Gearmotors for AMR Growth

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

 

Two Offers for Warehouse Logistics

With the LogiDrive solution space, NORD offers its warehouse logistics customers two industry-optimised drive concepts. LogiDrive Advanced and LogiDrive Basic both impress with their low weight and compact installation space. In addition, they are optimised for different factors.

Chain and roller conveyors, belt and pallet conveyors, container and overhead conveyors: In warehouse logistics, they all require reliable drives with sufficient power for the corresponding application. This is guaranteed by both solutions from the drive specialist NORD. Furthermore, both feature maximum user-friendliness, easy wiring, low weight and compact installation space. What sets them apart: LogiDrive Advanced was optimised for energy efficiency and LogiDrive Basic with regards to costs.

The drive solutions in detail:
– LogiDrive Advanced
– Highly efficient IE5+ synchronous motor
– Decentralised NORDAC ON+ frequency inverter, which was specially designed for combination with the IE5+
– A gear unit from the NORD portfolio
– LogiDrive Basic
– IE3 asynchronous motor
– Decentralised NORDAC ON frequency inverter
– A gear unit from the NORD portfolio

According to the customer’s requirements: Focus on costs or energy efficiency

The LogiDrive Advanced drive solution ensures maximum energy efficiency and thus achieves high savings in CO2 emissions. It achieves its very high efficiency via large speed and load ranges, and allows for a variant reduction. This is particularly attractive for large systems with numerous drives: Fewer drive variants in a system result in streamlined logistics, warehouse and service processes and thus in reduced administrative costs.

The components of the LogiDrive Basic are perfectly matched. They meet all essential warehouse application standards and impress with a large adjustment range. This drive solution does not offer maximum efficiency but features low investment costs.

Whether LogiDrive Advanced or LogiDrive Basic: The decision is determined by the specific application requirements. Either way, the user receives a perfectly industry-optimised solution, including a frequency inverter with integrated multi-protocol Ethernet interface. Furthermore, both solutions are equipped with all international certifications and can thus be used worldwide, which is important for globally active companies.

Sustainable Electric Solutions in the Spotlight

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.

Nord Drivesystems Optimistic About Growth

In a challenging year, NORD DRIVESYSTEMS also looks back on positive developments. Just before the turn of the years 2022/2023, the drive manufacturer passed the one billion euro sales threshold for the first time, increased its number of employees to 4,900 and opened new production locations worldwide.

“2022 was a very successful year, but at the same time characterised by crises”, says Gernot Zarp, Sales Manager at NORD DRIVESYSTEMS. “The customers’ feedback, however, was very positive as despite the bottlenecks in the supply chains we always tried to make everything possible for our customers.”

Focus topics and products

In 2022, the focus was mainly on innovative, energy-saving drive solutions to significantly reduce the energy consumption in industrial applications and to appropriately respond to the increasing energy costs – for example by using the patented DuoDrive and the high-efficiency IE5+ motors. The NORD ECO service supported companies in finding the most efficient drive solutions.

In addition, the NORD Group focussed on the topic sustainability: Internal processes have been made more efficient but also further aspects have been shifted into focus, such as environmental protection, the training and promotion of employees, human rights in the supply chain, certificates (EcoVadis and ISO 14001) and the signing of the UN Global Compact.

Investments and growth

In 2022, NORD DRIVESYSTEMS invested heavily in the extension of the capacities in Germany and abroad. The new office and administration building in Bargteheide was built, the production location in Yizheng, China, was completed and in the first quarter of 2023, the company’s fourth global assembly plant for industrial gear units will be opened in India to map the local growth. Furthermore, the manufacturer plans to extend the electronic production at its Aurich location, and to significantly increase the capacities of the motor factory in Poland.

Prospects for 2023

“The last years have shown that companies must position themselves more broadly. This is why the topic of Multisourcing will get a higher priority, especially in the fields of supply chain and production, but also in the global orientation of the target industries”, Zarp explains. In 2023, the focus will be on industries such as post & parcel, airport, warehouse logistics, bakery and packaging industry, and applications on bulk handling or mixing and agitating.

“Currently, energy-efficient solutions such as our patented DuoDrive and IE5+ motors are very popular as they provide a particular customer benefit. The same applies to our MAXXDRIVE® XD industrial gear units or the NORDAC ON frequency inverters, the power ranges of which we will expand to 3 kW”, says Zarp. Topics such as factory automation and digitalisation will also play an important role this year, particularly with regard to the growing Asian market.

“All in all, we look optimistically to the new year and assume a further improvement of the supply situation and further growth”, says Zarp. In the field of electromechanical motors and geared motors, the manufacturer is already back on pre-crisis level with its standard delivery times achieved and a reliability of more than 90%. “We all yearn for normality and stability instead of crises.”

Drive solutions for the bulk goods industry

Whether storing, conveying, weighing and dosing, or loading and unloading, Nord Drivesystems says it develops and produces scalable drive solutions for all sectors of the bulk goods industry. The drives are individually tailored to the customised application, and offer high energy efficiency paired with a robust design.

Large temperature fluctuations, abrasive ambient media, rough operating conditions: Demanding ambient conditions are common in the bulk goods industry. Drive systems used in this sector must be adequately resistant. At the same time, they should operate as energy efficiently as possible, provide easy maintenance and high reliability, and achieve a long service life. Different bulk goods require different plant arrangements that need customised drives.

Bulk goods handling from a single source

Being a long-time partner of the industry, Nord Drivesystems says it knows precisely the specific requirements of the bulk goods industry. The drive specialist globally supports operators of systems for storing, conveying, weighing, dosing, loading and unloading of bulk goods with optimised drive solutions, profound application expertise and technical support.

The powerful drive systems are characterised by maximum reliability, safety and robustness, and ensure smooth operation even in the harshest ambient conditions. Fully featured Nord drive solutions based on a modular system, consisting of frequency inverter, motor, gear unit, couplings, and brakes are selected as the basis. They are combined with solutions individually developed and designed according to customer requirements.

Ultimate reliability

Nord manufactures all gear units – even the industrial gear units up to 282kNM – with a UNICASE housing. An enclosed gear unit housing, which combines all elements of the gear unit is produced from a single piece of material. All bearing points are integrated in the housing block so that there are no sealing surfaces, which are subject to torque and radial loads. This way, the Nord gear units achieve a longer bearing life than gear casings manufactured from jointed parts and ensure efficient power transmission and high tolerance for peak loads and impacts.

Large low-friction roller bearings ensure extremely high axial and radial load capacities; high-precision axis alignment ensures quiet running.

Future-proof

Nord drives are highly reliable, have a long life, are easy to maintain and have a low energy consumption. They thereby help to reduce operating costs and minimise CO2 emissions. The system solutions also meet the requirements for Industry 4.0 applications, and with their integrated PLC functionality allow for condition monitoring and predictive maintenance.

 

Modular System for all Drive Solutions

NORD Drivesystems supplies its customers from more than 100 industries with optimally matched drive systems that are precisely adapted to their individual requirements. The company is one of the leading international full-service suppliers of drive systems and develops and manufactures gear units, motors and drive electronics. The portfolio includes gear units for torques from 10 Nm up to more than 282 kNm, electric motors for power ranges from 0.12 to 1,000 kW and frequency inverters up to 160 kW.

Configurable for any application

With NORD’s modular system, drive systems can be combined individually for almost any application – this guarantees solutions which are perfectly tailored to the customer’s requirements. The competent NORD consultants develop tailored concepts that can be optimised with regard to energy efficiency, version reduction and the Total Cost of Ownership (TCO). Users can also configure their drive components online, using the product configurator.

NORD’s production is characterised by a high degree of vertical integration: All quality-determining components are produced at NORD and manufactured in our own factories. The international production capacities and a network of local subsidiaries in 36 countries ensure a reliable and short-term worldwide supply with service support and spare parts.

Familiar with customer industries

NORD supplies efficient drive solutions for more than 100 industries and is very familiar with their specific requirements. For intralogistics and warehousing, for example, the drive specialist has just defined industry-specific optimised solutions. These solution variants are called LogiDrive and – depending on the required application – are offered in a basic and an advanced version.

The patented DuoDrive geared motor is recommend for applications in the food or beverage industry as well as in the pharmaceutical sector. An efficient IE5+ synchronous motor, which tops the highest defined efficiency class IE5, is integrated into a single-stage helical gear unit – which not only allows for a compact installation space but also ensures high system efficiency.

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NORD technology optimises TCO

In customer projects, NORD Drivesystems always aims to reduce Total Cost of Ownership (TCO) for the customer as much as possible. TCO includes all costs associated with the purchase, operation and recycling of a drive system. By using highly efficient technology in combination with a consistent version reduction and standardisation, a significant optimisation of life cycle costs is possible.

NORD offers a wide range of innovative products and services, assisting drive technology customers in reducing their system’s Total Cost of Ownership. The NORD modular system makes a customised reduction of versions possible at the time of purchase. With the help of efficient drive solutions from NORD Drivesystems, energy costs incurred can then be reduced significantly. In addition, matched online tools facilitate spare part management for the relevant industries.

Eighty-five percent of a drive’s life cycle costs are incurred during operation: Energy costs, administrative costs, service and maintenance costs, training and documentation, personnel costs, spare part stocking as well as failures and downtimes but also costs for recycling and disposal. Aspects like energy efficiency, operational reliability, maintenance costs and version reduction are therefore essential for TCO optimisation.

The long service life and the low maintenance of NORD drive systems also have an especially positive impact on the reduction of the Total Cost of Ownership. A most effective measure for reducing the Total Cost of Ownership is the use of highly effective synchronous motors. Developed by NORD, these motors have an efficiency class that is sometimes even better than IE5. The current standard in Europe is efficiency class IE3.

Cost optimisation

Synchronous motors reveal their full potential in applications with a partial load range and low speed ranges. Systems such as baggage handling and post and parcel processing can achieve significant cost savings through the use of synchronous motors. High cost reductions are achieved over the entire product life cycle. NORD’s high-efficiency portfolio was developed with focus on the highest energy efficiency, maximum power density and the best possible user-friendliness. It consists of the patented DuoDrive geared motor, the integrated IE5+ synchronous motor and the NORDAC ON frequency inverter. It is the ideal solution for reducing the Total Cost of Ownership.

With the NORD ECO service, NORD specialists analyse the drives installed at the customer with regard to their energy efficiency, dimensioning and the number of versions to create a tailor-made drive concept for reducing the life cycle costs for the existing application.

NORD presents innovative drive solutions at LogiMAT

The specialist LogiMAT exhibition in Stuttgart offers a comprehensive overview of the intralogistics and process management market, and as one of the market leaders for drive technology, NORD will be there to present its solutions for the industry. The exhibition highlights include the revolutionary and patented DuoDrive geared motor, the highly efficient IE5+ synchronous motor, the NORDAC ON/ON+ decentralised frequency inverter (pictured), as well as an intelligent concept for status-oriented maintenance according to Industry 4.0.

Modern automated intralogistics systems place high demands on drives in horizontal as well as vertical conveyor technology. NORD Drivesystems provide the industry with innovative drive solutions, combining reliability with profitability. The DuoDrive is setting new standards for intralogistics. The innovative and patented geared motor integrates a high-efficiency IE5+ synchronous motor into the single-stage helical gear unit housing. This not only guarantees a compact size and minimal noise emissions but also high power density and overall high system efficiency. Together with its simple plug-and-play commissioning, the complete DuoDrive solution results in a significant reduction in Total Cost of Ownership (TCO) compared to other drive systems.

Economic Solution for IIoT environments

The decentralised NORDAC ON/ON+ frequency inverter was specially developed by NORD for the requirements of horizontal conveyor technology. An integrated Ethernet interface, full pluggability and a very compact design make it the smart inverter for decentralised use in Intralogistics. The frequency inverter can be mounted directly on the drive housing and covers lower power ranges of up to 1.0kW. The combination with the IE5+ synchronous motor (NORDAC ON+) enables significant efficiency potential.

Downtime avoidance is also one of the decisive targets in intralogistics. To increase system availability, NORD has designed “Condition Monitoring For Predictive Maintenance”. The integrated PLC in NORD frequency inverters can process data in connected sensors and actuators, initiate autonomous control sequences and communicate drive and application data to the control centre, networked components or to cloud storage. This allows continuous condition monitoring and therefore forms the basis for predictive maintenance concepts as well as optimum plant dimensioning. Impermissible operating states can be recognised early, unplanned downtimes can be avoided and maintenance becomes predictive.

These and more drive solutions will be presented by NORD Drivesystems from 31st May to 2nd June 2022 at LogiMAT in Stuttgart (Stand D10 in Hall 03).

NORD sets new standards for food sector

From 26 to 29 April 2022, NORD DRIVESYSTEMS will exhibit at ANUGA FOODTEC (Hall 7.1 on stand A030). With the IE5+ synchronous motor, the company is setting new standards with regard to energy efficiency of drive systems in the food industry and intralogistics. The high-efficiency IE5+ motor has now been integrated into a single-stage helical gear unit – thus further optimising system efficiency – and is also launched in the next size.

The new DuoDrive geared motor features high system efficiency and a consistent version reduction paired with a smooth, unventilated and compact design. Elimination of many wearing parts results in lower maintenance. In combination with the simple commissioning of the complete solution via plug-and-play, this results in a significant decrease of the Total Cost of Ownership (TCO) compared to existing drive systems. DuoDrive is suitable for use in the food industry as well as intralogistics.

With the IE5+ synchronous motor, NORD DRIVESYSTEMS is setting new standards again: The new motor is now available in ventilated or smooth surface versions for powers from 1.1 to 4.0kW with a continuous torque of 6.8 to 18.2Nm.

Taking integration to the next level

DuoDrive is a NORD DRIVESYSTEMS’ revolutionary integrated geared motor in hygienic wash-down design where the IE5+ synchronous motor and the single-stage helical gear unit are installed in one single housing. As a system, the very compact DuoDrive concept achieves a significantly higher energy efficiency than the already proven combination of IE5+ synchronous motor and NORDBLOC.1 bevel gear unit.

At up to 92%, DuoDrive currently offers one of the highest efficiencies on the market for geared motors in this power class, and achieves its very high systems efficiency even in the partial load range. It is thus future-proof and a real cost reducer.

The first available DuoDrive size covers gear unit speed ratios of i=3.24 to i=16.2 and is designed for torque ranges of up to 80Nm and speeds of up to 1,000min-1. As it is easy to clean, corrosion-resistant and wash-down capable, DuoDrive is also ideal for use in hygiene-sensitive and harsh environments, and ensures higher system availability and lower cleaning costs through lower cleaning effort. If required, the motors are provided with a very smooth surface or the nsd tupH surface treatment.

An alternative to stainless steel

In case of stringent requirements on surface and corrosion protection, nsd tupH surface treatment is the technology of choice. Thanks to a special method, the surface is made corrosion-resistant and harder and makes aluminium behave like stainless steel with regard to corrosion protection.

This is not a coating, but a surface treatment that creates a protective layer which is permanently bonded to the substrate material. So nothing can detach or flake off. Damage remains locally restricted and does not spread. The drives are easy to clean and largely resistant to acids and alkalis.

It is even possible to use high-pressure cleaners or apply aggressive media. nsd tupH treatment is available for most of the aluminium products in the NORD modular drive system, and ideally suited for hygienically sensitive applications in the food sector.

 

Altra expands virtual exhibition stand

Altra Industrial Motion Corp. has expanded its virtual exhibition with new explorable 3D application environments, booths, event areas and products.

Viewable from a web browser at any time, the Altra virtual exhibition stand offers visitors the chance to engage with market-leading power transmission products, 3D models, videos, literature and downloads. The stand features bearings, brakes, clutches, couplings, drives, engine braking solutions, gearing, limit switches, linear actuators, motors and more for a wide variety of challenging applications. Users can navigate products via hotspots, which offer easy access to content and quick contact with experts if required.

New additions to the stand include detailed 3D virtual application environments for the water, mining, oil and gas sectors. Places to explore include an oil rig and surface ship; a surface mine, an underground mine and processing area; as well as a complete wastewater treatment plant. By clicking on highlighted installations, visitors can instantly view relevant brands and products, as well as all associated media. This allows quick filtering of suitable solutions for each application, speeding up specifying.

Also new is Innovation Spotlight, which will be updated monthly with a technically advanced product. In the recently added Auditorium, visitors can sit and watch an extensive library of Altra webinars and presentations in a virtual room. Furthermore, the user interface for the stand has been refreshed.

Leading brands represented at the virtual exhibition include Ameridrives, Bauer Gear Motor, Bibby Turboflex, Boston Gear, Delroyd Worm Gear, Formsprag Clutch, Guardian Couplings, Huco, Kilian, Kollmorgen, Lamiflex Couplings, Marland Clutch, Matrix, Nuttall Gear, Portescap, Stieber, Stromag, Svendborg Brakes, TB Wood’s, Thomson, Twiflex, Warner Electric and Wichita Clutch.

Showcasing innovative power transmission solutions from the leading brands of Altra,

CLICK HERE to visit the stand.

 

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