Mechatronic Drive Systems for Intralogistics and Automated Material Handling

Bonfiglioli exhibited its expanded portfolio of automation and drive solutions engineered for intralogistics, parcel handling, and e-commerce sortation systems. The hardware integrates low-voltage permanent magnet motor technology with modular gearboxes to address the distinct kinematic requirements of autonomous mobile platforms and compact storage structures within distribution centers.

Low-Voltage Synchronous Motors for Autonomous Platforms
The transition from fixed conveyor infrastructures to autonomous mobile solutions necessitates drive systems with specific power density and dynamic response characteristics. The BMD Series three-phase synchronous motor operates within a 24 - 48 V low-voltage architecture utilizing permanent magnet brushless technology. Compared to conventional DC stepper motors typically deployed in early-generation automated guided vehicles (AGVs), the BMD system yields a higher dynamic torque response and reduced inertia. At the Parcel+Post Expo 2026 held in London from September 23 to 24, Bonfiglioli demonstrated the motor coupled with an MP Series planetary gear unit, a configuration that utilizes multiple backlash classes and a modular gear ratio selection to align with specific material handling payload capacities.

For autonomous mobile robots (AMRs), Bonfiglioli introduced a wheel-mounted configuration of the BMS Series. The low-voltage synchronous AC motor integrates directly with a planetary gearmotor in a flange-free, compact structure. This design delivers high torsional stiffness and low moment of inertia, translating to the precise positioning accuracy essential for AMRs navigating dynamic warehouse environments.

Compact Drive Packages for Vertical Storage Systems
Vertical storage solutions and compact warehouse elevator axes present severe space constraints and necessitate intermittent, high-dynamic duty cycles. To address this, Bonfiglioli integrates the BMD brushless motor with the F Series parallel shaft gearbox. The resulting drive package provides the precise control necessary for the rapid horizontal and vertical translation of drawer-based storage modules.

The system operates in conjunction with the AxiaVert drive controller. The integration of advanced functional safety protocols within the AxiaVert unit is critical for vertical warehousing applications, as human operators frequently interact with the system's loading and unloading bays in shared working zones.

Frequency Inverters and Helical Bevel Gearmotors
The Axia drive family encompasses both the AxiaVert, structured for complex motion control and comprehensive functional safety, and the AxiaAgile, engineered for general-purpose applications. The AxiaVert platform incorporates three functional safety tiers (Basic, Standard, and Motion), allowing system integrators to eliminate external safety relays and contactors, thereby reducing electrical cabinet footprints.

For continuous conveyor operations, the EVOX gearmotor platform integrates a dynamic brake configured for the high-cycle stop-and-start operations inherent in parcel sortation. The motor utilizes a universal brake power supply and an orientable terminal box to simplify machine wiring. The EVOX motor is coupled with a high-efficiency helical bevel gearbox, providing the necessary stiffness for dynamic acceleration while maintaining certification for operation in potentially explosive industrial atmospheres.

The electromechanical systems are supported by Bonfiglioli's Industrial IoT (IIoT) infrastructure. Dedicated sensors facilitate condition monitoring and predictive maintenance by transmitting real-time kinematic and energy consumption data to a proprietary IoT platform, enabling operators to schedule maintenance prior to mechanical failure.

Additional Context
This section details technical specifications and competitive benchmarking not included in the original news release.

The automated material handling and AMR drive market features established competing architectures, most notably from SEW-Eurodrive (CMP synchronous servomotors) and NORD Drivesystems (LogiDrive and IE5+ synchronous motors). While standard industrial conveyor drives typically operate on 400V or 480V AC architectures, the Bonfiglioli BMD and BMS series utilize a 24–48 V low-voltage AC synchronous topology.

This low-voltage approach directly competes with specialized AMR mobility drives from manufacturers like Dunkermotoren and Nidec. By standardizing on 24–48 V, the Bonfiglioli units allow direct integration with standard onboard robot battery systems without requiring intermediate step-up DC-DC converters, which add weight and thermal load. Comparatively, while NORD’s intralogistics solutions focus heavily on decentralized high-voltage stationary conveyor applications, Bonfiglioli’s flange-free, wheel-mounted BMS planetary configuration provides a highly specialized, space-optimized footprint explicitly benchmarked for the tight wheelbase and vertical clearance constraints of low-profile autonomous mobile robots (AMRs). Furthermore, standardizing the AxiaVert drive safety features directly inside the unit eliminates external safety relays, offering a measurable reduction in electrical cabinet volume compared to standard drive systems lacking integrated functional safety tiers.

Edited by Aishwarya Mambet, Induportals Editor, with AI assistance.

www.bonfiglioli.com