As reported in more detail in the September issue of Electricity + Control, SEW-EURODRIVE has supplied 150 MOVIGEAR® mechatronic drive units to a leading automotive manufacturer in Gauteng, enhancing conveyor efficiency, safety and energy savings in a newly expanded buffering zone. The integrated decentralised system reduces maintenance, simplifies stockholding and includes real-time condition monitoring for predictive maintenance.
MOVIGEAR® with DDI (digital data interface) cabling enables seamless condition monitoring and real-time performance tracking for optimised operational efficiency.
The project saw the MOVIGEAR units supplied to drive conveyors in a high density storage area. Willem Strydom, Electronics Business Development Manager at SEW-EURODRIVE, says the customer sought to standardise equipment to simplify stockholding and maintenance, while meeting strict safety and performance requirements. With just two variants of MOVIGEAR these goals were met, which otherwise would have required up to 30 conventional motor variants. The MOVIGEAR solution thus also significantly reduces inventory complexity.
Each MOVIGEAR unit integrates a servomotor, gearbox and electronics, providing decentralised functionality with onboard communication and safety features. The system eliminates the need for traditional control panels with all units linked to a compact PLC via hybrid cabling in a daisy-chain configuration. This enables faster installation and reduces infrastructure costs.
SEW-EURODRIVE worked closely with the original equipment manufacturer responsible for the conveyor installation, providing design input and on-site support during installation and commissioning. The reliability of the MOVIGEAR units has already been proven across various industries, including food and beverages, and the units at this site have been running reliably since commissioning in January 2025.
A second phase of the project introduced condition monitoring using MOVIGEAR’s digital data interface, enabling real-time tracking of performance variables such as vibration and temperature. The data is used to predict maintenance requirements, creating a digital twin of each unit to help prevent unexpected failures and extend equipment life.
With ultra-premium efficiency IE5 SEW electric motors, the MOVIGEAR system also delivers substantial energy savings – estimated at over 38% compared to conventional motors – and a protection rating of IP69K ensures protection in harsh environments.
Strydom highlights that the project demonstrates the value of SEW-EURODRIVE being engaged at an early stage through to final optimisation, providing a fully integrated and future-ready solution that supports the manufacturer’s productivity, safety and sustainability objectives.
For more information visit: www.sew-eurodrive.co.za
