DHL

Customer Profile

Since August 1, 2019, a new air freight hub at the Cologne Bonn Airport has been part of the DHL network. “With the air freight logistics center at the Cologne Bonn Airport, we achieve higher efficiency and larger sorting capacities, and can thus offer our network and our customers a better service“, Jörg Balmes, Senior Manager Technical – MHS at DHL Airways GmbH explains the reasons for the new construction.

The DHL hub at the Cologne Bonn Airport provides a warehouse space of 12,000 m² and a sorting capacity of 10,000 parcels per hour. A 400-meter main sorter and a 200-meter flyer sorter sort the different parcel sizes – 24 hours a day, six days a week. Added to this are conveyors with a total length of 2.5 km, which are operated by NORD® drive systems with a belt speed of up to 2 m/s and an acceleration of up to 5 m/s.

Project Requirements

<h3>DHL’s Goal: Zero Emissions in 2050</h3>

As the world’s leading logistics company, DHL assumes the responsibility to set a good example in terms of sustainability, and is investing heavily in environmentally friendly logistics solutions. “In 2050, DHL wants to be emission-free. The topic of energy efficiency is therefore of highest priority to us. The building in Cologne/Bonn is CO₂-neutral and is equipped with latest technologies, such as an ice storage tank for heating and cooling. For the conveyor belt motors, energy efficiency as well as short maintenance intervals have also been the main requirement. NORD® was able to deliver this to us and therefore we are very satisfied with the NORD® motors.” Jörg Balmes emphasizes.

<h3>Complete Drive Systems from a Single Source</h3>

Thanks to plug-and-play technology, LOGIDRIVE™ systems are extremely easy to service and install. The entire system has a modular design, so that all components of the drive technology can be individually serviced. This minimizes maintenance and repair costs. All NORDAC® LINK variable frequency drive connections are made via simple plug connectors and have been individually configured for DHL. A total of 12 plugs are available for encoder feedback, safe stop and others. In addition, the variable frequency drives are equipped with a maintenance switch and a key switch for setup operation. An integrated Ethernet-based bus system was also implemented. The combination of an integrated PROFINET interface and these other components in a single compact solution was launched on the market in 2019 – and at the time was an absolute unique selling point for NORD®.<br><br>

To complete the drive solution, NORD® also supplied the cables. Potential sources of error were thus eliminated, facilitating commissioning. The compact LOGIDRIVE™ drive system design saves space and is light in weight due to the aluminum housing. Thanks to individual optimization in the motor shaft bearing arrangement, noise emissions could be reduced, ensuring sufficiently quiet operation at the Cologne Bonn Airport. Due to the motor design and the variable frequency drive operation, the same motor variant can be universally used worldwide.

<h3>NORD® Drives Support DHL on its Way to Climate-Friendly Logistics</h3>

The operation of parcel distribution centers is energy-intensive. Highly efficient drive systems such as the NORD® LOGIDRIVE™ drive system significantly reduce energy consumption and therefore CO₂ emissions. In this way, they decisively contribute to more sustainability and climate protection in logistics. Furthermore, a fast Return on Investment (ROI) is achieved due to their high efficiency. In summer 2019, the DHL hub at the Cologne Bonn Airport was put into operation. Since then, the NORD® drives have been running smoothly and everybody is highly satisfied. Jörg Balmes is delighted: “We have been working with the NORD® drives in continuous operation for three years now and the failure rate is extremely low. Consulting and servicing also convinced us. In challenges, NORD® always supported us with quick solutions.” NORD® supported the project from the first inquiry through to the commissioning.