Electricity and Control September 2025

Control systems + automation

Le†: MOVIGEAR units ready for dispatch, reflecting SEW-EURODRIVE’s local assembly commitment to rapid delivery of high performance drive solutions tailored for industry. Right: SEW-EURODRIVE’s local MOVIGEAR assembly includes advanced electronic components, enabling faster turnaround times and enhanced support for smart drive solutions.

Safe and energy eicient Among the challenges faced by local industrial players are the unreliable electricity supply and rising energy costs. Customers are therefore turning to advanced technologies to reduce risk and improve competitiveness. “MOVIGEAR enables industrial facilities to automate key conveyor processes while maintaining the highest level of safety,” says Strydom. “A bu•ering zone, for instance, is an open area of conveyors where people are working and moving. Importantly, our onboard system incorporates integrated safety features to ensure a safe working environment.” A further benefit in this installation is the use of ultra-premium e•iciency IE5 SEW electric motors. This means the units also o•er significant energy savings, helping reduce operating costs and carbon footprints. Strydom estimates that energy savings of up to 38% can be achieved compared to conventional motors. Additionally, the units are built to last, with an IP69K rating for ingress protection, suitable for high-pressure washdowns when needed. Designing for success “On this project, we worked closely with the OEM responsible for the conveyor installation to review the design requirements and specify the units,” Strydom explains. “We believe we o•er the most value when we are engaged from the beginning with our mechatronic teams of mechanical and electronic engineers.” Solutions are usually developed based on the plant layout and the required conveyor speed and torque. The MOVIGEAR range includes three sizes – 1, 2 and 4 – covering torque applications from up to 100 Nm to as high as 400 Nm. “In this project, the flexibility of our technology meant all the requirements could be met by the size 2 and size 4 units,” he says. Condition monitoring for preventive maintenance MOVIGEAR’s hybrid cable includes a digital data interface (DDI) that enables live monitoring of each unit’s operation and condition. As part of the second phase of this project, SEW-EURODRIVE rolled out this functionality. The cable also enables automatic identification of each unit based on its digital nameplate. “This phase involved implementing our condition monitoring

so‘ware and training the plant sta• who will access the data,” says Strydom. “The system monitors variables like vibration and temperature to predict the remaining lifespan of components like bearings, as well as monitoring oil levels.” This proactive approach replaces the need for manual inspections and oil analysis with real-time accurate predictions of equipment health. “Essentially, the system creates a digital twin for each MOVIGEAR unit,” he says. “It can send push notifications by email or apps like WhatsApp if it detects anomalies.” If required, these notifications can also be sent to SEW-EURODRIVE’s service team, and the team can provide direct support when needed. Customers are trained to use a dedicated app – installable on laptops or smart devices – to understand and manage system parameters. Initial and final optimisation Strydom highlights the growing popularity of SEW-EURODRIVE’s system optimisation service, now a standard specification in many OEM and end-user contracts. The company o•ers both an initial and final optimisation phase. “A‘er physical installation and connection, but before the system goes live, we check every connection including to the VSDs,” he says. “This is documented so any snags can be resolved systematically. Only once approved by all stakeholders is the system powered up.” A‘er commissioning, final optimisation checks ensure correct operating parameters and installation compliance. Fast tracking In this project, rapid deployment was a critical factor. With its substantial local stockholding in Johannesburg, backed by global resources, SEW EURODRIVE could meet this requirement too, providing swi‘ assembly and delivery. “The value of the MOVIGEAR drive systems in this project has been assured through our involvement throughout the process,” says Strydom. “From design to commissioning and optimisation, we delivered a tailored, integrated solution that is e•icient, reliable and scalable,” he says. “Our a‘er-sales support and services, including service level agreements and inspections, ensure uptime and help our customers remain competitive.”

For more information visit: www.sew-eurodrive.co.za

7 SEPTEMBER 2025 Electricity + Control