Bonfiglioli Transmission and Automation Product Selection Reference

Bonfiglioli Industrial Transmission and Automation Product System Selection Engineering Reference

In the field of industrial transmission and automation, system integrators and field engineers often face a core challenge: how to quickly and accurately select the most suitable combination solution for specific working conditions among complex motors, reducers, frequency converters, and precision control components. As a world-class supplier of power transmission and control solutions with over 60 years of experience, Bonfiglioli's product line covers a complete chain from conventional gear motors to high dynamic servo systems, from universal frequency converters to explosion-proof drives. This article will systematically review the technical positioning, selection logic, and collaborative integration points of Bonfiglioli's main product lines from an engineering application perspective, providing engineers with a practical product system reference manual.

Selection logic of gear motor and reducer product line

Bonfiglioli's gear motors and reducers are divided into multiple series based on transmission structure and application scenarios. Engineers need to match them reasonably according to installation methods, load characteristics, and speed ratio requirements.

1. A series - helical bevel gear motor

This series combines the high load-bearing capacity of helical gears with the right angle transmission advantage of bevel gears, with a torque range of 100-14000 Nm and a power coverage of 0.22-150 kW (1400 min ⁻¹ input). Its output forms are extremely diverse, including various options such as foot/flange installation, key bonded hollow shaft, keyless shrink disc, metric/imperial solid shaft, spline hollow shaft, etc.

Typical applications: conveyor lines, mixers, extruders, lifting equipment.

Key points for engineering selection: The simplest installation method can be selected based on the output shaft form to avoid additional design of transition connectors. For situations that require frequent forward and reverse rotation, pay attention to verifying the radial load capacity of the output shaft bearing; The options of Reinforced bearings and Reduced backlash need to be determined in advance based on dynamic load requirements.

2. C series - inline helical gear motor

The C series emphasizes torque density and compactness, with a torque range of 45~12000 Nm, a speed ratio of 2.6~1481, and a maximum power of 213 kW. Its tooth surface is precision ground, and the operating noise and vibration are extremely low.

Typical applications: pumps, fans, compressors, and general mechanical equipment.

Selection advantage: The speed ratio difference is fine, and precise speed matching can be achieved by replacing gear pairs without the need for additional transmission devices.

3. F series - shaft mounted gear motor

The F series is designed specifically for conveying machinery and bulk material handling, with a torque range of 140~14000 Nm. The output uses a bonded hollow shaft or shrink disc that is directly fitted onto the equipment shaft, eliminating the need for couplings and bearing seats, resulting in an extremely simplified structure.

Key points of the project: During installation, it is necessary to use a torque arm to fix the box body and prevent it from rotating. The tightening torque of the shrink disc must be tightened in a staggered manner according to the instructions, otherwise it may cause slipping or damage to the shaft neck.

4. VF/W Series - Worm Gear Motor

The worm gear structure comes with self-locking characteristics (depending on the speed ratio), with a torque range of 13~7100 Nm and a speed ratio of up to 7~10000 (including two-stage worm gears). The VF series adopts optimized tooth profile and advanced materials, which significantly improves transmission efficiency compared to traditional worm gears.

Typical applications: lifting platforms, valve actuators, packaging machinery, and occasions that require self-locking.

Selection note: Self locking only holds true when the speed ratio is high (usually>40:1) and the static friction coefficient is sufficient. For lifting applications that require reliable braking, additional mechanical holding brakes are still required.

5. 300 series - planetary gear reducer

This series is Bonfiglioli's heavy-duty flagship, with a torque range of 1250~1286000 Nm, a maximum power of 450 kW, a speed ratio of 3.4~5234, and a total of 20 tight differential specifications. Adopting a planetary transmission structure, it has extremely high power density and impact resistance.

Typical applications: mining machinery, grinding machines, rotary drives, shield tunneling machines, large cranes.

Selection points: Two versions are available: inline and right angle (with Gleason bevel gear). The output shaft forms include solid keys, splines, spline hollow, and shrink disc hollow. For working conditions with frequent impact loads, it is recommended to choose a model one level larger than the adjacent specifications and install cooling coils or independent fans.

6. HDP/HDO series - Heavy duty parallel shaft/bevel gear helical gearbox

HDP is a parallel axis structure with a torque of 5000~21000 Nm; HDO is a right angle bevel gear helical gear structure with a torque of 28200~21000 Nm. Both use ductile iron housings and the gears undergo high-precision grinding.

Typical applications of HDP: belt conveyors, bucket elevators, and building materials machinery.

Typical applications of HDO: agitator, paper machine, steel rolling auxiliary transmission.

Common selection points: All options include backstop to prevent the inclined conveyor belt from reversing, forced lubrication system, oil temperature/level sensor, Drywell seal, and Taconic high-temperature resistant seal to adapt to extreme environments.

7. TA series - shaft mounted reducer (special heavy-duty)

The TA series is a shaft mounted reducer designed for harsh environments in mines and quarries, with a torque range of 150-16000 Nm (under 900 min ⁻¹ conditions). The housing is made of sturdy cast iron and is suitable for outdoor installation. The backstop is a standard option and can be directly inspected externally.

Engineering advantages: With a simple structure and low maintenance workload, it is an ideal choice to replace large chain or belt drives.

8. RAN Series - Cone Gear Steering Box

It has been detailed in the second article of this series and will not be repeated here.

Specialized solutions for special environments

1. EP series - corrosion-resistant/sanitary grade worm gear motor

This series is fully anti-corrosion treated on the basis of VF/W worm gear, including stainless steel hollow shaft, stainless steel fasteners, oil seal with stainless steel spring, sealed (no ventilation) box, IP56 motor protection level, and optional FDA certified grease (H1 level) and washable seal.

Application areas: food processing, pharmaceuticals, chemicals, and marine ship deck equipment.

Engineering precautions: EP configuration is suitable for VF44~VF110 and BN63~BN112 motor specifications. During installation, ensure that all unused screw holes are closed with plugs to prevent hygiene blind spots.

2. ATEX series - explosion-proof gearbox

ATEX certification covers the C series, A series, F series, VF/W series, and 300 series, suitable for 2G/2D explosive environments (gases and dust).

Certification basis: European Directive 94/9/CE (ATEX), specific specifications can refer to the torque range list on page 19.

Deployment suggestion: When selecting, complete area classification (Zone 1/2 or 21/22), gas group (IIA/IIB/IIC), and temperature level (T1~T6) must be provided, and the manufacturer can determine the sealing, grounding, and anti-static configuration based on this.

3. 3/H series - planetary bevel gear combination box

This product connects the 300 series star rating and HDO series bevel gear helical gear stages in series, with an output torque of up to 98000~120000 Nm, a speed ratio of 1:100~1:1000, and a maximum power of 980 kW. It is mainly designed for extremely harsh working conditions with low-speed heavy loads and right angle inputs.

Typical applications: large grinding machines, rotary kilns, ship propellers.

Key selection points: A detailed load spectrum (torque speed time curve) is required to verify the heat capacity and lubrication method (forced or oil bath).

4. HDPE series - extruder specific gearbox

A dedicated housing for single screw extruders based on the HDP platform, with a torque of 4650~75000 Nm and a speed ratio of 7.1~125. The core feature is heavy-duty thrust bearings (294... E series), specifically designed to withstand axial thrust from screws. The output hollow shaft can be customized according to customer specifications.

Key points of the project: The input end can be directly installed with a motor (with a coupling bell cover) or an independent input shaft, and the cooling system (cooling coil or independent cooling unit) is a necessary option.

Selection and classification of precision planetary gearboxes (servo grade)

Bonfiglioli's precision planetary product line is divided into multiple levels based on accuracy, torque, and installation form. Engineers should choose the appropriate series according to control accuracy requirements and space limitations.

Series torque range (Nm), maximum acceleration torque (Nm), backlash (arcmin), structural form, typical applications

LC 12~450 20~700<12 (standard)/<6 (low) inline universal servo positioning

LCK 10~450 20~700<12/<6 right angle compact space right angle transmission

MP 20~1000 30~1200<15/<10 Straight/Right Angle/Hollow Axis Medium High Dynamic Positioning

TR 20~1000 30~1200<5/<3 High precision positioning for inline/right angle/hollow axis

SL 25~155 35~300<12/<6 inline (with optional pulley) synchronous belt conveyor servo

KR 3~120 14~170<8 right angle (hollow/solid shaft) small right angle steering

TQ 30~800 45~1200<4/<2 Straight (square flange) high dynamic rigidity

TQK 30~800 45~1200<5/<4 right angle (square flange) compact high rigidity

Key points of selection project:

Back clearance selection: For point control (such as picking and placing, machine tool changing), a back clearance of ≤ 3 arcmin (TR series) can achieve the best repeat positioning accuracy; For regular speed control, standard backlash is sufficient.

P "high torque density option: The LC/LCK/SL series can choose the" P "option, which can increase torque by up to 40% while achieving miniaturization, reducing acceleration mass, and improving energy efficiency.

Installation method: All precision series are designed to be installed in any direction, without worrying about lubrication issues (lifelong lubrication).

Input adaptation: All series offer flange/coupling kits that are compatible with mainstream servo motors in the market, reducing the need for transitional component designs.

Industrial motor product line

Bonfiglioli provides a complete matrix from universal AC motors to high-efficiency IE3, single-phase, and DC motors.

BN/M series: Universal IEC motor, 0.06~30 kW, 2/4/6/8 pole and multi speed versions, equipped with inverter duty as standard, brake can be powered by DC/AC (including quick release rectifier).

BE/ME series: IE2 high-efficiency motor, 0.75~22 kW, meets IEC 60034-30 standard, also suitable for frequency conversion.

BX/MX series: IE3 ultra efficient motor, 5.5~22 kW (4-pole), reflecting a commitment to environmental sustainability.

BS series: single-phase induction motor, 0.06~1.5 kW, with running capacitor, optional starting capacitor to increase starting torque, suitable for household and light industrial equipment.

BC series: Permanent magnet DC motor, torque 0.3~4.5 Nm, powered by 12~180 Vdc, IP54 protection, suitable for battery powered or DC speed control systems.

Engineering Tip: All AC motors come with thermistor (PTC) and thermostat protection options, as well as independent forced cooling (for low-frequency long-term operation) and encoder (incremental line drive or push-pull). Explosion proof certification (ATEX) also applies to some BN/BE specifications.

Servo motor product line

Bonfiglioli's servo motors are mainly designed for high dynamic and high-precision positioning applications.

BMD series: Permanent magnet synchronous servo motor, using Salient Pole technology, neodymium iron boron magnetic steel, locked rotor torque of 0.85~125 Nm, rated speed of 1600~6000 min ⁻¹. Feedback supports rotary transformer (8/10 kHz), EnDAT 2.1 absolute encoder (single/multiple turns), and Hiperface. Protection level IP65/IP67.

BTD series: Compact servo motor with a locked rotor torque of 0.26-27 Nm, emphasizing small size and low temperature rise, with a protection level of IP65 (optional IP67).

BCR series: High performance servo motor, locked rotor torque of 0.2~115 Nm, with extremely high instantaneous overload capacity, suitable for heavy-duty servo applications.

Key selection points:

Select the matching feedback method based on the drive type (such as Active Cube supporting rotary and EnDAT/Hiperface) to ensure closed-loop compatibility.

For situations that require safe braking, 24 Vdc electromagnetic brake can be integrated (hold braking, non dynamic braking).

Inverter and Drive Family

Bonfiglioli's frequency converters cover both simple and servo driven types, seamlessly integrating with their own motors.

AGILE series: economical sensor vector frequency converter, 0.12~11 kW, supports asynchronous motors and permanent magnet synchronous motors (sensorless). Built in Safe Torque Off (STO), MMC memory card, integrated Modbus, and multiple fieldbus options. Suitable for applications that are cost sensitive but require vector performance.

ACTION series: Universal system driver, 0.55~132 kW (ACT401 covers high power up to 132 kW), as detailed in the previous article (ACTION 401/201 series).

Active Cube Series: Drivers for high-end servo and motion control, 0.25~132 kW (ACU401) and Size 8 (160~400 kW, including ACU601 690V level). Equipped with 32 programmable motion blocks, 36 zeroing modes, absolute/relative positioning, Touch Probe, Teach In and other functions, it can directly control servo motors such as BMD/BCR, and complete complex single axis movements without the need for an external PLC.

VCB series: high-power universal frequency converter, 132-800 kW, suitable for large equipment such as fans, pumps, compressors, etc., with optional protection level of IP54.

S2U series: Compact mini frequency converter, 0.20-2.2 kW, V/F control, built-in PID and 8-speed, suitable for simple speed control applications (such as small conveyor belts and packaging machines).

HMI and software tools

BMI series human-machine interface: three sizes of 3.5 ", 7", and 10 ", IP65 front panel, standard Ethernet interface, optional fieldbus (Profibus, CANopen, etc.). Can be combined with the built-in PLC function of Agile/Active Cube to build a compact control system that does not require an independent PLC.

VPlus software: Bonfiglioli's unified driver programming, monitoring, and diagnostic platform. Support parameter setting, oscilloscope (KP232 required), logic programming, remote diagnosis, and motion block configuration.

Collaborative suggestions for engineering selection

During the project design phase, it is recommended that engineers follow the following process:

Clearly define the load conditions: torque speed curve, duty cycle (S1~S10), ambient temperature, protection level, and whether there is a risk of explosion.

Choose the type of reducer: Determine the product family (A/C/F/VF/300/HDP/RAN, etc.) based on the axis layout (parallel, right angle, coaxial), installation method (foot, flange, shaft installation), and speed ratio range.

Matching motor: Select BN/BE/BX series based on power, efficiency level (IE2/IE3), supply voltage, and brake requirements.

Select driver: If high dynamic positioning is required, choose the Active Cube+BMD/BCR servo combination; If only speed regulation is required, choose ACTION or AGILE; If it is a simple control, S2U is sufficient.

Confirm attachments and options: braking resistor, incoming reactor, EMC filter, encoder cable length, thermal protection sensor, etc.