An Overview of Regal Rexnord's Smart Powertrain Solutions, Growing IIoT Capabilities
A warehouse distribution center in North Carolina saved over $90,000 in one year after integrating the Regal Rexnord® ModSort® Divert and Transfer Module.
Inside a large distribution warehouse in Charlotte, North Carolina, a team of workers faced a daunting challenge: manually handling incoming package types ranging from boxes to polybags while managing other business. The polybags were placed into totes, which helped ensure proper package conveyance. However, the totes also increased manual labor and the time it took to sort bags. The team spent 80 hours per week manually grabbing and pulling totes at a labor rate of $21.50.
Was there any kind of “smart” technology that could help?
Indeed. The low-maintenance ModSort Divert and Transfer Module® from Regal Rexnord was installed in the facility to assist the workers by conveying polybags without totes. Quiet, safe, and low maintenance, the ModSort offers run-on demand technology on only 24 volts. The ModSort module easily integrated into the warehouse’s package handling process. Conveyor speeds increased from 50 to 90 ft/min. Annual labor costs dropped by $90,000.
This is a true story, and it’s one Regal Rexnord is incredibly proud to tell. Manufacturing industries are experiencing a significant shift towards investing in the Industrial Internet of Things (“IIoT”) and “smart” technology. With the advent of advanced connectivity and data analytics capabilities, manufacturers are leveraging “smart” technology to optimize operations, decrease downtime, and prolong the lifespan of mission-critical equipment.
In addition to end-to-end Powertrain Solutions such as ModSort, Regal Rexnord is proud to offer Perceptiv™ Intelligent Reliability Solutions, an interconnected matrix of sensors, gateways, and data, which empowers manufacturers to monitor products in real time and make data-backed decisions. While the industry has advanced considerably in recent years, the digital transformation is far from over. As AI and Language Learning Networks continue to evolve, manufacturing technologies will, too. It is critical that engineers, integrators, equipment manufacturers, and end users stay up to date on the latest developments.
Advancements in “smart” technologies for material handling, intralogistics industries
The material handling and intralogistics industries are driven by sustainability, automation, and innovation. In baggage handling, postal and parcel centers, and warehouses and distribution centers, revenue is determined by the performance of downstream industries and markets that bolster industry demand. Margins are thin, which is why so many facilities are excited by digital transformation.
In addition to ModSort, AGVs can minimize energy consumption and optimize production output. By combining the ModSort system with Kollmorgen technology,
“Smart” systems that are IIoT-enabled are backed by decades of application knowledge and engineering expertise. Not only are the products reliable; engineers are often a phone call away.
Regal Rexnord® AGVs optimize facility operations and decrease downtime. How does ModSort work?
The idea for ModSort started in 2015 quite simply: a blue System Plast® belt with embedded rollers. OEMs were excited by the technology, but needed help developing it to meet their system needs. ModSort evolved to include a belt and MDR rollers. Now, ModSort comes in many sizes and can include Perceptiv IIoT sensors, motors, bearings, and gearing. There is great flexibility to meet the demands of various applications. And the developments aren’t stopping any time soon. At the upcoming MODEX tradeshow the Regal Rexnord booth will have a full ModSort loop and a ModSort mounted onto an AGV.
The patented ModSort® Divert and Transfer Module can be added to an existing or new conveyor system and utilizes industry standard 24V connections. 
Integrating “smart” technology boosts sustainability, worker safety
Change is hard. There is always an upfront cost; sensors to monitor brake oil levels or coupling vibration are not free. A custom engineered ModSort sortation system takes time and money to develop. However, the Return on Investment, coupled with increased productivity, sustainability and decreased downtime, proves the value.
When it comes to conveying and sorting, older technologies are not as efficient as newer options in the marketplace. Many have old-style pusher arms that are very loud and run by pneumatics. Those require frequent maintenance and adjustments to make them functional. ModSort, on the other hand, is designed from the ground up to be a maintenance-friendly product. It’s easy to take apart and put back together, and if there is a problem it doesn’t take much time to figure out what that is. ModSort takes no compressed air and runs on 24 volt DC current. It is extremely quiet, approachable and safe.
ModSort is just one example, but like many “smart” technologies, its benefits are far greater than economic. Worker safety and sustainability increase while maintenance and downtime decrease.
A graduate of East Carolina University, Tom Eure has worked in the packaging and material handling industry since 1999. He started his career as a conveying engineer with System Plast. He and his colleagues have tailored solutions for many beverage producers in North America, allowing them to run production completely dry with the New Generation® (NG-EVO) “run dry” technologies. Today, Tom is a Strategic Account Executive at Regal Rexnord. Reach Tom at [email protected] or on LinkedIn.
Talk To Our Sales Team
We're here to help. Our team of experts is ready to help energy-efficiently power your business.