A case study in advanced manufacturing automation.

Nidec Drives has been a pioneer in motor control technologies for over 50 years. With its headquarters and manufacturing facilities in Newtown, Mid Wales, and as the largest employer in the local area, Nidec Drives has consistently sought to drive innovation, evolving and adapting from Industry 3.0 and now advancing towards Industry 5.0. Maintaining a reputation for advancement in automation; Nidec Drives remains committed to the progress of manufacturing technology whilst contributing to environmental sustainability through the deployment of Control Techniques variable speed drives.

Addressing the challenge – Identifying and overcoming the complexities of manual handling

Over the past five decades, Nidec Drives' UK manufacturing facilities have undergone significant expansion and transformation. To maintain its renowned quality standards while continuing to serve its customers, employees, and stakeholders efficiently, a new solution was required to tackle a critical challenge.

As the manufacturing site grew, the movement of raw materials from the warehouse to the module assembly plant was handled manually. Operators were physically transporting materials between buildings via forklift trucks and internally across three separate levels. This process was not only time-consuming but also resource intensive. Given the complexity of interlinking different levels within the facility, a bespoke solution was essential for Nidec Drives.

Jamie Evans, Warehouse and Distribution Manager at Nidec Drives spoke about the plan: “We conducted value stream mapping, and by taking an overview of production, preparation, and process, were able to formulate the plan for a conveyor and lift system which would move raw materials around the factory, where they needed to be, and when they needed to be.”

Identifying the right partner: Invar the trusted intralogistics experts

Jamie embarked on a mission to find the ideal vendor for implementing the latest advancements in automated warehouse solutions. Nidec Drives operates under the ‘Nidec Way,’ a business management principle created by Nidec's founder, Shigenobu Nagamori. This principle emphasises excellence through lean management strategies, such as Just in Time (JIT) inventory management. Continuous improvement, or ‘kaizen,’ is fundamental to Nidec’s operations, so Nidec Drives needed a partner who could design a solution that embodied these dynamic strategies.

“We invested significant time in researching the right supplier to collaborate with us on achieving the optimal solution. Through extensive dialogue and interaction with Invar, they emerged as the clear frontrunner,” commented Jamie.

Invar are intralogistics engineering experts, who provide unique turnkey automation solutions specified to individual clients. Both Invar and Nidec Drives share core values of innovation and efficiency. Invar proposed a solution that was fully tailored to Nidec Drives’ needs and values, offering a highly experienced and expert team. Invar was committed to delivering a warehouse logistics solution that would enable Nidec Drives to continue upholding the principles of efficiency and excellence.

Project overview – Nidec Drives’ variable speed drives prove pivotal to installation of new conveyor system

One of the most unique and exciting features of Nidec Drives' UK manufacturing site is that, where possible, the automated machinery in use—from component store cranes to production equipment—runs on the very Control Techniques variable speed drives manufactured by  Nidec Drives. The new conveyor and lift system would be no exception. This practice underlines Nidec Drives' dedication to delivering Control Techniques products of the highest standards, simply put: “Our drives make your drives.”

Invar, being non-affiliated, selected only the best elements for the project. By combining teamwork, top-quality components, and incorporating Control Techniques variable speed drives, Invar successfully completed the project ahead of schedule and within budget.

In response to the optimised completion of the project, Sham Jama, Project Manager at Invar, remarked: “I would like to thank everyone involved in this project. This achievement wouldn’t have been possible without the exceptional collaboration and support from Nidec.”

Providing a sustainable solution

Invar’s solution involved the implementation of a tote transportation system comprising approximately 300 metres of Interroll powered tote conveyor and three Nerak lifts, spread across three buildings. The conveyor system features two tiers for goods in/out and the main assembly area. Operators use screens at the infeed stations to select the tote’s destination.

In any building on the manufacturing site, the tote License Plate Number (LPN) is scanned, and the operator places the carton onto the powered conveyor, selecting the tote’s destination using the HMI screen. The tote is then transported to the first lift and directed to the operator station. Once the operator has completed their tasks, the process of scanning the LPN, choosing the destination, and dispatching the materials is repeated. Additionally, in the store area of the facility, the lift allows for infeed or outfeed from both sides, depending on where the materials need to go next.

However, the true efficiency lies in the system's ability to operate on demand, halting completely between tote loads. This energy and cost-saving feature significantly reduces the unnecessary consumption of precious resources, and is expected to achieve a return on investment (ROI) in under a year.

Leveraging Control Techniques products

Integral to the efficient stop/start nature of this system are the Control Techniques drives. For this project, two types of drives were utilised: three Unidrives, and eleven Digitax HD M750.

The Control Techniques Unidrive was selected for the lifts within the system. Unidrive offers exceptional control stability and bandwidth for all industrial motor types, with the M702 variant featuring onboard Ethernet and dual STO inputs.

Several option modules were fitted to the Unidrive. The SI-I/O Interface Module provided additional input and output connections. The SI-Universal Encoder Module, which ensures positional accuracy by connecting to a rotary encoder on the motor, was also added. This module checks if the encoder’s value matches that of a second encoder measuring position with a laser; if the values align, the Programmable Logic Controller (PLC) allows the drive to run; if not, the system’s brakes are applied.

Nidec engineers also utilised the PTi210 Easy Motion Controller. With this module there is no need for software development; it was simply plugged into the drive, then connected through PowerTools Studio software, enabling the creation of quick, simple, and repeatable routines which the Unidrives in the conveyor executes repeatedly. The PTi210 is compatible with both Unidrive and Digitax HD M750 drives.

For single axis motion with complex controls such as the conveyor, the PTi210 and Power Tools software package is a cost-effective way to provide simple, fast, and effective motion control. Users of all skill levels are able to configure, programme, select functions, and set up parameters; expediting the configuration, management, and long term maintenance of the conveyor.

Finally, the KI-Keypad was installed, allowing users to adjust drive parameters while displaying key information, such as current draw, RPM, or faults.

The Control Techniques Digitax HD M750 servo drive series complements the Unidrive range by providing maximum servo performance in a compact package. Digitax HD M750 is optimised 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 servo drive.

The Digitax HD M750 drives chosen in this project were used for controlling the drum motors along the powered roller conveyors, and on the conveyor belt’s incline and decline. This drive was selected due to its compact size; whilst offering high power density, dual STO, and being able to communicate on the PROFINET network.

As a full machine control solution, the Unidrive works in harmony with three Leroy-Somer IMfinity 3-phase induction motors; one on each lift of the conveyor. Provided by Nidec ACIM, IMfinity motors reach premium efficiency up to IE4; maximising energy savings, enhancing performance, and optimising 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 electromagnetic noise.

The application of various Nidec components within the Invar conveyor culminates to provide an efficient, modern, and functional conveyor and lift system; establishing the synergetic qualities of a full Nidec solution.

Impact and future developments

The installation of the new conveyor and lift system was completed in just four months. Since its implementation in April 2024, the impact on productivity and staff morale has been significant. The team can now retrieve parts without physically moving and accessing bulk materials, production bottlenecks have been eliminated, and individual efficiencies have markedly increased.

As part of Nidec Drives' commitment to continuous improvement (kaizen), Jamie Evans explains: “The conveyor is just the latest step in our ongoing efforts to enhance our manufacturing facilities. We are always exploring the next steps we can take to improve efficiency and quality, and we look forward to further growth.”

Sham Jama adds: “At Invar, we install a legacy for our clients. We work hard to meticulously maintain every element of our solution through bespoke maintenance, communication, and strong connections with our customers. This project ran so smoothly with the help of Jamie and his team, I believe this marks the beginning of a long and fruitful relationship.”

Looking ahead, Nidec Drives is considering the implementation of Autonomous Mobile Robots (AMRs) at the UK manufacturing site. AMRs address many challenges in high-specification manufacturing by independently navigating their environment, picking, sorting, and transporting components. These robots enhance employee safety and allow the teams to focus on more complex tasks.

Nidec Drives will collaborate with Nidec Automation, which produces motors, motor control solutions, integrated drive solutions, and battery management systems for AMRs, to explore how these robots can further improve efficiency and quality at the Nidec Drives manufacturing site. This exciting development will solidify Nidec Drives' position at the forefront of UK manufacturing excellence and open new avenues for innovation and development in the production of Control Techniques product ranges and solutions.

Nidec Drives created the world’s motion. The company provides electric drive solutions that add value to the world, from the production of food, movement of materials and people, to keeping comfortable in any environment. These precision engineered drives are designed to improve performance, efficiency, and productivity, creating essential motion towards a sustainable future.

For more information, visit www.ControlTechniques.com 

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