Energy Efficiency Archives

From Drive Systems to Solutions

Posted on 25 June, 20251 August, 2025 by David Priestman

Whether conveying goods or lifting heavy loads, every movement needs a drive system. However, different applications have different requirements. As a developer of drive solutions, NORD offers via its modular product range all components of drive technology that can be combined in various configurations.

NORD implements the appropriate selection, design and calculation of the drives. Drive systems consisting
of gear unit, motor and drive electronics thus become tailor-made solutions for specific industry applications. Hence, the company is able to fulfil a wide range of specific requirements.

A modular system offering numerous solutions

One example is the requirement for energy efficiency. NORD has electric motors that can be used worldwide and comply with all relevant international regulations. With its IE5+ synchronous motors, the developer surpasses the efficiencies of the currently highest defined energy efficiency class (IE5). They are also part of the integrated gear unit/motor concept DuoDrive that combines the IE5+ motor with a single-stage helical gear unit in one housing. DuoDrive achieves one of the highest efficiencies on the market within this power class. Users also benefit from expertise and additional services, such as the NORD ECO efficiency analysis that allows the implementation of upcoming drive tasks with optimal energy consumption.

Another current example is condition monitoring that NORD can integrate into its drive solutions. With an IIoT solution, it is possible to determine and analyse drive and status data via the integrated PLC of the frequency inverter. The data can also be made available to the central systems of the users. This provides important information for predictive maintenance, allowing machinery and equipment to be maintained proactively, while reducing downtimes and increasing overall system efficiency.

Solutions to optimise user performance

“Requirements are changing – and we are actively following this path” reports Jörg Niermann, Head of
Marketing at NORD. “We are continuously developing our drive components to provide our customers with
solutions that help them progress technically, economically and environmentally.” By combining a wide
modular product range with technical expertise and knowledge in more than 100 industries, NORD creates
drive systems that are tailored to specific needs and delivered as complete solutions from a single source.

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Bulldoor Addresses Extreme Weather Challenges

Posted on 12 June, 202429 July, 2025 by David Priestman

Union Industries, a leading manufacturer of bespoke high-speed industrial doors, has helped LoneStar Leeds Limited, a provider of precision engineered components, sealing technologies and specialised coatings and plating reduce costs and improve efficiency through the triple installation of its Bulldoor.

Union Industries was first approached by LoneStar in 2023 and was subsequently tasked with providing solutions for site enhancement projects at its facilities, primarily on doorways frequently accessed by forklift trucks for deliveries and stock movement. The three Bulldoors were designated for deployment across LoneStar’s two sites in Leeds.

Headquartered in the West Midlands, UK, and employing more than 1,000 people across 13 sites, LoneStar Group has proven itself in global logistics. It utilises a worldwide network of its own manufacturing and distribution operations, as well as primary supply sources, to supply and support customers in America, Europe, the Middle East, Central and South East Asia and Australia with precision engineered components

The primary objective was to mitigate heat loss within the premises, thereby reducing energy expenditure and improving the company’s ECG performance. The existing roller shutters and sectional overhead security doors, characterised by slow operational speeds, often remained open, resulting in substantial heat dissipation and increased energy consumption, especially during harsh weather conditions.

Union Industries developed tailored solutions for each opening, including reducing the opening size of a large doorway to curtail heat loss while maintaining optimal clear opening sizes to suit LoneStar’s requirements. Additionally, it crafted a door to fit within tight spatial constraints without compromising operational functionality. Importantly, all three doors seamlessly integrated with existing security measures, ensuring comprehensive site security post working hours.

Like other doors in their range, Bulldoor also benefits from Union’s simple yet proven ‘Crash Out and Auto-Reset’ facility, in case of vehicle impact to the bottom beam, thus ensuring minimal downtime and repair costs.

Rob Howe, Technical Sales Engineer at Union Industries, said: “We take pride in delivering tailored solutions that address our clients’ unique challenges. The successful installation of our Bulldoors at LoneStar underscores our commitment to innovation, efficiency, and customer satisfaction.”

Gemma Juniper, HR & HSE Manager at LoneStar Leeds, said: “The installation of Union’s doors was a pivotal step in our journey toward environmentally focused improvements across our company portfolio. The comprehensive heat loss payback report highlighted not only the potential cost savings but also the tangible benefits of enhanced energy efficiency.”

Union Industries increases stock levels

Tailored Drive System Solutions

Posted on 26 February, 2024 by Keith McKinley

ABM will present complete drive solutions for a wide range of intralogistics applications at the upcoming LogiMAT in Stuttgart (19–21 March) in Hall 3 at Booth 3B15. The system supplier tailors the drive solutions in close cooperation with the customer to his unique application and requirements – while maintaining a strong focus on ensuring sustainability and efficiency of the proposed drive package.

As a full-service provider, ABM develops and manufactures drive systems for stationary and mobile applications in all areas of intralogistics. In electric buses or trucks they are used, for example, for auxiliary units such as hydraulic pumps, air compressors and cooling fans. They are also installed in pallet trucks, forklift trucks and automated guided vehicles (AGVs) as well as in container and pallet conveyors, cranes and industrial doors. The system solutions consist of motors, gearboxes, brakes and inverters – selectively for mains or battery power supply.

Drive Components for Traction, Lifting and Steering

ABM offers all drive solutions for driving, lifting and steering of forklift trucks as a single source. The motors, gearboxes and inverters comply with strict environmental requirements, are safe and are extremely responsive for precise movements even at low speeds. One of the available drive options are the two stage bevel gearbox units of the series TDB. These drive units come with plug-and-play capability for easy integration and are both powerful and energy-efficient. They offer high power densities at optimum efficiencies. The compact series is available with manual or individual steering as well as with integrated electric steering drive.

The drive specialist will present the TDH series electric-steering hub-wheel drive units with inverters for AGVs, pallet jacks, cleaning machines, industrial trucks or track-bound vehicles. These units are compact, robust and capable of handling high static and dynamic wheel loads. For the motor control specific sensors that record speed, rotor position and temperature are included.

Driven with High Energy Efficiency

The wide product range includes induction motors as well as the sustainable and high-efficiency Sinochron motors. Because Sinochron motors already meet the requirements of premium energy efficiency class IE5, users do not have to worry about compliance with legal regulations. The synchronous motor has a compact design and can easily be integrated into systems. With the unique feature sensorless control, the inverter calculates the rotor speed and the instantaneous rotor angle from electrical feedback. With this data, the currents for torque generation can be fed precisely to the motor. The motor can be optimally controlled over a wide speed range with a high starting torque – without the need for expensive sensors.

The comprehensive product range also contains helical gearboxes with torques from 30 to 2000 Nm, parallel shaft gearboxes with 50 to 2300 Nm and angular gearboxes with 60 to 450 Nm. They can be supplied with flanges, solid shafts or hollow shafts. Also available are brakes and sensors.

Via an intelligent modular system, the provider can adapt the various gearbox configurations to the respective application and rapidly deliver a drive solution with high cost efficiency with regard to functionality and efficiency. ABM also offers industry-tailored concepts. For special applications, ABM can also develop completely new system solutions as partners in close cooperation with customers.

Integrated Drive System for Accumulation Roller Conveyors

One innovation example is the highly integrated drive system for accumulation roller conveyors. During development focus was placed on compactness, maximum efficiency and cost. Efficient and dynamic motors are installed as direct drives for small loads. For higher loads – such as in pallet conveyors – the drives can be combined with angular, helical or parallel shaft gearboxes. Added to that is an inverter series designed especially for intralogistics applications. This series is available in three sizes with power outputs of up to 2.2 kW and a high overload capacity of 250 per cent. With the series, ABM covers all common applications in container and pallet conveyor systems. And because most drives in intralogistics only operate at part load, the Sinochron motor with sensorless control are the perfect match.

Externally Excited Motor

An externally excited motor for e-mobility, which is still under development at ABM, is also sustainable and efficient. At its booth, ABM will offer an early look at the innovation, which is completely free of rare earth magnets. The good field weakening behaviour mirrors the torque/speed requirements for traction drives, because they can be controlled more efficient and variable. ABM supplies drive solutions for intralogistics as a single source. The customer receives a tailored, installation-optimized, highly energy-efficient solution for the given application. With this, ABM continues to pursue its goal of delivering high-quality, reliable drive solutions and as a partner supporting its customers with engineering and manufacturing expertise.