Logistics & Warehousing .

Boneng K-series helical-bevel gear motors are mounted on the drive pulley of a belt or chain conveyor. The compact hollow-shaft layout allows side-mounting of the drive on the pulley without an additional coupling. For distribution centers with noise limits, versions with a herringbone output stage are selected — 3–5 dB quieter than spur-cut equivalents.

• K-series (helical-bevel) or R-series (in-line helical)
• Power 0.37–7.5 kW, gear ratio 10–200
• Hollow output shaft with key or shrink disk
• Service factor of at least 1.3 for distribution centers

High-bay stacker cranes in automated warehouses 25–45 m tall use helical or planetary hoist gearboxes with a brake and an incremental encoder. Height positioning accuracy is 3–5 mm and cycle rate is up to 200 operations per hour. Typical choices are Guomao GR/GS and Boneng HB with flange mounting and an integrated brake on the high-speed shaft.

• Gear ratio 25–80, output torque 1,500–8,000 N·m
• Built-in spring-set brake on the high-speed shaft
• Low backlash for accurate positioning (≤ 6 arc-min)
• Compatibility with HTL/TTL encoder on the motor non-drive end

Planetary wheel gear motors are integrated with the drive wheel of a stacker or reach truck. They run with frequent reversals and sharp accelerations, with peak torque up to 2.5× nominal. Steering drives use worm or planetary gear motors with servo control and steering-angle feedback.

• Planetary layout with hollow shaft for the wheel half-axle
• Radial load from the machine plus load up to 5 t
• IP65 sealing (operation in areas with water and cleaning agents)
• Compatibility with a PMSM motor and servo drive

Parcel sorters use dozens of drive modules with compact 0.75–2.2 kW gear motors to accelerate the carrier up to 2.5–3 m/s and discharge the parcel within 0.3–0.5 s. Boneng and Guomao R/S series with low rotor inertia are typical. Tilt-tray sorters add a servo tilt drive with encoder.

• Low output-shaft inertia (fast acceleration and braking)
• Compact flange layout for in-carrier mounting
• IP54 protection, operation at 5–40 °C
• Service life of at least 20,000 h in S4 duty

Tier-1/Tier-3 airport baggage handling systems (BHS) run conveyors with a total length of up to 30 km. Each section is driven by an individual gear motor — F-series (parallel-shaft) or K-series (helical-bevel). Noise limits of ≤ 75 dB(A) at 1 m and reliability targets (MTBF > 50,000 h) are critical.

• Low noise level of ≤ 75 dB(A)
• Thermal margin for continuous S1 24/7 operation
• Jam protection (shear pin or slip sensor)
• Model standardization to simplify service (3–5 sizes across the entire BHS)

Wolong YE3/YE4 (IE3/IE4) and Huali YBK3/YE4 series are fitted to conveyor drive pulleys and inside gear motors. IP55 protection, class F insulation. In 24/7 distribution centers IE4 motors are preferred — saving 4–6 % over IE3 at equal torque. Soft-start can be used for long conveyors.

• Power 0.37–7.5 kW, 4 or 6 poles
• Efficiency class IE3 or IE4
• IP55, class F insulation with class B thermal margin
• Inverter-rated (for variable-speed conveyors)

Traction drives for mobile robots use permanent-magnet synchronous motors (PMSM) with 17–23-bit encoders and an integrated holding brake. They are fed from a 48 V traction inverter. Inovance MS1H4 and Wolong ZW series for AGV chassis provide 2–10 N·m of torque with a compact 80–110 mm flange. The same series in short-frame versions are used for steering drives.

• PMSM, 48 V DC supply from a LiFePO4 battery
• Absolute encoder with resolution ≥ 17 bit
• Built-in holding brake engaged on power loss
• IP65 for operation in floor-cleaning and washdown areas

Cross-belt and tilt-tray sorters use dozens of 200 V AC servo motors rated 400–1,500 W. Control runs over an EtherCAT/Profinet fieldbus with a 1 ms cycle, which lets the parcel discharge be synchronized with the receiving chute at 3 m/s. Inovance SV660N series provide 3× peak overload torque.

• Peak overload torque of 3× for 1–2 s
• EtherCAT or Profinet/Profidrive fieldbus interface
• Low rotor inertia (fast acceleration)
• Fed from a common DC bus with regeneration

Wheel traction motors and the hydraulic pump motor in modern reach trucks are also PMSMs at 48 or 80 V. Wolong ZW and Inovance deliver 50–150 N·m at the wheel and 80–200 N·m at the lift pump. Regeneration during load lowering and braking returns 15–25 % of energy to the battery, extending shift time without recharging.

• Power 5–22 kW, 48–80 V DC supply
• Regenerative braking support
• Liquid or forced-air cooling
• CAN bus compatibility (CANopen/J1939)

Huawu YPZ2 electromagnetic disc or shoe brakes are fitted on the high-speed shaft of the hoist gearbox. They are fail-safe (normally closed): on power loss the spring engages the brake within 80–150 ms. This is an EN 528 safety requirement for AS/RS systems. Heavy-duty stacker cranes carrying up to 3 t use a dual setup (two brakes on the same shaft).

• Spring-set fail-safe brake (normally closed)
• Braking torque with a 1.75 safety factor over rated hoist torque
• Engagement time on power loss of ≤ 0.15 s
• IP54 protection, at least 10 million cycles

Tianiu NJ/NF backstop one-way clutches are fitted on the high-speed or low-speed shaft of the gearbox on an inclined conveyor. They transmit torque in one direction (drive) and lock the reverse direction at standstill. For long conveyors (1 km+), a low-speed-disengagement backstop is selected to reduce roller wear inside the cage during operation.

• Reverse-direction holding torque up to 80 kN·m
• Low disengagement speed (for long conveyors)
• Mounting on either high-speed or low-speed shaft
• Roller service life of at least 30,000 h

Besides hoisting, a stacker crane has a horizontal travel drive running along the rack aisle. The brake here serves both as a service brake (positional stop) and as an emergency brake (holding on power loss). Jingu YWZ series (electrohydraulic thruster) are used for heavy machines or Huawu DZE (electromagnetic) for light ones. Stop accuracy is 5 mm.

• Horizontal stop accuracy of ± 5 mm
• Electromagnetic or electrohydraulic actuation
• Manual release for emergency evacuation
• Lining wear monitoring (limit switch)

Traction servo motors for mobile robots and reach trucks come with a built-in holding brake on the motor non-drive end. It is a spring-set electromagnetic brake that engages on power loss and holds the machine on grades up to 5 %. The same brake is used to park the machine during charging. Lining wear sets in after 5 million engage/release cycles.

• Motor-integrated electromagnetic brake
• Holds the loaded machine on grades up to 5 %
• 24 V DC supply from the on-board bus
• At least 5 million engagement cycles

Anneng HFP-series enclosed conductor bars with 4–8 poles (three phases + neutral + signal lines) are installed along each rack aisle 50–150 m long. They are protected against dust and accidental contact (IP23), which is critical for automated warehouses without on-site operators. The signal poles support Profinet/Ethernet POWERLINK for real-time commands to the stacker crane.

• Load current 60–200 A, voltage 400 V AC
• 4–8 poles (power + signal/Ethernet)
• IP23 protection minimum
• Flexible section assembly (section length 4–6 m)

Anneng JTA/JTD spring-driven and motor-driven cable reels feed power and signals to short moving sections (up to 30 m of travel). Typical uses include telescopic truck-unloading conveyors, short-aisle stacker cranes, and lifting platforms. The motor-driven version maintains constant cable tension and prevents loops.

• Wound cable length of 10–50 m
• Spring-driven or motor-driven (three-phase)
• Support for hybrid cables (power + Ethernet)
• IP44 protection minimum

Warehouse overhead and gantry cranes and beam cranes require VFDs with a Crane mode (DTC control, S-ramp, anti-sway protection). Invt GD350-Crane and Inovance MD500-T series support an integrated encoder interface, anti-sway, and automatic load take-up on start. A built-in braking chopper with resistor handles the braking energy.

• Crane control mode (DTC + S-ramp + anti-sway)
• HTL/TTL/SinCos encoder channel
• Built-in braking chopper rated 100–150 % of drive power
• Profinet/EtherCAT for WMS integration

Inovance SV660 / IS820N multi-axis servo drives on a common DC bus are housed in the sorter cabinet and feed dozens of servo motors at once. Regenerated braking energy from one motor powers the acceleration of the others — saving 15–20 % of electricity. For AGVs, compact 48 V DC traction controllers with a CAN bus are used.

• Common DC bus across a group of drives
• Regeneration into the DC bus (no braking resistor required)
• EtherCAT fieldbus interface with 1 ms cycle
• Support for standard CiA 402 / SoE profiles