Drive systems and inverters for warehouse automation

Electrification and automation are reshaping warehouse equipment design, particularly in forklifts, conveyors, and autonomous mobile robots (AMRs). In this context, Bonfiglioli presented drive systems, inverter platforms, and electric motor technologies for logistics automation at LogiMAT 2026 (March 24 - 26) in Stuttgart, Germany.

Focus on electrified warehouse vehicles and handling equipment
For material handling vehicles such as pallet trucks, stackers, and reach trucks, Bonfiglioli presented the steerable drive EL Series, designed with torque ranges from 450 Nm to 2,500 Nm and support for wheel loads up to 4,000 kg. The system integrates a low-voltage motor and parking brake and is available in manual and power steering configurations.

For three- and four-wheel counterbalance forklifts, the company also presented the 600F Series traction systems combining electric motors with low-maintenance braking systems. The 610X dual drive version was positioned for heavier vehicles, with a design intended to improve manoeuvrability in confined warehouse environments while supporting reduced energy consumption and longer battery service intervals.

Additional subsystems included an idle steering system, a DC/DC converter, and a TFT touchscreen developed by Selcom, part of the Bonfiglioli group since 2023.



600F Series

Motor technologies for material handling and off-highway equipment
Electric motor developments focused on permanent magnet and induction motor designs for material handling and off-highway vehicles.

Among these, the BPM Series synchronous permanent magnet motors were presented for forklifts and aerial platforms, with a modular design available in four sizes covering 48–400 VDC supply ranges and optional SAE flange configurations.

Bonfiglioli also showed the BTM Series induction motors for demanding applications such as pump drives up to 400 V. These motors feature protection ratings up to IP67 and integrated sensors intended to support simplified control and maintenance processes.

Expanding inverter portfolio for logistics automation
A further development presented at the exhibition was the AxiaAgile inverter series, extending the Axia inverter family alongside the established AxiaVert platform.

AxiaVert addresses motion control requirements with modular architecture, functional safety features, and motion safety functions including STO, SS1, SBC, SLS, SLP, and SOS. It also supports EtherCAT FSoE safety communication to allow safety data exchange between inverter and PLC through fieldbus infrastructure, reducing wiring complexity.

AxiaAgile was presented as a compact inverter platform for general-purpose logistics applications, with four variants (Basic, Standard, Enhanced, Advanced) supporting sensorless and simple closed-loop control as well as multiple fieldbus protocols. The system integrates Safe Torque Off (STO) functionality and shares commissioning and diagnostic tools such as AxiaManager and Axia Manager Mobile with AxiaVert.

Power ratings extend up to 15 kW for AxiaVert and up to 11 kW for AxiaAgile.

Conveyor drive packages with predictive maintenance functions
For conveyor automation, Bonfiglioli presented gearmotor systems combining EVOX CP helical inline gearboxes with IE3 MXN series asynchronous motors rated up to 7.5 kW with protection classes up to IP56.

For smart conveyor applications, the company demonstrated A Series helical bevel gearmotors integrated with asynchronous and synchronous reluctance motors and sensorised decentralised inverters. These inverter units act as control nodes communicating with integrated sensors to enable predictive maintenance functions associated with industrial IoT environments.

Drive platforms for AMRs and AGVs
Developments targeting autonomous logistics systems included the BlueRoll Platform for AMRs and AGVs, available in Basic, Advanced, and Compact configurations.



BlueRoll Platform

The modular wheel drive platform is designed to reduce integration complexity while supporting positioning accuracy and energy efficiency. A precision wheel drive variant presented at the event was designed to fit within axle spaces and provide sufficient torque capacity to move loads of approximately one tonne per drive wheel.

The system uses a compact low-voltage planetary servo gearmotor compatible with 24 V and 48 V battery architectures, supporting both new vehicle designs and retrofit scenarios.

R&D work on remanufacturing processes
Beyond product developments, Bonfiglioli also highlighted participation as an end user in the RE-PAIR project under the JARVIS cascade funding programme within the EU Horizon Europe framework.

The project focuses on improving remanufacturing processes for axle drives through the use of machine vision systems and human-robot interaction tools. The approach aims to reduce inspection times, support defect identification, and improve traceability of quality assessments while reducing material waste across the value chain.

Edited by industrial journalist Aishwarya Mambet, with AI-assistance.

www.bonfiglioli.com