Integrated drive systems improve heavy machinery performance

Manufacturers of construction, mining, and aggregate processing equipment must design machines capable of operating under continuous load, high torque, and demanding duty cycles. These operating conditions require drive technologies that maintain efficiency and reliability while minimizing maintenance and simplifying machine architecture.

Original equipment manufacturers (OEMs) therefore seek integrated drive systems that combine mechanical robustness, precise control, and adaptability to different machine configurations. In addition to reliability, equipment builders increasingly focus on improving energy efficiency, enabling electrification, and reducing the total cost of ownership across the machine lifecycle.

To address these requirements, drive technology provider Bonfiglioli developed a portfolio of integrated hydraulic, electric, and mechatronic drive solutions for mobile and industrial machinery applications.

Closed-loop hydraulic drive systems for mobile equipment
One of the core technologies presented by Bonfiglioli at CONEXPO-CON/AGG 2026  (March 3–7, 2026) in Las Vegas is its closed-loop hydraulic drive system architecture for hydrostatic-driven mobile machines.

These systems combine axial piston hydraulic motors with planetary gear units to form complete drive assemblies for equipment such as compact track loaders, road construction machinery, aggregate processing machines, surface mining equipment, and material-handling systems.

The hydraulic motors use a swash-plate design and can operate in single-speed, two-speed, or continuously variable displacement configurations. Operating pressures reach up to 400 bar for Delta configurations and 430 bar at the inlet, enabling the drives to deliver high torque in continuous-duty applications.

Integrated spring-applied hydraulic-release (SAHR) parking brakes and configurable flushing valves further support reliability and thermal management in machines operating under heavy loads.

By combining the hydraulic motor and gearbox into a unified system, the solution simplifies system integration for OEMs while maintaining flexibility for different machine architectures.

Mechatronic integration through electronic control systems
System integration has become increasingly important in modern mobile machinery. To support this requirement, Bonfiglioli integrates electronic and control capabilities from Selcom, a member of the Bonfiglioli Group.

Selcom develops custom electronic control and power-management systems that enable closer coordination between mechanical drive components and digital control functions. This integration supports closed-loop control strategies and facilitates the development of electrified or hybrid machinery platforms.

Through this system-level approach, machine manufacturers can optimize drive performance while simplifying the design of control architectures.

Electric drive solutions for electrified machinery
The transition toward electrified construction and mining equipment has increased demand for electric traction and motion systems capable of replacing conventional hydraulic or diesel-driven architectures.

Bonfiglioli’s electromobility portfolio addresses this shift through electric drive units designed for traction and slew applications in electric and hybrid machines. These systems combine electric motors with gear units in compact assemblies.

Pre-paired electric motors designed to operate with specific inverter configurations simplify integration for OEMs, while high-efficiency motors support pump-drive applications in electrified hydraulic systems. The architecture is scalable, enabling implementation in machines ranging from compact equipment to heavy-duty platforms.

Drive solutions for aggregate processing and asphalt production
Beyond mobile machinery, Bonfiglioli also develops drive technologies for stationary industrial equipment used in aggregate processing, material handling, and asphalt production.

One example is a drive solution developed for twin-shaft mixers used in concrete and bitumen batching plants. The system is based on an evolution of the company’s modular planetary gearbox technology.

Twin-shaft mixers require precise mechanical synchronization of the mixing shafts while maintaining high torque output during continuous operation. Bonfiglioli’s solution integrates planetary gearbox modularity with mechanical synchronization, ensuring stable mixing performance in demanding industrial environments.

By eliminating traditional belt-and-pulley transmission systems, the design simplifies machine layout and reduces installation complexity. This configuration also lowers maintenance requirements, contributing to improved equipment availability and reduced operating costs.

Supporting OEMs throughout the machine lifecycle
Bonfiglioli works with equipment manufacturers from the concept stage through commissioning, providing system integration support and application-specific engineering. This collaboration allows OEMs to select the most suitable drive technology—hydraulic, electric, or hybrid depending on machine requirements.

The integrated drive systems presented at CONEXPO-CON/AGG 2026 illustrate how combining mechanical, hydraulic, and electronic technologies can improve reliability, simplify machine design, and support the evolution of heavy machinery toward more efficient and electrified platforms.

www.bonfiglioli.com