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Solutions for electromobility
Bonfigliolisolutions
wind
photovoltaic
industrial
mobile
3
About us
Bonfiglioli, one name for a large international group.
It was back in 1956 that Clementino Bonfiglioli established in Bologna, Italy, the company that still bears his name. Now, some fifty years later, the same enthusiasm and dedication is driving Bonfiglioli to become the world’s top name in power transmission and control solutions.Through directly controlled subsidiaries and production plant around the world, Bonfiglioli designs, manufactures and distributes a complete range of gearmotors, drive systems and planetary gearboxes, and boasts the most integrated offering on the market today.
Now, to emphasise its commitment to health, safety and environmental sustainability, Bonfiglioli is adding the term “green” to the description of its offering.
In a market in which excellent product quality alone is no longer sufficient, Bonfiglioli also provides experience, know-how, an extensive sales network, excellent pre-sales and after-sales service and modern communication tools and systems to create high level solutions for industry, mobile machinery and renewable energy.
This committment becomes now more visible and evident thanks to the solutions that can respect the environment: hybrid and electric vehicles are now an important drive for electric piece of Bonfiglioli offer. This is our way to contribute to a better world.
Bonfigliolielectromobility
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Heavy duty vehicle manufacturers are eagerly seeking improvements in efficiency. OEMs are looking for solutions that can increase productivity and reduce the total cost of ownership for the end user. Over the next few years we can also expect the emission regulations currently applied to the automotive industry to be extended to heavy duty vehicles too, and the strict standards involved can only be met by improving powertrain efficiency. Heavy duty powertrains are therefore being electrified: the hydraulic motors conventionally installed in these machines are gradually being replaced by electric motors which are intrinsically more efficient.Bonfiglioli Trasmital began developing and producing powertrains consisting of planetary gearboxes driven by electric and hydraulic motors back in the 1980s. More recently, Bonfiglioli Mobile Solutions also began investing in the personnel, tools and technologies needed to develop electric powertrain technology. As a result, Bonfiglioli Mobile Solutions can now serve the electric powertrain market with two different but complementary offerings.
Standard products for various applicationsVarious products have been designed specifically for use with electric motors, and offer a wide range of performance specifications and deliverable torque ratings. The latest products include a series of planetary drives for electric material handling vehicles and planetary drives with integrated electric motors for hybrid agricultural machines. These solutions have been shown to deliver numerous benefits in terms of machine manoeuvrability, reliability, operating costs and sustainability, thanks to low emissions and low working noise levels.
Custom solutionsWherever a custom solution is required, manufacturers benefit from Bonfiglioli’s vast technical expertise. Bonfiglioli works closely with powertrain designers and component suppliers to develop innovative, tailored solutions. Bonfiglioli can draw on years of experience in powertrain design for light and medium duty vehicles, and the concepts and technologies involved are likely to be scaled up to heavy duty applications over the medium term.
Electric powertrain solutions
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Electric solutionsfor material handling
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600F seriesElectric powertrains formaterial handling trucks
Bonfiglioli supplies high efficiency, low noise planetary axles and drives with integrated, high performance electric motors and low maintenance braking systems for Class 1 material handling vehicles. Typical applications include 3 and 4 wheel counterbalance lift trucks and ground support equipment. Bonfiglioli electric powertrains are fully tested in the factory and guarantee reduced energy consumption. This, in turn, means longer battery operating times, extended service intervals and a lower total cost of ownership. Bonfiglioli’s 600F Series drives are complemented by a range of idle steering systems based on axles or steering units, depending on the number of wheels on the vehicle.
Application•Materialhandlingvehicles(CBforklifts,airportequipment)• Indoorandoutdooruse•CBtruckswithliftcapacityfrom1.6to5.0tons•GSEvehicleswithdrawbarpullfrom6000to25000kgf•Vehiclespeedsupto20km/h
Standard features•Dualplanetarygearbox•Optimisedgeardesignformaximumefficiencyandminimumnoise•Wetdiscservicebrakewithlowdisplacementactuation•Parkingbrakewithmechanicalleveractuation• Integrated,customisedmastsupport• IntegratedACtractionmotorinIP20orIP43protectionratings• Integrated,highaccuracy,siliconbased,KTYtemperaturesensor• Integrated,highresolution,Halleffectspeedsensor
Optional features available on request•Springappliedhydraulicreleaseparkingbrake•Mechanicaldisengagementfortowing,withnoneedtoremovethewheeland
without oil drop
Type Lift capacity [kg]
601 F
602 F
603 F
2000
3500
5000
Type Max deliverable torque [Nm]
601 F
602 F
603 F
3000
5500
7000
Type Maxinput speed
Rated motor power
Typical wheelsize
[min-1] [kW,S2-60’] [inches]
601 F 5500 2x4.5 18
602 F 5500 18 23
603 F 4500 26 28
Functional diagram
Inverter
Batterycharge/converter
Bus DC
Auxiliary drivese.g. lift motor
DC
DC
AC
DC
Battery pack
Mobile solutions
600F series
Type AFlange to flange
BFrame mounting
CMast mounting
DWheelstudPCD
[mm] [mm] [mm] [mm]
601 F 1015 610 630 120
602F 1090 640 600 170
603 F 1150 670 620 225
B
C
A
D
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Electric solutionsfor aerial platforms
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BT 150- BT 170- BT 200-
050 100 150 050 100 150 050 100 150
VDC V 24 24 24 48 48 48 80 80 80
Pn kW 1.3 2.4 3.4 2.2 3.3 5.5 2.9 5.3 7.5
In Arms 71 124 173 58 82 135 46 81 110
Brake Nm 20 20 40 40 40 75 75 75 125
Type L1
600 WE 300 350 400
602WE 520 430 480 530
603 WE 500 550 470 520
605 WE 530 450 500 550
L2 L3 L4 D1 D2 D3 D4 D5 D6 D7 D8
600 WE 120 47 66 232 235 220 200 190 215 8xM8 6xM10
602WE 240 130 70 275 275 250 220 200 240 9xM12 9xM16
603 WE 260 120 100 275 300 275 250 200 245 8xM16 6xM18
605 WE 240 160 70 310 300 275 250 220 275 8xM18 6xM20
600WE seriesElectric powertrains for aerial platforms
D1
D2
D3
D4 D5
D6
L1
L2
L3L4
D8D7
Bonfiglioli’s 600WE planetary drives incorporate an integrated, maintenance-free electric motor and offer significant benefits in terms of compact dimensions, low noise and high efficiency. 600WE Series drives are designed for use with all kinds of aerial platforms, including articulated and telescopic boom types, vertical and scissor lifts with service heights from 5 to 27metres,forindooruseintightspacesoroutdooruseevenonroughground.Thisadvancedpowertrain solution uses a two or three stage gearbox offering reduction ratios of up to 1:95 to satisfy the widest possible range of needs. The gearbox is coupled to a low voltage inductionmotor(BTSeries)speciallydevelopedfortractionpowerandcontrolapplications.
Application•Aerialplatforms(vertical,scissor,articulatedortelescopicboom)• Indoorandoutdooruse•Full-loadvehicleweightsfrom1.0to16.0tons•Vehiclespeedsupto6km/h•Workingheightsfrom5to27m
Standard features•Twostageorthreestageplanetarydrivewithreductionratiosofupto1:95•Optimisedgeardesignformaximumefficiencyandminimumnoise•Parkingbrake(springappliedwithhydraulicorelectromagneticrelease)• Integrated,lowvoltage,3phaseinductionmotorwithinvertercontrol• Integrated,highaccuracy,siliconbased,KTYtemperaturesensor• Integrated,highresolution,Halleffectspeedsensor
Optional features available on request•Speedsensor-bearing•Othertypesoftemperaturesensor•Mechanicaldisengagementfortowing,withnoneedtoremovethewheeland
without oil drop
Type Max deliverable torque [Nm]
600 WE
602 WE
603 WE
605 WE
900
3500
7000
8500
Type Rated motor power
Typicalmachine weight
[kW,S2-60’] [tons]
600 WE 1...2 1 ... 3
602 WE 2...4.5 4 ... 9
603 WE 4.5 ... 6 9 ... 13
605 WE 6 ... 9 13 ... 16
Functional diagram
WheelDrive
Mobile solutions
600 series
Electric motor
Inverter
Batterycharge/converter
Bus DC
Auxiliary drivese.g. lift motor
DC
DC
AC
DC
Battery pack
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Electric solutionsfor lightweight vehicles
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600D seriesElectric powertrains forlightweight vehicles
Type Max deliverable torque [Nm]
600 D
601 D
602 D
1000
1500
3000
Type Rated motor power
Vehicleweight
[kW,S2-60’] [kg]
600 D 5...20 700...1250
601 D 20...30 1300 ... 1750
602 D 30 ... 45 1800 ... 3500
Bonfiglioli supplies versatile, low noise drives coupled to electric motors for all-electric, battery powered vehicles like urban passenger cars, commercial vehicles and delivery trucks. This solution ensures more energy-efficient operation and extended autonomy from the battery thanks to optimised, low backlash helical gears and high speed bearings. Bonfiglioli’s600DSeriesofdrivesisextremelylightweightthankstocastaluminiumcasingsdevelopedusingallofBonfiglioli’svastprocessexpertise.600Ddrivesallowvehiclemanufacturers to satisfy even the toughest restrictions on gross vehicle weight. They are complemented by a range of electric motors, inverters and matched mechanical joints and shafts to provide vehicle OEMs with complete powertrain solutions.
Application•Lightduty,lightweight,batterypoweredvehicles•Passengertransportand/orcommercialdeliveries•Urbanorsuburbanuse•Vehicleweightsfrom700to3500kg•Vehiclespeedsupto100km/h•Batteryautonomyfrom100toover200km
Standard features•Multi-stage,parallelshaftgearboxwithreductionratiosofupto1:15•Optimisedgeardesignformaximumefficiencyandminimumnoise• Integratedmechanicaldifferential•Lightweightcastaluminiumhousing•Versatilegearboxinstallationinthechassis•Lowvoltageelectrictractionmotorwithinvertercontrol
Optional features available on request• Integratedmechanicalparkingbrake• Integrated,highresolution,Halleffectspeedsensor•Matchedmechanicaljointsandshafts•Matchedelectricmotorsandinverters
Functional diagram
Inverter
Batterycharge/converter
Bus DC
Auxiliary drivese.g. heater, instrument panel
DC
DC
AC
DC
Wheeltransmission
Electric motor
Battery pack
Mobile solutions
600D series
B A
E
C D
Type A B C D E
[mm] [mm] [mm] [mm] [mm]
600D 375 175 229 154 148
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Electric solutionsfor agriculture
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600 series wheel drivewith BPD electric motorSolutions for hybrid agricultural machinery
This complete mechatronic solution from Bonfiglioli was originally conceived for use on self-propelled crop sprayers. It can, however, also be applied to other types of new-generation hybrid agricultural vehicle capable of integrating electrical power with a mechanical transmissionandweighingbetween7and20tons.Itincorporatesahigh-powerelectricmotor, instead of the conventional hydraulic motor, and a braking system.Acentraltyreinflation/deflationsystemmaybealsoincludedinthesolutiontoimprovetheoverallefficiencyofthedieselenginetowheeldrivetrain.Powerlossesdue to incorrect inflation can be avoided by optimising pressure to suit field work or on-road transport conditions.
Main benefits•Technologicallyinnovative:outmostmechatronicsapplicationintheagriculturefield•Poweranddiffusedavailabletorquearealwaysefficientlydelivered•Outmostcontrollability:eachtransmissiondrivecanbecontrolledindependentlyby
means of the dedicated inverter•Extremecompactelectricsolution:dimensionsarereallycomparabletostandard
solutions•Possibilitytostoreorregenerateenergyduringpassiveactivity(e.g.downhill)•Hybridsolutioniscleaner:nooilcontaminationforcrop/cultivation
Functional diagram
WheelDrive
sprayingPumpMotor
InverterInverter
Converter
Generator
Converter
BatterypackEngine
Bus DC
Auxiliary drives
DC
DC
AC
DC
Mobile solutions
600 series
Electric motor
Gearbox data
TechnologyBonfiglioli Trasmital planetary multi stages
Type606W
Gear ratio 1:47
Max output torque12000Nm
BrakeNegative multi-disc
Weight90 kg
Motor data
TechnologyBPD© Hairpin Stator
Electric power30-60 kW
DC bus voltage 560 V
Max speed9000 rpm
Cooling typeLiquid,inputtemperature:max100°C
Weight45 kg
Solution main features
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Electric solutionsfor concrete mixers
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500 series drum drivewith electric motorSolutions for hybrid concrete mixers
Thissolutionisdesignedforusewithmedium/largemixertrucksthathavemedium/longdeliverydistancestotravel.Drumrotationspeedisbetween15and22rpmandcapacity between 6 and 14 m3. Bonfiglioli innovative solution comprises a gearbox of Bonfiglioli’s historical 500 Series coupled toanACelectricmotorthatprovidesnormalpowerandaDCelectricmotorforemergencyuse.This solution not only guarantees greater energy efficiency and reduced fuel consumption, but alsohelpscutcementmixertruckoperatingcosts(forexamplebyextendingserviceintervalsandmakingservicingsimplerthanonhydraulicdrivesolutions).Performanceisimprovedtoo:rotationspeedcontrolismoreaccurate,operatingnoiselevelsaresignificantlylower(thankstotheelectricmotorandthehelicaltoothprofileofthehighspeedgearboxstage).Finally, functionality remains higher in the event of a failure: the presence of a second, backupDCmotorgivesreassuringredundancyandeliminatestherisksandpotentiallyhazardoussituationscausedbyfailuresofthedrumemptyingsystem(ifthedrumcannotrotate,thecementcansolidifyandputthemixertruckoutofaction).
Main benefits• IncreasedEnergyEfficiency•Reducedfuelconsumption•Serviceintervalslessfrequentandsimplifiedvsthestandardhydraulicsolution•Betterdrumrotationspeedcontrol•Optimisedgeardesignformaximumefficiencyandminimumnoise•TheemergencyelectricDCmotorallowsahigheravailabilityincaseofmachine
failure
Functional diagram
DrumDrive
Inverter
Converter
Generator
Batterypack
Transmission +Wheel traction
Engine
Auxiliary drives
DC
DC
AC
DC
Mobile solutions
500 series
Electric motor
Gearbox data
RatioMain:1:220Emergency:1:2200
Max output torqueMain: 60000 NmEmergency: 10500 Nm
Max input speedMain: 3500 rpmEmergency:2000rpm
Oil quantity8 lt
Dry weight 328kg
Motor data
TypeMain: Induction ACEmergency:PMDCmotor
Rated Power Main: 40 kWEmergency:2kW
VoltageMain: 170 VacEmergency:24Vdc
Protection degreeIP66
CoolingMain:LiquidEmergency: Air forced
Solution main features
16 Our quality
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Sharing the valueof our work with you.
The development of effective, tailored solutions for a wide range of applications is a fundamental aspect of our work.We succeed in this because we co-operate closely with our customers, listen to their requests and work with them to improve our own performance. Bonfiglioli is determined to deliver the best service possible – before, during and after the sale of any of our products – by applying all our know-how, experience, technology, and advanced communication tools. Bonfiglioli works to the strictest standards of quality and safety, as certified by seven different internationally recognised institutes.
We believe in innovation, and back up this belief by dedicating 100 of our people and 5 activity centres to research and development, and by working hand in hand with some of the world’s most prestigious universities.
Our work increasingly brings us into contact with other nations and cultures, for which we have the greatest respect and with whom we share a vision of sustainable development based on renewable energy.This bond of commitment allows us to be an authoritative and reliable global partner for the present and the future.
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Branches and facilitiesOur branches
ITA1Bonfiglioli Riduttori S.p.A.Gearmotor assembly plantPrecison gearbox manufacturing & assembly plantVignola, Modena
BMRBonfiglioli Mechatronics ResearchBrushless motor productionRovereto, Trento
BU Industrial Headquarters BU Wind & MobileBU Regenerative & Photovoltaic
ITA2Bonfiglioli Riduttori S.p.A.Casting and gearcutting plantCalderara di Reno, Bologna
B2Bonfiglioli Riduttori S.p.A.Assembly HDP, HDO, 300 seriesCalderara di Reno, Bologna
HQBonfiglioli Riduttori S.p.A.Lippo di Calderara, Bologna
B6Bonfiglioli Riduttori S.p.A.Planetary gearboxes manufacturing & assembly plantForlì
BTPLBonfiglioli Transmission PvtGearmotors and planetary gearbox manufacturing and assembly plantChennai, India
BVNBonfiglioli VietnamElectric motor plantHo Chi Min, Vietnam
BSKBonfiglioli Slovakia SroLarge gearboxes manufacturing plantPovazska BystricaSlovakia Republic
BVBonfiglioli Vectron GmbHInverter plantKrefeld, Germany
Our production facilities
BonfiglioliCanada
BonfiglioliUSA
BonfiglioliFrance
BonfiglioliBrasil
Bonfiglioli United Kingdom
BonfiglioliSouth Africa
BonfiglioliDeutschland
BonfiglioliIndia
BonfiglioliÖsterreich
BonfiglioliSouth East Asia
BonfiglioliItalia
BonfiglioliVietnam
BonfiglioliAustralia
BonfiglioliTürkiye
BonfiglioliNew Zealand
BonfiglioliChina
Tecnotrans Bonfiglioli
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Bonfiglioli Worldwide Network
MechatronicDrives&Solutionsdedicatednetwork
Bonfiglioli New Zealand88 Hastie Avenue, Mangere Bridge, Auckland2022,NewZealand-POBox11795,EllerslieTel.(+64)096346441-Fax(+64)[email protected]
Bonfiglioli ÖsterreichMolkereistr4-A-2700WienerNeustadtTel.(+43)0262222400-Fax(+43)[email protected]
Bonfiglioli South East AsiaNo21WoodlandsindusrialparkE1#02-03Singapore757720Tel.(+65)68936346/7-Fax(+65)[email protected]
Bonfiglioli South Africa55GalaxyAvenue,LinbroBusinessPark-SandtonTel.(+27)116082030OR-Fax(+27)[email protected]
Bonfiglioli Türkiye Atatürk Organize Sanayi Bölgesi,10044Sk.No.9,35620Çigli - IzmirTel.+90(0)2323282277(pbx)Fax+90(0)[email protected]
Bonfiglioli United KingdomIndustrial, PhotovoltaicUnit7,ColemeadowRoadNorthMoonsMoat-Redditch,WorcestershireB989PBTel.(+44)152765022-Fax(+44)[email protected], Wind3-7GrosvenorGrange,WoolstonWarrington - Cheshire WA1 4SFTel.(+44)1925852667-Fax(+44)[email protected]
Bonfiglioli USA3541HargraveDriveHebron,Kentucky41048Tel.(+1)8593343333-Fax(+1)8593348888www.bonfiglioliusa.com
Bonfiglioli VietnamLotC-9D-CNMyPhuocIndustrialPark3BenCat-BinhDuongProvinceTel.(+84)6503577411-Fax(+84)[email protected]
Bonfiglioli Australia2,CoxPlaceGlendenningNSW2761LockedBag1000PlumptonNSW2761Tel.(+61)288118000-Fax(+61)296756605www.bonfiglioli.com.au - [email protected]
Bonfiglioli BrasilTravessa Cláudio Armando 171Bloco3-CEP09861-730-BairroAssunçãoSãoBernardodoCampo-SãoPauloTel.(+55)1143442323-Fax(+55)1143442322www.bonfigliolidobrasil.com.brbonfigliolidobrasil@bonfiglioli.com
Bonfiglioli Canada2-7941JaneStreet-Concord,OntarioL4K4L6Tel.(+1)9057384466-Fax(+1)[email protected]
Bonfiglioli China 19D,No.360PuDongNanRoadNewShanghaiInternationalTower-200120ShanghaiTel.(+86)2150543357-Fax(+86)68862686www.bonfiglioli.cn - [email protected]
Bonfiglioli Deutschland Industrial, Mobile, WindSperberweg12-41468NeussTel.+49(0)213129880-Fax+49(0)21312988100www.bonfiglioli.de - [email protected], PhotovoltaicBonfiglioli Vectron EuroparkFichtenhainB6-47807KrefeldTel.+49(0)215183960-Fax+49(0)[email protected]
Bonfiglioli España Industrial, Mobile, WindPol.Ind.ZonaFrancasectorC,calleF,n°608040 BarcelonaTel.(+34)934478400-Fax(+34)933360402www.tecnotrans.com - [email protected],46-Edificio2-28042MadridTel.(+34)915030125-Fax(+34)[email protected]
Bonfiglioli France 14RueEugènePottierBP19ZoneIndustrielledeMoimontII-95670MarlylaVilleTel.(+33)134474510-Fax(+33)134688800www.bonfiglioli.fr - [email protected]
Bonfiglioli India PLOTAC7-AC11SidcoIndustrialEstateThirumudivakkam - Chennai 600 044Tel.+91(0)4424781035-24781036-24781037Fax+91(0)4424780091-24781904www.bonfiglioliindia.com - [email protected]
Bonfiglioli Italia ViaSandroPertinilotto7b-20080Carpiano(Milano)Tel.(+39)02985081-Fax(+39)02985085817www.bonfiglioli.it - [email protected]
Bonfiglioli Riduttori S.p.A.ViaGiovanniXXIII,7/A40012LippodiCalderaradiRenoBologna(Italy)
tel:+390516473111fax:[email protected]
Bonfiglioli has been designing and developing innovativeand reliable power transmission and control solutionsfor industry, mobile machinery and renewable energyapplications since 1956.
TR_CAT_ELMOB_STD_ENG_R00_0
