Sustainability through electrification of Bonfiglioli’s final drives

Sustainability through Bonfiglioli’s next gen electrification

Bonfiglioli supports customers on their path toward electrification, regardless of their field of application. At Bauma, Bonfiglioli is showcasing its steps along this path which involves the final drives, not just the main power source. This approach, compared to the one where the engine is replaced by a single electric motor, offers significant advantages in terms of energy efficiency, reduced emissions and a considerable reduction of maintenance costs, resulting in a much faster return on the initial investment.

Electric swing drive for excavators - 700TE Series

In earth moving, the electrification process targets excavators (mini and midi) for which a special kit has been developed, combining three different components: an electric swing drive of the 700TE Series, ultra-compact and high-performing, equipped with an electromagnetic brake and speed and temperature sensors; an electric track drive of the 700CE Series, easy to install and maintain due to the reduction of mechanical parts; and an electric motor for pump drive of the BPM Series, featuring permanent magnets with SAE connections and ideal for the electrification of mobile machines. The system is completed by inverters responsible for motor control. By adopting Bonfiglioli’s Next Gen Electrification Approach, the Battery Capacity can be reduced by 50% thanks to the improvement in energy efficiency and reduction of maintenance costs.

Electric track drive for compact track loaders

Electrified is also Bonfiglioli’s flagship solution for compact track loaders: machines ranging from 1.5 to 6 tons, for which it supplies the planetary track drive paired with high-power density electric motors, specifically designed for electric systems. The 5–6-ton compact track loader version also integrates, as option, the IoT functionality through the sensorization of the gearmotor, allowing the user to view all the main operational data of the machine and use it correctly. Bonfiglioli’s electrified solution represents a cutting-edge product already available as standard on machines from leading manufacturers.

Electric drive for pavers

For road construction, reliable, high-performance gear solutions were showcased, which keep the fleet of pavers and tandem rollers running smoothly. For both, a totally electrified solution was proposed, i.e. all drives – track and loader for the paver, drum rotation for the tandem roller – and motors – in the latter, the ones responsible for the vibration and steering functions – are electric. The same transformation has also involved cranes and aerial platforms. For the former, Bonfiglioli develops winch drives – 800 Series – marked by high modularity and flexibility, thanks to the possibility to add further standard stages, motor flanges and bevel gears of the 300 Series. For aerial platforms, scissor lifts and boom lifts, Bonfiglioli provides the travel drives of the 600WE series, boasting compact dimensions, low noise and high efficiency. An advanced powertrain solution which uses a two- or three-stage gearbox offering reduction ratios of up to 1:145 to satisfy the widest possible range of needs.

Twin shaft mixer

A dedicated solution for twin shaft mixers used in road and building construction has been presented. This is an evolution of Bonfiglioli’s modular planetary drive from the 300 Series — a highly versatile gear system featuring several options for mounting, gear layout, and output shaft configurations. It includes a housing with a specific bevel gear set that allows to have both e-motor bell connection and a synchro drive shaft. Easy to fit and almost maintenance-free, it optimizes the machine’s structure, avoiding pulleys and belts and increasing efficiency with a positive impact on the Total Cost of Ownership. The set ensures the easiest layout configuration for asphalt and concrete mixers, simplifying assembly and maintenance procedures.

For electrified mining equipment, the protagonist is the gear unit of the 3/H Series, a product boasting resistance, robustness, thermal capacity, high performance and torque density, thanks to the combination of the planetary and the helical bevel Heavy Duty gear units. In this case, the drive is integrated into an apron feeder, but also suitable for several applications, such as bucket wheels for stackers/reclaimers and horizontal roller crushers, as well as belt filters. For apron feeders, Bonfiglioli offers the entire system in an ultra-compact design, consisting of gearbox and motor that can be mounted directly on the machine shaft or installed with a baseplate. All units can be supplied with IoT instruments for predictive maintenance function, able to measure real time working conditions, in order to support end users within their mantenance programs. The 3/H Series is designed to endure extreme environmental conditions, withstand temperatures ranging from -50 to +50 °C, high shock loads and an extremely dusty environment.

Bonfiglioli’s participation in Bauma reaffirmed its commitment to innovation and excellence in the construction and mining industry, showcasing cutting-edge solutions designed to enhance performance, efficiency and sustainability in heavy-duty applications.