I do this trip at least once in a year and taken up most of the available routes in all these years. Now from past few years I am taking up following route:
Hyderabad -> Zaheerabad -> Solapur (Take Bypass) -> Mohol->Tembhurni (from here take right turn towards Karmala) -> Karmala -> Ahmednagar -> Ghodeygaon -> Shani Singnapur -> Shirdi
We start from Hyderabad (KPHB) around 4 AM and reach Shirdi by evening 6 PM. We stop at Shani Signapur for darshan while going and it takes around 1 hr in total, other than that almost 1.5 hours break for breakfast and lunch.
Hyderabad to Solapur: Out of ~290 KM's last 90 KM's towards Solapur is not in good shape
Solapur Bypass to Tembhurni: Excellent 4/6 lane road
Tembhurni to Karmala: Good roads
Karmala to Ahmed Nagar: Good roads
as advised even in previous thread, please start as early as you can.
Another Important Point: If you reach Shirdi by 6 PM then check-in to a Hotel, fresh-up and then go for Darshan around 08:30pm/9pm, trust me you don't need any special passes for darshan during this time, we do this all the times and come out of the temple within 30 mins after Darshan. Most buses reaches there early morning and that when it becomes crowded and takes hours to get darshan.
Hope this helps, update this thread once you are back from your trip.