Integrated drive solutions for intralogistics applications This article highlights some of the integrated Industry 4.0 solutions Bonfiglioli can offer to meet the intralogistics needs of Industry 4.0 manufacturing and assembly plants.
I ntralogistics systems play a crucial role in ensuring that materials, components, and finished products flow smoothly and efficiently, supporting just-in-time assembly, packaging, palletising, automated storage, warehousing, and much more. For these applications, Bonfiglioli has developed a wide range of integrated drive solutions, as well as modular machine design and software options to help manufacturers improve ef- ficiency, reduce errors and enhance control over their internal operations. Bonfiglioli drive solutions are at the heart of modern electric forklifts and reach trucks, as well as assembly-line roller and belt con- veyors. They are used in automated guided vehicles (AGVs) and automated moving robots (AMRs) in automotive and Industry 4.0 as- sembly and manufacturing facilities, as well as in automated warehouses used to store materials and components. Typical Bonfiglioli solutions comprise a geared motor combined with an inverter for efficient motion control, and application-spe - cific software that enables the entire system to perform detailed handling tasks accurately. Automatic baggage and parcel handling For roller conveyor drives, Bonfiglioli’s typical solution range uses its EVOX CP Series co- axial or orthogonal helical bevel gearboxes, its compact EVOX IE3 electric motors, and a decentralised IP65 DGM-MPM inverter, all bundled into a single module. The gearbox's compact design offers high torque density and low warehousing costs, thanks to its universal mounting system.
The modular motor delivers uncompromis- ing efficiency, while Bonfiglioli DGM-MPM Inverters, available in power ranges from 0.55 to 30 kW, are simple to install. They in - clude features such as an inventory manager, advanced, sensorless control at low speeds, controlled DC braking and support for field - bus communication. The combined modular package is de- signed for easy washdowns and reduced electrical wiring, and it includes a host of other application-specific options. A similar solution is available for belt conveyors, which typically utilise an A-series helical bevel gearbox to minimise installation space and provide high stiffness for dynamic applications. The BSR Series synchronous IE4 electric motor is preferred for its efficiency, positioning and dynamic performance. A decentralised DGM-MPM Series Inverter can be attached to drive and control the belt. AMR, AGVs and Material Handling Vehicles For forklift trucks, the heart of the traction system is a Bonfiglioli high-efficiency, low- noise planetary axle and drive, which includes integrated high-performance electric motors and a low-maintenance braking system. These are typically used for 3- and 4-wheel counterbalance lift trucks and ground sup- port equipment. These electric powertrains are thoroughly tested in the factory, guaranteeing low energy consumption. This, in turn, means longer bat- tery operating times, extended servicing intervals and lower costs of ownership. Electric or hydraulic steering units, cus-
Above: A Bonfiglioli solution for roller conveyors using a EVOX CP Series gearbox, a compact IE3 electric motor, and a decentralised DGM-MPM inverter. Below: Belt conveyors typically utilise an A-series helical bevel gearbox,
a synchronous IE4 electric motor and a decentralised Inverter.
tomised vehicle displays, and DC-to-DC converter options complete the package for these vehicles. With the AGV (automated guided vehicle) sector constantly expanding, Bonfiglioli's modular design solutions are increasingly being deployed in facilities such as vehicle assembly plants, where the necessary compo- nents need to be delivered to a specific point on an assembly line at precisely the right time. These computer-controlled component- handling vehicles are programmed to safely transport manufacturing materials and components between designated pickup and delivery points within a busy working facility, enhancing workplace safety by eliminating accidents caused by human error. Bonfiglioli conceives, designs and pro- duces custom solutions for AGVs, leveraging extensive expertise and experience in the intralogistics industry. These solutions are
Bonfiglioli solutions for airports include tow tractors, baggage-handling systems and baggage-claim conveyors.
18 ¦ MechChem Africa • November-December 2025
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