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When end users think about new materials handling equipment, they’re logically going to be focused on applications. What can that new sorter do for your e-commerce speed and efficiency? How much storage can you gain by implementing an automated storage and retrieval system? Would a new high-speed conveyor be worth the investment?
Those are all good and necessary questions worth pondering when considering a big capital expenditure. But behind the scenes of all automated equipment are the motors and power transmission systems that feed them. While somewhat out-of-sight/out-of-mind, there’s a strong argument for understanding these unsung heroes of the warehouse. Today’s power sources can have an enormous impact on your operations. Getting an education from your vendor partners is well worth your time.
“Customers need to understand the full scenario surrounding their equipment,” says Scott Brown, key market specialist at NORD Gear Corporation. “If we don’t provide customers with this information, we’re doing them a disservice.”
End users want their materials handling equipment engines to deliver reliability, efficiency and insights. The good news is that modern power transmission does all of that—but you won’t necessarily know that if you don’t ask, or if your vendor partner doesn’t supply that intel. It’s time end users sharpen their motor knowledge base to make the most of their equipment purchases.
Several advancements in power transmission are worth understanding. One is sizing—a big topic of conversation—says Brown. At stake: costs, efficiency and longevity when you get it wrong. Specifically, if you oversize your motor, you’ll experience energy waste and premature failure. If undersizing, you may face overheating, reduced lifespan and high maintenance costs.
“We believe sizing is application specific,” says Brown. “You can break it down into cycles, environmental factors and more to get the full picture.” Simply going off serial numbers, in other words, won’t get you the deep dive you need for your specific application.
The motors that power your equipment will supply you with a rated load capacity. “If you’re working on a higher load than it is rated for, you’re consuming more energy, creating more heat, wear and tear,” says Roberto Solis, senior product manager at Turck. “You’ll be wasting energy and shortening the lifespan of your equipment.”
Sizing is made easier depending on the type of motor you’re using. Variable flux (VF) synchronous motors, the newer kid on the block, are smaller in size, yet provide more power. They also run synchronously with the power they have to work with, making them a viable option when looking to maximize the performance of a smaller motor.
“Traditionally, motor sizing and load assumptions were based on estimates, often leading to inefficiencies,” says Antonio Di Vaira, senior vice president of power products, North America, at Schneider Electric. “Today’s systems are smarter, more responsive and more integrated, enabling real-time monitoring, control and optimization of energy use.”
At Beckhoff Automation, a new software tool can help end users select the right sized motor for the mechanics of the system. “It’s based off load, and the speed and motion profile,” explains Matt Prellwitz, drive technology product manager at Beckhoff Automation.
For instance, the tool will take inputs on the types of torques and speed needed to move a certain load on a conveyor. The tool analyzes the mechanics to ensure the motor is up to the job.
A final word on sizing: newer, lighter weight motors are more environmentally friendly. Depending on the rating of energy efficiency—anything from the lowest standard of IE1 on up to the highest rating IE5—the motors will also get lighter as you move up the scale.
Lighter weight means an improved carbon footprint from the get-go, from shipping on through to installation and usage. It’s worth learning about ratings and understanding them, both from a sizing standpoint and energy efficiency standpoint.
While size plays a role in motor efficiencies, so too do many other factors—and modern motor designs have efficiency as a top priority.
“When we work with clients, one commonality in all our conversations is ‘how efficiently does your motor run?’” Prellwitz says. “We’ve made many advancements in what motors are capable of, including efficiency.”
Prellwitz says that Beckhoff has made a special push into safety, starting with its encoder. “The application can operate at a safe limited speed and stop a motor where it is to monitor its position,” he explains.
This can be useful around moving equipment like conveyors. Say there’s a light curtain designed to keep employees away from a moving conveyor, but they break through it. “If people are there, our motor can stop everything until they are out of the area,” says Prellwitz. “We ensure the motor isn’t spinning when people are in proximity.”
End users today are also demanding more heat resistance, which leads to better overall energy efficiency, says Brown. “Outdated motors are like little heaters,” he adds. “If you have motors all over your warehouse, you’re putting a lot of heat out into the buildings. Permanent magnet motors are emerging that offer more power and produce less heat.”
Brown sees a push for more permanent magnet motors going forward, thanks to their efficiencies with both high- and low-level loads. Standard motors will run at the same power no matter what, whereas permanent magnet motors are more adaptable.
“Whether peak season or off-peak season, the end result is longevity and a return on investment,” he says.
Another trend in motors is the elimination of control cabinets. Instead, you can use a machine mountable power supply. These options are compatible with 48-volt motor-driven roller (MDR) motors, which are becoming more common and popular when applications call for more velocity and torque. “It takes heat generation from the inside to the outside and sits on the drive on the back side of the motor,” says Prellwitz.
Solis says that when the power supply is mounted close to the machine, it enables customers the freedom to modularize their floors. “There are advantages in not having the power supply going back to the PLC,” he explains. “There’s benefit from decentralized, local control.”
For example, when trouble arises, with remote power supplies, you can troubleshoot easier because of their proximity to the actual machine. “Smart, remote power supplies allow you to better protect against failure,” says Solis.
As with everything else materials handling technology, motors and power transmission is becoming more efficient at data collection and analysis.
“While data on motor performance has long been available, the ability to interpret and act on that data has significantly improved,” says Di Vaira. “Modern systems now feature dynamic alarms and intuitive interfaces that help operators quickly understand equipment status. This enables proactive responses, such as diverting loads to avoid stoppages, ultimately reducing downtime and extending equipment life.”
The integration of digital intelligence is a boon to motor operational efficiency. Combining sensors and AI tools, end users can better dive into diagnostics and move forward quickly with any issues.
“Artificial intelligence, machine learning and digital twins are playing an increasingly important role in power distribution,” says Di Vaira. “These technologies enhance decision-making and system adaptability, especially as more equipment becomes connected. The more data that flows through these systems, the more powerful the insights become—driving smarter operations and more sustainable outcomes. We’re excited to be at the forefront of this evolution, helping shape a more resilient and efficient industrial future.”
Prellwitz says that smart-system diagnostics allow for real-time temperature and vibration monitoring, allowing users to understand whether damage is underway.
“Machine learning and AI are enhancing the ability to understand when the windings are breaking down, or the motor is running hot,” he says. “We’ve integrated all that into an analytics package to help ensure your motors are running properly.”
All those data analytics and diagnostics tools have led to the development of dashboards for the power supply.
“That information can feed into software and make decisions about potential issues going forward,” says Solis. “That’s really useful feedback.”
As the workforce ages, companies are more reliant on solutions that can provide better visibility into machine performance to bridge the labor gap, according to Di Vaira. Smart load management technologies offer that visibility. And that, as much as anything new with motors, may be central to lasting, sustainable power going forward.
“Smart load management enables proactive maintenance, minimizing downtime and allowing teams to monitor more equipment from a centralized location,” he says. “This not only boosts productivity but also enhances workforce efficiency.”
Amanda Loudin is a contributing editor for Modern Materials Handling. Her published articles have appeared in The New York Times, The Washington Post, Money Magazine and ESPN. When she’s not writing, she can be found hitting the trails with her four-legged running partner.
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