The sorting and distribution center in Melbourne, Australia, boasts an impressive capability of processing up to 35,000 parcels per hour. This achievement has set Toll IPEC, the nation's largest freight company, apart in the rapidly growing e-commerce logistics sector. As their transportation solution provider, BCS has pioneered a modular smart device that ensures swift and efficient package handling, from collection to sorting and finally onto trucks. For the drive unit configurations, BCS collaborates closely with Nordstrom Drive Group, relying heavily on Nord’s transmissions due to their ease of installation and maintenance.
*Figure 1: Over 1,000 motors powering various conveyor belts in modular equipment within parcel distribution centers.*
Melbourne's new facility can sort an incredible 35,000 parcels per hour. Toll IPEC has seen its business in the country triple, with the international airport serving as a key transportation hub. This has made Melbourne's sorting center the fastest in Oceania. To achieve this, BCS engineered automation equipment comprising more than 1,000 conveyor modules. These modules manage everything from parcel arrival to registration, equipment tracking, system control, high-speed sorting, and truck loading. Given the vast distances involved—often hundreds of meters—the conveyor often needs to change speeds or reverse direction. "We require more than 1,000 drives," explained Frank Kassai, BCS Group’s engineering manager. "These range from 0.37 to 5.5 kW."
Nordstrom Drive Group tailored the drive equipment specifications to fit the internally manufactured geared motors and frequency converters. Their primary product, the NORDBLOC.1 two-stage spiral bevel gear reducer, was specifically designed for internal logistics. Compact, user-friendly, durable, and with a long service life, it features a wide gear ratio (i = 3.58 to 70), making it adaptable to various requirements. For BCS, the ability to mount the geared motor on different-sized shafts without altering the shaft was crucial. Despite having diverse conveyor modules, managing numerous drive devices remained manageable. Kassai also emphasized the high efficiency of the geared motor. The frequency converter, designed for transport applications, integrates seamlessly with motors into mechatronic drives. The NORDAC FLEX series ranges from 0.25 to 22 kW, with interfaces for all major fieldbuses, allowing connection to AC vector motors and system controllers.
*Figure 2: The drive system combines a spiral bevel gear reducer, high-efficiency motor, and NORDAC FLEX inverters.*
Effortless Installation and Maintenance
"Toll represents BCS's largest express delivery project in Australia," said Kassai. "Thus, the installation and commissioning processes had to be seamless. Thanks to Nord's ready-to-use drive packages, which are pre-installed and parameterized, we saved significant commissioning time." Each unit is numbered according to its assigned location, simplifying the correct matching of conveyor modules during installation. Hollow-shaft geared motors can be mounted directly onto the machine shaft using a shrink disc. Equipped with a torque arm that secures to the rack with just one point, installation is significantly simplified compared to the traditional method requiring eight screws. Kassai noted further: "Nord also offers plug-and-play connections, making maintenance and installation even simpler. Operators can replace motor drive units within minutes without needing an electrician to reconnect the new device." Each AC vector motor comes with a maintenance switch for safe power disconnection. Replacing an AC vector motor involves transferring parameters via a pluggable EEPROM module to the replacement unit.
*Figure 3: Drive electronics include maintenance switches for safe power disconnection and easy replacement.*
Integrated Load Monitoring and Braking Management
Nord’s advanced drive electronics enable fully integrated, plug-and-play drive units, drastically reducing the wiring work required by BCS. Distributed frequency converters offer mechanical resistance, high overload capacity, and resilience against common disruptions like fluctuating voltages or rapid temperature changes. Thanks to integrated protection mechanisms, BCS eliminated the need for additional control cabinet components, such as motor protection switches and reversing contactors. The inverter monitors overvoltage, undervoltage, overheating, short circuits, grounding faults, and overcurrent (I2t), preventing shutdowns, motor damage, or network interference. At Toll IPEC's distribution center, Nord’s products are used to drive horizontal and inclined conveyors, with lifting technology being another standard application. The frequency converter supports four-quadrant operation, enabling bidirectional acceleration and braking. These features ensure wear-free braking, precise speed control, high starting torque, and safe torque management.
*Figure 4: NORDAC FLEX Distributed Drives power both horizontal and inclined conveyors and effectively manage demanding braking associated with tilted loads.*
In Conclusion
This distribution center isn't the first collaboration between BCS and Nordstrom Group, nor will it be the last. Besides this project, they’ve also worked together on baggage handling systems at Australian airports. The foundation of their long-term partnership lies in Nord’s unwavering customer service, consistently meeting BCS’s high expectations. Kassai remarked: "We’re extremely satisfied with Nord, and there have been no issues."
About Nord Drive Group
As a leading developer and manufacturer of drive technology, Nord Drive Group has been in existence for over 50 years and employs 3,400 people globally. It ranks among the world’s top providers of comprehensive and integrated drive solutions. Nord’s product portfolio spans standard drives to specialized solutions like energy-efficient or explosion-proof drives. In 2016, Nord’s sales reached approximately 560 million euros. With subsidiaries in 89 countries, Nord maintains an extensive distribution and service network to ensure quick deliveries and prompt customer service. Nord’s transmissions cover a torque range from 10 Nm to 250,000 Nm. They also produce motors with outputs ranging from 0.12 kW to 1,000 kW, along with electrical controls including 160 kW inverters and servo controllers. Nord not only offers traditional centralized cabinet inverters but also integrated machine products for distributed control.
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