Nidec Drives has led motor-control innovation for decades from its UK headquarters in Newtown, Mid Wales. Recently, the company updated its own manufacturing operations from Industry 3.0 operations dominated by manual tasks to Industry 5.0. For example, raw materials were once manually transported by operators from a warehouse to a module assembly plant via forklift trucks and across three separate levels. This process was time-consuming and resource intensive.
“We conducted value-stream mapping, and by taking an overview of production, preparation, and process formulated the plan for a conveyor and lift system to move raw materials around the factory — where and when they needed to be,” said Nidec Drives warehouse and distribution manager Jamie Evans.

Shigenobu Nagamori’s Nidec Way is a business-management principle employed at Nidec to promote lean-management strategies such as just in time (JIT) inventory management and kaizen (continuous improvement). Intralogistics engineering experts Invar was chosen as a partner to update the Nidec operations because of the company’s dedication to the similar core values of innovation and efficiency. Invar proposed a solution that was fully tailored to Nidec Drives’ needs and values for maximally efficient warehouse logistics.
Core to the design are pieces of production equipment, conveyors, and component store cranes that are (when possible) run off Nidec’s own Control Techniques variable speed drives.
A tote transportation system uses about 300 meters of Interroll powered tote conveyor complemented by three Nerak lifts across three buildings. Two conveyor tiers transport goods in and out of the main assembly area. Operators use screens at the infeed stations to select totes’ destinations.
In short, a tote license plate number (LPN) is scanned, and the operator places the carton onto the powered conveyor ± selecting the tote’s destination via an HMI. The tote is then transported to the first lift and directed to the operator station. Once the operator has completed their tasks, the directing and transport process repeated. Plus, in the store area of the facility, a lift allows for infeed or outfeed from both sides depending on where the materials need to go next.
On-demand operation and halting between tote loads minimizes unnecessary energy consumption and could yield a return on investment (ROI) in less than a year.

Integral to the system’s efficient stop-starting are three Control Techniques Unidrives and eleven Digitax HD M750 drives. Unidrives for the system lifts impart control stability and bandwidth for all industrial motor types, with the M702 variant featuring onboard Ethernet and dual STO inputs.
Option modules fitted to the Unidrive include an SI-I/O interface module and an SI-Universal encoder module for positional accuracy. The latter checks if the encoder’s value matches that of a second encoder measuring position with a laser; if the values align, a PLC lets the drive to run. Otherwise, brakes are applied.
Nidec engineers also utilized a PTi210 Easy Motion Controller to avoid the need for software development. The module was simply plugged into the drive and connected via PowerTools Studio software — thus enabling quick creation of simple and repeatable routines repeatedly executed by the conveyors’ Unidrives. (The PTi210 is compatible with both Unidrive and Digitax HD M750 drives.) For implementing advanced control over a single axis (as with a conveyor) the PTi210 and Power Tools software make for a cost-effective option. Users of all skill levels can configure, program, select functions, and set parameters — expediting the configuration, management, and long-term conveyor maintenance.
Finally, the KI-Keypad was installed to display current draw, RPM, and faults as well as let users adjust drive parameters.
Control Techniques Digitax HD M750 servodrives complement the Unidrive range by providing maximum servo performance in a compact package. Digitax HD M750 is optimized for high-dynamic applications, offering flexibility in both standalone and modular configurations. This drive delivers full servo control, plus open-loop permanent magnet motor and induction motor control, across four functionality levels: EtherCAT, MCI machine control, Ethernet, and the flexible Base servodrive.
The Digitax HD M750 drives chosen in this project control drum motors 1) along the powered roller conveyors and 2) on conveyor inclines and declines. The drives’ benefits are compact size and high power density, dual STO, and PROFINET connectivity.

As a full machine control solution, the Unidrive works in harmony with three Leroy-Somer IMfinity three-phase induction motors — one on each lift of the conveyor. Provided by Nidec ACIM, IMfinity motors reach premium efficiency up to IE4; maximizing energy savings, enhancing performance, and optimizing the productivity of the lifts. The robust design of the IMfinity range of Leroy-Somer motors ensures guaranteed performance and reduced cost of maintenance. To work seamlessly with the Unidrive, the IMfinity motors have winding protection as standard … thermal reserve for maintaining the rated torque over an extended speed range … and adaption of the metal support plate to reduce EMI.
“The conveyor is just the latest in ongoing efforts; we’re always exploring the next steps we can take to improve efficiency and quality, and we look forward to more growth,” added Evans.
“At Invar, we meticulously maintain every element of the solution through bespoke maintenance, communication, and strong connections,” said Invar project manager Sham Jama.
Looking ahead, Nidec Drives may soon implement autonomous mobile robots (AMRs) at the UK manufacturing site as well. By independently navigating their environment and picking, sorting, and transporting components) AMRs enhance employee safety and let teams focus on more complex tasks. In addition, Nidec Drives will collaborate with Nidec Automation (producing motors, controls, integrated drives, and AMR battery-management systems) to explore how these robots can boost the manufacturing site’s performance.
Nidec Drives | www.ControlTechniques.com
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