, all in one. That gives us total control over quality and design, and helps our customers reduce their supplier base without compromising performance.”

For Bonfiglioli, the future is compact, smart, and collaborative. And as the AMR and logistics sectors continue to demand speed, flexibility and intelligence, it is really gearing up to meet it.

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Italian Specialist Bonfiglioli to Present Electric Drives at LogiMAT

 

Solutions for Intralogistics Needs at LogiMAT

Posted on by David Priestman

Bonfiglioli boosts its intralogistics participation at LogiMAT with two booths: the first, in the Hall 10, is dedicated to Solutions for Mobile Intralogistics (Booth 10D13), the second, in the Hall 7, is focused on Logistics Automation Solutions (Booth 7F09). This double presence holds significant strategic importance, reflecting the company’s steadfast commitment in the development of complete cutting-edge solutions for warehouse operations, under the sign of efficiency and sustainability. Showcased is a wide array of systems for belt and roller conveyors, AGVs, AMRs, forklifts and automatic storage systems, as well as an IoT platform.

In the Hall 10, Bonfiglioli dedicates ample space to the 600F series, electric drive axles for forklifts, which makes a significant return. The series is equipped with planetary axles and drives featuring integrated high-performance electric motors and low-maintenance braking systems, and it can be applied to 3- and 4-wheel counterbalance lift trucks and ground support equipment. These drives are available in different sizes, also for bigger forklifts, and offer reduced energy consumption, resulting in longer battery operating times, extended service intervals and a lower overall cost of ownership.

The EL Series which identifies steerable powertrains for pallet trucks, stackers, reach trucks and other types of warehousing machinery, has been expanded this year into the new size EL 16. Developed for heavy load warehouse equipment, it is equipped with a multifunction unit that ensures the complete control of acceleration, steering and braking. It can carry a vertical load up to 4.5 tons and thus represents the best choice for the most demanding warehousing applications.

BlueRoll is also on display. This innovative platform features wheel-mounted gearmotors tailored for AGVs and AMRs, boasting an ultra-compact and energy-efficient design to ensure prolonged operational cycles. The modular drive system offers three configurations – Basic, Advanced, and Compact – with customizable single gearbox loads ranging from 360 to 1020 kg and a maximum speed of 2m/s.

In Hall 7, Bonfiglioli unveils three solutions that improve efficiency, boost productivity and reduce downtime. An AGV solution featuring the platform BlueRoll is also present at this booth.

The first intralogistics solution showcased at the Booth 7F09 and which has been specifically developed for post & parcel handling systems, combines high efficiency and reliability, low maintenance costs and a wide torque range. It consists of a compact right-angle A gear unit available in a wide torque range, an IE4 certified reluctance synchronous motor of the BSR series – an ecological and high-performance product (thanks to the absence of magnets) – and a DGM decentralized inverter, fitted with a sensorless vector operation for an optimal dynamic control. The right angle layout between INPUT and OUTPUT makes the A Series particularly compact. The gear set combination makes this right-angle product the most efficient and durable in Bonfiglioli’s light and medium-duty portfolio. The A Series can be completed with a wide range of electric motors entirely manufactured by Bonfiglioli.

For heavier applications, i.e. logistics and transport on roller conveyors carrying out bulky parcels and pallets, Bonfiglioli has developed the second combined solution featuring a helical in-line CP47 gearbox, a MXN 20 asynchronous reluctance motor and a DGM decentralized inverter. Indeed, DGM inverters offer many benefits in terms of efficiency, reliability and safety, because wiring and troubleshooting costs are reduced, while product modularity and interchangeability are enhanced. Moreover, real time check of main gearmotor parameters is guaranteed through fieldbus interfaces or protocols.

Intralogistics at LogiMAT

The third solution boasts a BMD servomotor – a permanent magnet synchronous motor with highly compact dimensions and low inertia – combined with an A20 helical bevel gearmotor and the inverter AxiaVert. Top-level functional safety and high control performance for a wide spectrum of applications are the key benefits and features of the AxiaVert platform. A drive which offers seamless integration into automation networks and compatibility across an extensive range of fieldbus protocols, both on a serial and on an Ethernet basis, fostering production optimization in accordance to Industry 4.0 standards. Its different Functional safety variants allow to optimize configuration, reducing the need for external safety components and ensuring a safe and controlled operation to minimize hazards. Additionally, precise motion control for open and closed loop applications maximizes efficiency and productivity, for a wide range of motion requirements. Its modular structure allows flexible adaptation to diverse applications by selecting appropriate hardware modules and customizing operational behavior through user-level PLC software programmability. Available in different selectable cost and performance related variants – Basic, Standard and Motion: the latter including the networked safety protocol FsoE (Fail Safe over EtherCAT). AxiaManager is the comprehensive engineering software designed for the planning, commissioning, operation, and monitoring of the AxiaVert inverter series. Furthermore, Users can count on support from a Bonfiglioli expert from commissioning to troubleshooting thanks to an online remote assistance function.

Finally, Bonfiglioli presents its Condition Monitoring and Predictive Maintenance services, which respond to the necessity of maintaining comprehensive control and visibility over machinery. The former allows customers to know the overall status of their equipment by regularly collecting real-time data and identifying significant changes in parameters through an IoT platform equipped with sensors that measure performance, consumption and real duty cycle of the machine. The latter helps prevent damages and downtime by providing key information about, for instance, oil change intervals and hence planning the necessary technical operations in advance.

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Italian Specialist Bonfiglioli to Present Electric Drives at LogiMAT

 

Custom Solutions for Mobile Collaborative Robotics

Posted on by David Priestman

The 2023 SPS trade fair in Nuremberg represented an important opportunity for Bonfiglioli to showcase its experience and expertise for industrial automation. Its innovative, cutting edge offer included mechatronic solutions specifically designed for packaging, intralogistics, robotics and IoT applications.

A corner of the booth was dedicated to Bonfiglioli’s technologies for cartesian, delta and articulated robots, the latter solution consisting of a custom designed, precision planetary gearbox and servomotor developed for ABB.

Remaining in the field of mobile robotics applications, the spotlight was on BlueRoll: the high-performance, wheel-mounted gearmotor platform for AGVs and AMRs, featuring an ultra-compact and energy-efficient design for a long operating cycle. The modular drive system is available in three configurations, Basic, Advanced and Compact, with a customisable single gearbox load ranging from 360 to 1020 kg and a maximum speed of 2m/s. In response to evolving market demands, Bonfiglioli is currently developing integrated solutions with the aim of providing customers with a complete AGV movement package, including complete drive and transmission control systems. This approach allows Bonfiglioli to deliver ready-to-assemble, turnkey solutions, thereby minimizing the need to purchase interface devices from the AGV/AMRs manufacturers.

The Group is also expanding its product folio by focusing on enhancing payload capacity, catering to the rigorous specifications demanded by robotic sector. The capacity to offer a diversified array of products ranging from standard precision gears and gearboxes to specially designed motors for axis movements and completely customised ones, as well as integrated solutions for AGV/AMRs drive controls, places Bonfiglioli among the leading players in this sector. The codesign with customers grant significant value in terms of performance optimisation, cost saving and accelerated time to market.

Solution-oriented approach to packaging and intralogistics

Flow pack packaging processes require automatic machines that are able to keep pace with high production rates, for which Bonfiglioli offers a wide range of compact, modular, dynamic, high-precision drive and control solutions for horizontal and vertical forming, filling and sealing machines. These include the package presented during SPS, which features a TQ in-line high precision planetary gearbox combined with a BMD permanent magnet synchronous servomotor and a highly versatile AxiaVert smart inverter. Alongside this process, we are also able to extend maximum handling speed to the finished products palletization, thanks to a solution incorporating our BMD synchronous servomotor, Series A right-angle gear unit and ANG Series servo inverter.

During the fair, we also presented two intralogistics solutions: the first solution, designed for use with post & parcel and airport baggage handling systems, consists of a compact, right-angle Series A gear unit, available in a wide range of torque ratings, the IE4-certified BSR synchronous reluctance motor – an ecological and high-performance product (thanks to the absence of magnets), and a DGM MPM decentralized inverter, featuring sensor-less vector operation for optimal dynamic control. The second solution, designed for use with roller conveyors, combines the EVOX CP helical in-line smooth surface gearbox that can be fitted on any machine thanks to its compatibility with market standards, the MXN asynchronous low-voltage e-motor (IE3) developed to be modular, reliable, energy efficient and compliant with international certification requirements, and a DGM MPM sensor-less inverter.

Visitors had the chance to get an up-close look at the two successful applications, which have been designed in partnership with Modula S.p.a. and I.DE S.r.l., for whom Bonfiglioli has developed complete, customised technical solutions.

Open Door to Future of Industrial Automation

Posted on by David Priestman

At the SPS manufacturing event in Parma, Italy, Bonfiglioli presented technologies including its mechatronic solutions for industrial automation, packaging and intralogistics, robotics and IoT.

The flow pack packaging process requires automatic machines that can keep up with high production rates, for which Bonfiglioli offers a wide range of compact, modular, dynamic and high-precision drive and control solutions for both horizontal and vertical forming, filling and sealing machines. These include the package on display during the three-day event, featuring a TQ in-line high precision planetary gearbox combined with a BMD permanent magnet synchronous servomotor and AxiaVert smart inverter, the latter characterised by high application versatility. In addition, the company is able to ensure maximum handling speed for finished products during the palletization process thanks to a solution that incorporates our BMD synchronous servomotor, Series A right-angle gear unit and ANG Series servo inverter.

Two intralogistics solutions were also presented at the fair. The first solution for post & parcel use and airport baggage handling systems consisted of a compact right-angle Series A gear unit available in a wide torque range, the IE4-certified BSR synchronous reluctance motor – an ecological and high-performance product thanks to the absence of magnets, and a DGM MPM decentralized inverter with sensorless vector operation for optimal dynamics control. The second solution designed for roller conveyors combined the EVOX CP helical in-line gearbox with smooth surface that can be fitted to any machine thanks to its compatibility with market standards, the MXN asynchronous low-voltage e-motor (IE3) developed to be modular, reliable, energy efficient and internationally certified, and a DGM MPM sensorless inverter.

Visitors got an up-close look at the two successful applications designed in partnership with Modula S.p.a. and I.DE S.r.l., for which Bonfiglioli has developed complete and tailor-made technical solutions.

The latest frontier in mobile collaborative robotics applications

Bonfiglioli also showcased its technologies for Cartesian, delta and articulated robots, the latter solution consisting of a custom precision planetary gearbox and servomotor developed for ABB.
Still in the field of mobile robotics applications, there was a strong interest in BlueRoll: the platform of high-performing wheel-mounted gearmotors for AGVs and AMRs with an ultra-compact and energy-efficient design for a long operating cycle. The modular drive system comes in three configurations, Basic, Advanced and Compact, with a customisable single gearbox load ranging from 360 to 1020 kg and a maximum speed of 2m/s.

Bonfiglioli’s IoT enables condition monitoring and predictive maintenance

Downtime, sudden breakdowns, high maintenance costs, short life spans and collateral damage to assets are some of the greatest issues faced by industrial machinery manufacturers and operators. As a technological partner, the Bologna-based group offers condition monitoring and predictive maintenance services, as well as post-sales assistance. Bonfiglioli responds to customer needs to monitor the general status of gearboxes and motors with its IoT platform, thanks to the presence of sensors capable of measuring performance, consumption and cycle times by monitoring significant parameters such as vibrations or temperature. The predictive maintenance service, on the other hand, helps prevent damage and downtime by making key data accessible to predict technical assistance interventions in advance.

“We have designed specific sensors for Bonfiglioli motors and gearboxes,” commented Marco Bertoldi – Global Sales & Business Development Director at Bonfiglioli. “The recent acquisition of Selcom Group S.p.A. has allowed us to expand our knowledge of engineering and design for the integration of electronics into our mechanical solutions, enhancing our offer of turnkey mechatronic solutions”, he concluded, highlighting the advantages of this collaboration, with the customised DC-DC converter and display for Toyota and the customised PLC for Robopack also on display.

The Bonfiglioli Group undertakes to reduce the environmental impact of all stages along its supply chain, limiting the energy consumption of factories and plants, while developing and promoting solutions for green economy sectors such as wind power, recycling and photovoltaics. Our environmental commitment translates into innovative energy efficiency solutions and products with a low environmental impact, as we ensure a responsible supply chain: our research and development teams constantly strive to explore new ways to reduce environmental impact and create products with a reduced carbon footprint. In the 4.0 area at SPS dedicated to sustainability, the EVOX ecosystem, featuring the CP range of high-performance coaxial gear units, BXN IE3 asynchronous motors and Agile series inverters, is ideal for applications that require precision and flexibility.

Sustainable Electric Solutions in the Spotlight

Posted on by David Priestman

New automation, efficiency and sustainability needs have emerged in recent years, prompting industry players to embrace innovation in order to boost their speed, precision and productivity while reducing costs and inefficiencies. In this context, latest-generation technological solutions are the new protagonists of warehouse operations, aiming, on the one hand, to reduce the environmental impact of logistics processes and operating costs and, on the other, to speed up the handling of goods, optimising movements in order to manage large volumes in shorter times.
Logimat was the perfect opportunity for Bonfiglioli to share the expertise and know-how capitalised in over 60 years of business with customers and to present its solutions for forklifts, warehousing trucks and automated storage.

More specifically, the 600F Series featuring high-efficiency planetary gears and drives with integrated electric motors for premium performance was on display in the forklift area. The 610 x3E model in particular, designed for machines capable of moving up to 16 tons on the fork, positions the company as a specialist on the market for large electric machines.

As regards warehousing trucks, the EL09 steerable powertrain for pallet trucks, stackers and reach trucks displayed ensures minimal noise and high manoeuvrability in tight spaces, thanks to a multifunction unit for the complete control of acceleration, steering and braking. In terms of production, the company has invested in a highly automated assembly line that guarantees high quality and process repeatability, with a takt time of 4 minutes. These solutions can be fully customised to meet manufacturer requirements. In the same area, BlueRoll completes the range that makes Bonfiglioli a full line supplier for intralogistics vehicles. This new platform of performing wheel-mounted gearmotors for AGVs and AMRs has an ultra-compact and energy-efficient design for a long operating cycle. The modular drive system comes in three configurations – Basic, Advanced and Compact – with a customisable single gearbox load ranging from 360 to 120 kg and a maximum speed of 2m/s.

Finally, Bonfiglioli showcased two solutions complete with gearbox, motor and inverter. The first solution, perfect for post & parcel use and airport baggage handling systems, consists of: a compact right-angle gear unit (A) available in a wide torque range, an IE4 certified synchronous reluctance motor (BSR), which guarantees an ecological and high-performance solution thanks to the absence of magnets, and the DGM MPM decentralised inverter with sensorless vector control operation for optimal dynamics control.

The second solution, designed for roller conveyors, includes the EVOX CP, a helical in-line gearbox with a smooth surface that can be fitted to any machine thanks to its compatibility with market standards, the MXN asynchronous low voltage e-motor (IE3) developed to be modular, reliable, energy-efficient and internationally certified, and a DGM MPM sensorless inverter.

Bonfiglioli designs, manufactures and distributes a wide range of gearmotors, electric motors, planetary gearboxes and inverters, capable of satisfying the most complex needs in the industrial automation, mobile machinery and renewable energy sectors. The Group offers complete solutions that serve more industries and applications than any other gearbox manufacturer and is the market leader in many areas; the three Business Units, Discrete Manufacturing & Process Industries, Motion & Robotics and Mobility & Wind Industries, express all the experience and skills acquired over the years in their respective fields of expertise. Founded in 1956, Bonfiglioli operates in 80 countries with 26 commercial sites, 20 production sites, an extensive distribution network that includes over 550 partners, and can count on over 4,700 professionals worldwide. Excellence, innovation and sustainability are the drivers that guide Bonfiglioli’s growth as a company and as a team and represent the guarantee of the quality of the products and services offered to its customers.

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