components Archives

Drive Systems at LogiMAT

Posted on 18 January, 2024 by Keith McKinley

At the LogiMAT trade show in Stuttgart the drive specialist Nord will present its reliable and energy-efficient drive systems units for the industry.

In intralogistics, parcels of different weights must be transported continuously – often over relatively long distances. Special requirements are placed on performance, reliability and energy efficiency of the drive technology used. For this purpose, NORD DRIVESYSTEMS designed suitable drive solutions – and will present them from 19 to 21st March 2024 at LogiMAT in Stuttgart.

NORD DRIVESYSTEMS has developed the DuoDrive gear unit/motor combination specifically for intralogistics. A highly efficient IE5+ synchronous motor from NORD is integrated into a helical gear unit, achieving an extremely high efficiency. DuoDrive achieves a constant torque over a wide speed range and thus allows for a significant reduction of drive variants in a system. This results in minimised administrative costs and streamlined service processes.

Compact, maintenance-friendly, pluggable

In addition, the decentralised NORDAC ON frequency inverters have been optimised for the requirements of horizontal conveyor technology. With their compact design, easy maintenance and full pluggability, they are especially suited for large intralogistics systems with various drive units. In the NORDAC ON+ version, they are specially designed for the combination with the IE5+ motor.

NORD does not only support its customers with suitable and resource-saving drive components, but also with competent services. The NORD ECO service, for example, helps to find the most efficient drive solution for a specific application. Here, the energy consumption behaviour of a system is checked with the aid of a measuring device. The data evaluation reveals the fields in which the system may work inefficiently, and NORD provides recommendations for efficiency-optimised drive solutions.

Drive Systems

At LogiMAT, NORD will also present its sustainability programme. The drive specialist commits itself to act in an ecologically, economically and socially responsible manner – providing security for those customers who are also amenable to the Supply Chain Act.

NORD DRIVESYSTEMS will present its drive solutions for intralogistics from 19 to 21st March 2024 at LogiMAT in Stuttgart. You will find the company at Stand 3C41 in Hall 3.

Things for Mobile Robot Manufacturers to Consider

Posted on 6 September, 202325 July, 2025 by David Priestman

Mobile robot manufacturers need to take a range of factors into consideration when selecting planetary gearboxes, writes Mike Gulliford, Managing Director, Apex Dynamics UK. The global mobile robots market is expanding rapidly and forecasts for mobile robot revenues were recently increased as a result. With such a wealth of opportunities in the market for autonomous mobile robots (AMRs) and autonomous guided vehicles (AGVs), manufacturers providing products that meet customers’ needs will see sales grow.

Strong outlook for mobile robots and planetary gearboxes

Precision gears are an essential component within the motion control systems of mobile robots, and planetary gearboxes will continue to play a significant role in the market going forward. Just under 50% of precision gear products sold in 2022 had a planetary design, according to market intelligence specialist Interact Analysis, demonstrating the enduring popularity of planetary gearboxes. In fact, mobile robots are predicted to become the #1 industry for planetary gear products by 2026, as high levels of demand continue within the mobile robot industry, driven by labour shortages and increased demand for warehouse automation in the wake of the Covid-19 e-commerce boom.

Planetary gearboxes are ideal for mobile robots

Planetary gearboxes are the ideal compact high-precision servomotor solution for mobile robots, with estimates showing that the vast majority of mobile robots employing precision gear products will have planetary gears (~95%) by 2026. It is of paramount importance that mobile robot manufacturers select the best precision planetary gearboxes for the specific needs of their robots and applications.

Here are seven key factors to consider when using planetary gearboxes in mobile robots, in order to ensure optimal performance, reliability and efficiency:

1. Torque and Power Requirements
Torque and power requirements are specific to the intended applications and payloads. Manufacturers must carefully address the torque demands of each robot’s motors and actuators in order to select planetary gearboxes that can handle loads effectively. Ensuring adequate torque ratings for planetary gearboxes can help to prevent premature wear, overheating and potential system failure.

2. Efficiency and Gear Ratios
A crucial element of mobile robot design, planetary gearboxes generally offer higher efficiency than other types of gearboxes. Manufacturers should carefully evaluate the efficiency of gearboxes and consider the gear ratios that suit each mobile robot’s operational needs. The selection of proper gear ratios ensures optimal motor speed and torque output, which translates into better energy utilization and enhances overall performance.

3. Size and Weight Constraints
Compact autonomous systems such as mobile robots often have limited space and weight allowances. Planetary gearboxes are known for their compact and lightweight designs, making them the preferred choice for many manufacturers. Manufacturers must give consideration to selecting gearboxes that fit within the space constraints and adhere to the weight limitations of their mobile robots without compromising performance.

4. Backlash and Precision
Precision gearboxes are designed to have low or zero backlash, meaning the clearance between interlocking teeth is much smaller than in standard gearboxes. This improves the accuracy and repeatability of robot movements, which is particularly important in applications where fast, precise movement is required, such as industrial automation or medical robots. Choosing planetary gearboxes with minimal backlash helps to maintain positional accuracy and reduce errors.

5. Lubrication and Maintenance
Choosing the correct type of lubrication and understanding the maintenance needs of planetary gearboxes is vital to ensure the smooth and efficient operation of mobile robots. For example, sealed gearboxes or those with extended intervals between lubrication may be preferred by mobile robot manufacturers in order to reduce maintenance requirements and extend system uptime.

6. Durability and Reliability
These factors are key to the overall longevity of mobile robot systems, with some robotic applications operating in or exploring harsh environments, or carrying out heavy-duty material handling tasks. Mobile robots operate in a range of environmental conditions, including extreme temperatures, and environments heavy on moisture and/or dust, with some even designed to operate in underwater environments.

Intense operating conditions make it crucial for mobile robot manufacturers to select gearboxes that are made from high-quality materials and that are precision manufactured to ensure they can withstand the rigours of the application, with adequate protection against corrosion, ingress and environmental contaminants. For example, all Apex Dynamics UK gearboxes are made in our CE and ATEX-certified manufacturing facility and come with a 5-year warranty.

7. Cost and Availability
A further consideration for mobile robot manufacturers is the cost of the gearboxes they are selecting for their mobile robots and their availability on the market. It is important to strike the correct balance between required performance and budget constraints to ensure the project (and product) remains economically viable. Furthermore, good delivery times for planetary gearboxes are crucial to ensure products are ready to ship to customers. At Apex Dynamics UK, we guarantee delivery within 3-4 weeks, combining high quality products with reasonable prices, excellent customer service and support.

With an array of possibilities to choose from when it comes to planetary gearboxes, there is the potential to find the right fit for each mobile robot and its potential applications. By considering the variables above, manufacturers can make informed decisions and help to ensure they develop robust, best-in-class products, with high performance, low backlash, precision, durability, minimal downtime, and success in their respective applications.

At Apex Dynamics UK, we supply products to the mobile robot industry and our new GL series of precision planetary gearboxes has been specifically designed for AGV applications. With a unique rotary housing that allows a drive wheel and pulley to be mounted over the exterior, Apex Dynamics’ GL helical planetary gearboxes are available with a shaft input (GLS), which allows the gearbox to be driven by belt and pulley. GL gearboxes are fitted with helical planetary gears hardened to 840 HV, patented input and output sealing, and a patented input bearing system that ensures perfect concentricity, making them the ideal choice for mobile robots.

Sustainable Innovation

Posted on 8 December, 2020 by Keith McKinley

Bonfiglioli is encouraged by its future opportunities, boosted by a new Bologna production plant and a new frequency inverter series. Paul Hamblin reports.

“Innovation becomes sustainability,” said Fausto Carboni, CEO of Italian gear motor and drive manufacturer Bonfiglioli at a September press conference. He painted a bullish picture of the
company’s recent performance, with revenues up 6.7% at €973 million last year, incorporating EMEA figures up 5% and North America up 20%.

Looking at the much more volatile recent months, he is encouraged by the contrast between April and August numbers this year. He quoted the example of India, down 99% year-on-year in April, for obvious reasons, but up 10% year-on-year in August. In an intriguing signal for the wider economy, he revealed that China will be Bonfiglioli’s most important market in 2020, with numbers boosted by 64% year-on-year in the territory. While Italy, France and Spain are all understandably down by over a half this year, Germany is a predictable outlier, with a less damaging slowdown than its European neighbours. Mr Carboni suggested that Germany’s growth is also boosted by its strong progress with the Circular Economy.

He went on to outline how Bonfiglioli has adapted to virus restrictions with new shift patterns, improved distancing, common space procedures and regular temperature checks of staff. These
have been incorporated at its new plant for industrial gear motors at Bologna. “#WeNeverStop is our new mantra,” he revealed. This promise is illustrated by the launch of a new premium frequency inverter series.

Bonfiglioli says that the new AxiaVert Series provides the ultimate combination of flexibility, modularity and connectivity, aimed at offering an optimal response to specific industrial application requirements across a wide range of sectors and with different degrees of complexity. AxiaVert is now available in 4 sizes, with a power range between 0.25–15 kW. Higher power versions will be released at a later stage.

The advanced digital and open communication protocols, complying with automation and Industry 4.0 standards, allow a smooth integration into automation networks, thanks to the compatibility
with a great variety of fieldbus protocols and machine controllers. Communication encryption is embedded by design in AxiaVert to ensure secure communication. In addition, thanks to
condition monitoring functions on the key inverter components as well as on the gearmotor critical parameters, AxiaVert is able to provide real time diagnostics, energy optimization and
predictive maintenance information related to the motion system up to the entire machine.

The wide range of advanced integrated functional safety functions, in compliance with EN ISO 13849-1 and IEC 61508 international standards, are available in different versions, to select the most suitable option in terms of costs and performance and match the actual needs. This approach simplifies configuration and reduces the need for external safety components, while ensuring a safe and controlled operation of different movements (e.g. lifting applications), thanks to Safe Brake Control and fast spindle axes with Safe Limited Speed, even sensorless.

Thanks to its modular structure and PLC software programmability, the system can be flexibly adapted and customized to meet many different application requirements, by defining the proper
software parameters and functions, and selecting the most suitable hardware modules, such as communication or encoder modules, variants and accessories. In addition, the AxiaVert Series offers a great variety of frame and power sizes, mounting variants and cooling concepts for greater freedom of design.

Great process versatility is ensured by the high compatibility with a wide range of motors (asynchronous, synchronous, synchronous reluctance) and by its high speed, position and torque control
accuracy, both for open and closed loop applications. Finally, user-friendliness is ensured by AxiaManager engineering software for programming, commissioning, operation and monitoring of AxiaVert. AxiaManager is available as a Windows PC GUI and as a mobile App for an instant access to the drive status and configuration with a simplified user interface.

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