Advancing Ground Support Equipment with Bonfiglioli’s High-Performance Electric Drive Solutions

Engineering Efficient, Reliable, and Sustainable GSE

Ground Support Equipment (GSE) is under increasing pressure to become more energy-efficient, compact, and environmentally friendly while maintaining high reliability in demanding airport environments. Engineers designing aircraft tugs, pushbacks, baggage tractors, and loaders need drivetrain solutions that optimize performance, durability, and ease of integration.

Bonfiglioli’s 600WE and 600F Series electric powertrains are engineered to address these challenges, delivering proven, high-efficiency solutions for GSE applications.

600WE Series: High-Efficiency Electric Drives for Aircraft Tugs, Baggage Tractors, and Loaders

The 600WE Series combines Bonfiglioli’s precision planetary gearbox technology with high-performance BPM permanent magnet motors, offering superior power density, efficiency, and reliability for demanding GSE applications.

Feature	Specification
Applications	Aircraft Tugs, Pushbacks, Baggage Tractors, Belt/Stair Loaders
Input Voltage	48Vdc - 400Vdc
Gearbox Design	Multi-stage planetary gearbox with rotating housing output
Motor Type	Bonfiglioli BPM Permanent Magnet Synchronous Motors (PMSM)
Rated Power	20kW - 150kW (Various models available)
Torque Output	17,000 Nm - 60,000 Nm
Housing Material	High-strength aluminum or cast iron
Cooling	Liquid-cooled for optimal thermal performance
Ingress Protection	Up to IP67 for extreme environmental conditions
Integrated Inverter Compatibility	Pre-paring with inverter done
Operating Temperature	-40°C to +85°C

Why Engineers Choose the 600WE Series

✔ High Efficiency: Permanent magnet motor technology optimizes battery usage and reduces power loss.
✔ Compact & Lightweight: The optimized gear and motor design minimizes space requirements, allowing for flexible vehicle integration.
✔ Thermal Management for Continuous Duty Cycles: Liquid cooling ensures stable operation under high load conditions, extending service life.
✔ Electromagnetic Parking Brake Option: Enhances safety for stationary applications.
✔ Customizable Configurations: Engineers can select voltage levels, shaft options, and mounting styles to fit specific machine requirements.

The 600WE Series delivers field-proven performance that enhances the reliability and efficiency of next-generation electric GSE.

600F Series: Rugged & Reliable Electric Drivetrain for Heavy-Duty Baggage Tractors

Designed for continuous operation in airport logistics, the 600F Series electric drive is a robust, low-maintenance solution built to withstand heavy loads and extended duty cycles.

Feature

Specification

Applications

Baggage Tractors, Tow Tractors

Gearbox Design

Dual-stage planetary gearbox with optimized gear design

Motor Type

Integrated AC traction motor

Lift Capacity

2,000 kg - 16,000 kg

Axle Torque

3,000 Nm - 50,000 Nm

Draw Bar Pull Force

8 kN - 30 kN

Brake System

SAHR (Spring-Applied, Hydraulically Released) Parking Brake, Hydraulic Service Brake

Sensors

Integrated silicon-based KTY temperature sensor, high-resolution hall effect speed sensor

Structural Integration

Supports custom mast configurations for simplified frame design

Ingress Protection

Up to IP54

Why Engineers Choose the 600F Series

✔ Built for Heavy-Duty Operation: Optimized for high torque, continuous operation, and maximum uptime.
✔ Reliability & Field Testing: Proven in real-world airport environments, reducing machine downtime risk.
✔ Superior Thermal & Lubrication Management: Optimized gear design, robust seals, and synthetic lubrication extend component lifespan.
✔ Flexible Mounting & Customization: Engineers can tailor mounting, coatings, and sensor configurations to match specific vehicle designs.
✔ Safety-Enhanced Braking Options: Integrated parking and hydraulic service brakes ensure maximum operator safety.

With its field-tested durability and advanced motor integration, the 600F Series offers the ideal drivetrain solution for electric baggage tractors.

Material Selection & Durability

· Gearbox: High-strength steel gears enhance load-bearing capacity, ensuring minimal wear over long duty cycles.

· Housing: Aluminum or cast iron construction provides a balance between weight reduction and thermal dissipation.

· Seals & Bearings: Heavy-duty seals and precision bearings reduce friction and improve service life.

Duty Cycle Optimization

· Designed for 24/7 operation in harsh airport environments.

· Thermal management via liquid cooling (600WE) and optimized gear designs (600F) maintain efficiency under continuous heavy loads.

· Integrated temperature and speed sensors enable real-time diagnostics and predictive maintenance.

Customization & Integration Options

· Voltage Selection: 48Vdc - 400Vdc options for compatibility with different battery architectures.

· Mounting Configurations: Engineers can select from multiple shaft, flange, and mast support options.

· Coatings & Protection: Corrosion-resistant coatings for harsh airport conditions.

· Predictive Maintenance Capabilities: Advanced sensor integration and diagnostic tools for real-time performance tracking.

Reliability & Maintenance Optimization

·Rigorous Testing & Validation:

·Load Testing for maximum torque verification
·Thermal Cycling to ensure heat dissipation efficiency
·Vibration Analysis for shock resistance in dynamic application

·Predictive Maintenance Integration: Real-time health monitoring reduces unplanned downtime.

·Global Service Network: Bonfiglioli’s OEM support ensures fast access to spare parts and expert assistance.

Key Benefits for GSE Engineers:

✅ Industry-Leading Energy Efficiency → Longer battery life, lower power consumption
✅ Proven Durability & Reliability → Field-tested designs reduce downtime
✅ Compact & Lightweight → Optimized packaging for easy integration
✅ Flexible Customization Options → Voltage levels, mounting styles, and protection options
✅ Seamless Inverter Compatibility → Supports CANopen, EtherCAT, and more

Bonfiglioli’s 600WE and 600F Series set the standard for high-performance electric ground support equipment, ensuring sustainability, reliability, and efficiency in modern airport logistics.