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DRIVES, CONTROLS & MOTORS Supporting deSign with drive technology R


eCon Waste Management recycles and recovers waste materials, with its washing


plant handling around 20 tonnes of mixed waste per hour. Here, an hydraulic feeder drive was being used, however there were not only gearbox problems but the use of hydraulics in the harsh environment resulted in high energy consumption, potential oil leaks and ongoing fluid maintenance. The company needed a


replacement for the hydraulic feeder drive that powered a drum at the head of a conveyor system. It had to start under load, handle variable material conditions and maintain a controlled feed onto the main belt, which carries material directly into the plant’s washing and screening equipment. It had to match the footprint, shaft position and mounting of the existing unit, had to deliver high torque at low speed, and needed to reduce energy use and maintenance requirements. Technidrive therefore proposed a right-angle


emissions. The mechanical design of the Drum Drive also supports low maintenance. The new drive was simply


bolted into place, aligning with the existing head drum and preserving the original conveyor geometry. Electrical connection to the W22 motor and associated control system completed the conversion from hydraulic to electric power. The waste washing plant


now benefits from a consistent, controllable feed of material onto the main conveyor, supporting stable throughput at around 20 tonnes per hour. By keeping its plant running


Technidrive Drum Drive


reliably and efficiently, ReCon can maximise recovery from these materials and help divert more waste from landfill.


80A Drum Drive as a direct electric replacement. This is designed for slow-speed conveyors, like feeders, that require high-torque compact solutions. Andrew Ritchie, technical sales manager at Technidrive, commented: “Our 80A Drum Drive uses 52% less mass, is 20% more cost-effective and delivers a 20% increase in torque capacity when compared to traditional solutions.” This uses a high reduction ratio to achieve the


necessary low output speed while multiplying the available torque. For this application, Technidrive engineered a bespoke solution combining a bevel helical gearbox with a planetary rotating case gearbox to provide a compact, high-torque, low-speed drive. The approach allowed the team to align shaft centres and mounting faces precisely with the existing arrangement. For the motor, Technidrive chose a WEG W22


IE3-rated electric motor, using an international Electrotechnical Commission (IEC) approved input so that any electric motor with IEC specification could be installed without custom machining. This meant the drive could be mounted in the same position as the original equipment while providing the torque and speed range needed. Replacing the hydraulic power pack with a


direct electric system resulted in significant efficiency gains. Modern high-efficiency electric motors combined with correctly sized gearboxes can reduce the power consumption of motor driven systems considerably. In the ReCon installation, the overall power


demand for the feeder drive dropped from around 50 kW on the original hydraulic system to under 30 kW with the new electric solution, cutting both running costs and associated CO2


www.designsolutionsmag.co.uk


lift drive systems In another application, Technidrive has developed a robust mechanical and software-driven drive solution to ensure safe lift operation. The lift needed to start, travel a defined distance, and stop accurately at the upper floor. It had to comply with safety standards such as BS EN 81-20. The drive system had to provide inherent


mechanical safety, alongside a reliable braking solution, without sudden starts or abrupt motion. Technidrive therefore worked closely with the


customer to develop a complete drive package that combined mechanical safety with intelligent control. The solution combined a gearbox, motor, braking system and variable speed drive (VSD) supported by bespoke software developed in- house by Technidrive’s automation specialists. Technidrive selected a Bonfiglioli W Series


worm gearbox paired with a BX electric motor. Due to its inherent inefficiency, the worm gear unit will not run back under load. This means that in the event of a brake failure, the gearbox itself will mechanically hold the lift in position. This mechanical holding capability formed the secondary safety system. The primary stopping and holding method was provided by a brake mounted on the rear of the motor. Together, these two independent systems delivered a robust and compliant safety solution. To achieve the smooth, controlled motion


required, Technidrive selected a Hitachi WJ200 VSD with an integrated SoftPLC. The VSD allowed precise control over acceleration, running speed and deceleration, ensuring the lift could start gently, travel efficiently and slow down well before reaching its final position. Rather than relying on physical encoders or


limit switches for control, Technidrive used the SoftPLC within the VSD to estimate the lift’s position. By calculating the lift position based on the output speed from the inverter, run time and


FEATURE


From developing a drive system for efficient waste


processing, to creating a solution for


safe lift operation, Technidrive helps meet safety and


efficiency requirements


the known lift height, the software could accurately determine when to initiate deceleration and bring the lift to a smooth stop. This virtual approach eliminated the need for expensive encoders, typically costing hundreds of pounds per installation, while also simplifying the overall system architecture. Furthermore, the software was designed to


be flexible. If a new lift variant was introduced with a different floor height that increased the travel distance, the installer could simply input the new height. The software would automatically recalculate acceleration profiles and slowdown points, without any additional hardware or re-engineering. Technidrive worked closely with the customer


throughout the project, and early in the process the abrupt stopping of the lift system was identified as a key area for improvement. Technidrive developed the ‘virtual slowdown’ to tackle this and constructed a full-height test rig at its own facility to validate the solution. Using the complete drive system and weighted


loads, the team simulated real-world lift operation and demonstrated the smooth start-up and seamless deceleration. Technidrive also carried out extensive endurance testing prior to installation. A dedicated software program was written to run the lift continuously for 50,000 cycles on a 24-hour operation cycle lasting several months, confirming that the system could maintain continuous performance over its lifetime. This also allowed Technidrive to determine the correct ratio for the worm gearbox. The drive package was supplied as a complete


kit ready for straightforward incorporation into production units, meaning that the customer was able to integrate the drive system into its own lift design and carry out installation in- house. The initial project was completed in 2015, with demand initially forecast at around 50 units per month. Volumes have since grown to approximately 100 units per month. David Strain, technical director at Technidrive,


said: “By understanding exactly what the customer needed to achieve and the unique requirements of the end-users, we were able to develop bespoke control software that removes unnecessary hardware and delivers smooth, reliable performance that stands the test of time.”


Technidrive www.technidrive.co.uk


JUNE 2026 DESIGN SOLUTIONS 45


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