Intralogistics 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.
Click to download and read pdf
Bonfiglioli's modular AGV design solutions are increasingly being deployed in facilities such as vehicle assembly plants.
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 efficiency, 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 conveyors. They are used in automated guided vehicles (AGVs) and automated moving robots (AMRs) in automotive and Industry 4.0 assembly 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-specific 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 coaxial 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 uncompromising efficiency, while Bonfiglioli DGM-MPM Inverters, available in power ranges from 0.55 to 30 kW, are simple to install. They include features such as an inventory manager, advanced, sensorless control at low speeds, controlled DC braking and support for fieldbus communication.
The combined modular package is designed 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 support equipment.
These electric powertrains are thoroughly tested in the factory, guaranteeing low energy consumption. This, in turn, means longer battery operating times, extended servicing intervals and lower costs of ownership.
Electric or hydraulic steering units, customised 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 components 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 produces custom solutions for AGVs, leveraging extensive expertise and experience in the intralogistics industry. These solutions are developed from the ground up, based on in-depth interaction between the customer and the Bonfiglioli team, to ensure that all required specifications and usage variations can be accommodated.
Bonfiglioli’s BlueRoll AGV System’s Platform enables AGV solutions to be:
Co-engineered to satisfy a wide range of different requirements, duty cycles and differing application constraints.
The freely configurable modular approach reduces complexity and makes various drive combinations and sizes available to match the performance requirements.
The platform can accommodate specific industry requirements, such as special operating temperature, surface IP protection, compliance with particular regulations, safety functionality, critical borderline application conditions and more.
The system offers three variants – BlueRoll Basic, BlueRoll Advanced, and BlueRoll Compact – with three gearmotor sizes, accommodating loads of 360 kg, 720 kg, or 1,020 kg at operating speeds of up to 2.0 m/s.
The roller drive comprises two rollers, each powered by a Bonfiglioli TQW wheel-mounted precision planetary gearbox and a premium-efficiency permanent magnet synchronous motor. This combination delivers high torque density, high overload capacity, exceptional precision and low vibration.
A wide range of feedback systems, including safety encoders, enables the motors to be accurately controlled, allowing these driverless vehicles to navigate autonomously between pickup and delivery points. AVG designs can be compact and are extensively customisable to suit application requirements.
With over 20 years of experience in creating tailored and forward-thinking motion control systems, Bonfiglioli has proven to be a reliable partner for entire motion drive trains in Industry 4.0 applications. Bonfiglioli centres of excellence continuously develop breakthrough mechatronic innovations, including low-backlash planetary gearboxes, servomotors, open- and closed-loop inverters, servo drives and regenerative energy units.