Van Erp International and Rotalink worked closely on the modular dosing control module for the Blue Lagoon range which is used across several products in single or multiple use. The design brief included compactness, performance, reliability, fast time to market and low cost. To ensure the most reliable and efficient pump system a number of AC synchronous motor and ovoid gearbox combinations were thoroughly tested at Rotalink using its in-house design, production and test facilities. This concurrent product development process  involved simulated pumping trials with various dosing pumps supplied by Van Erp International, helping reduce its own development burden and speeding development timescales. During this phase Rotalink were also able to offer specific design advice to Van Erp International engineers, improving the overall pump performance and MTBF rating whilst optimising costs.

Rotalink is also working closely with Van Erp International on other projects including motorised valve mechanisms for diverting pool and spa water for filtration and filter cleaning processes.

‘Our working relationship with Rotalink is an important part of our philosophy to combine high quality and large scale production techniques with close contact to the World’s best suppliers,’ explains Ms. Dami Leifkins, Van Erp International's Director of Sales. 'Rotalink have helped us at every stage of product development and continue to add value with excellent support in the production phase.’

Rotalink manufactures complete miniature power transmission assemblies that include motor technologies with innovative gearboxes, feedback sensors and motion controls - for applications up to 200 W and peak gearbox torque to 26 Nm.

The new HC motors form an integral part of Rotalink's strategy that brings together a range of brushed and brushless DC and AC motor technologies with its own innovative designs for gearbox, motor feedback and motion controls to realise highly competitive miniature power transmission solutions of up to 28 Nm output torque for rotary motion and  linear motion solutions to more than 50 N force.

Rotalink's range includes planetary and spur gearboxes in a wide choice of output torque ratings that feature standard or ultra polymer gears on sintered or ball bearings. For extremely high torque  output  in very compact designs, Rotalink manufacture a unique range of ovoid style gearboxes that combine spur and planetary gear stages using ultra-polymer materials technology that will provide up to 28 Nm peak torque in a gearbox case that measures just 95 mm x 60 mm x 31.5 mm deep.

Rotalink also manufacture incremental and absolute encoder feedback devices with pioneering space saving designs that are easily adapted into applications for speed control and position feedback together with motion controls such as the innovative Red Drive - a powerful DC motor drive, available in brushed and brushless DC control version, offering an easy-to use drag-and-drop flow chart programming language for motion control and combined TTL logic I/O.

The new Heavy Case motors are fully covered in Rotalink's new and revised full range catalogue along with new rare earth and brushless DC motor ranges and several new gearbox lines.

The new speed and direction controller may be used across Rotalink's extensive range of brushed DC motors which includes standard ferrite and high performance rare earth magnet systems as well as heavy case designs. The controller provides a convenient control solution as part of Rotalink's strategy that combines brushed and brushless DC motors as well as AC motor technologies with its own innovative gearbox, motor feedback and motion controls. Rotalink provide competitive miniature power transmission solutions of up to 28 Nm output torque for rotary motion and to more than 50 N force for linear motion.  

The full range includes a wide choice of planetary and spur gearboxes that feature standard or enhanced polymer gears on sintered or ball bearings. Rotalink manufacture a unique range of ovoid style gearboxes with extremely high torque output that combine spur gears with planetary stages using ultra-polymer materials technology.

Rotalink also manufacture a range of incremental and absolute feedback devices as well as motion controls for DC motors. The Red Drive controller  is available for brushed and brushless motors and features easy-to use drag-and-drop flow chart programming for motion control and combined TTL logic I/O.

The 310 series is aimed at machine automation applications where optimum performance and miniaturisation are key design factors or where existing size restricted machine designs require higher dynamic performance or increased life vs. duty. The 310 has a 6 mm diameter output shaft supported on twin ball race bearings and in addition to its very high torque is also an extremely quiet performer suiting the biomedical, theatre and vending equipment markets.

The mid range 210 series also uses Rotalink's combined spur and planetary output stage design in standard engineered polymer materials together with a 6 mm diameter output shaft supported on twin ball race bearings for torque output up to 2.2 Nm. This gearbox offers exceptional cost vs. performance and quiet performance for high torque applications in pumps and valves, instruments and CCTV equipment.

The moderately priced 222 series gearbox features an all spur gear design in engineering polymers with a 4 mm diameter stainless steel output shaft mounted on sintered front and nylon rear bearings. This gearbox is capable of delivering an output torque of up to 0.65 Nm and will suit medium performance applications for small instruments, pumps and valves, timers, and pan & tilt mechanisms for CCTV and the emerging IP Camera markets.

Through the 310 and 210 series a wide choice of standard ratios are available from 26:1 to 2794:1, whilst the 222 series offers ratios from 7:1 to 782:1. Custom ratios, special shafts, wiring and connector options can also be adapted within the gearboxes and supplied along with ancillary products such as leadscrews, pulleys, clutches and encoders.

The 310, 222 and 210 series are part of a comprehensive Rotalink designed and manufactured range which includes ovoid, inline and planetary gearboxes to 28 Nm, innovative feedback devices, servo drives and motion controls that are combined with competitively priced AC, DC brushed, brushless or specialist motors for high-value cost optimised miniature power transmission solutions.

These gearboxes are featured in detail in Rotalink's new full range catalogue which is available in downloadable PDF format from www.rotalink.com or as a 80-page full colour resource complete with additional application specific technical information.

The BL motor range is available in both 12 and 24 VDC versions, complete with three phase hall effect commutation for smooth and precise speed and/or position control. The highly efficient brushless design has an inherently low electrical noise factor and unlike brushed DC motors is not prone to commutation sparking; so the motor is ideally suited to EMC sensitive and safe environment use.  In addition, the non contacting characteristics will suit applications where long life and high reliability are of prime concern. The BL range includes five frame sizes with nominal diameters of 29 mm, 32 mm, 45 mm, 57mm and 65 mm.

The new BL brushless motors are particularly well matched for use with the brushless version of  Rotalink's recently launched drag-and-drop/flow chart programmed Red Drive motor driver and controller which has significantly reduced the entry costs for high performance yet easy-to-use brushless servo control. The BLDC Red Drive has a 10A current rating and is complete with hall sensor inputs for brushless commutation, incremental encoder feedback inputs plus 27 programmable TTL level I/O pins for analogue and digital machine interfacing.

Full details of the new BL range and the brushless Red Drive are covered in Rotalink's new 80 page miniature power transmission and motion control products catalogue. The catalogue and Rotalink's website at www.rotalink.com also features in depth coverage of the complete range of spur and planetary styles gearboxes with built-in flexibility to allow users to match their budget and performance requirements by selecting standard or enhanced polymer gears with a choice of sintered or ball bearings. Rotalink's unique ovoid style gearboxes feature combined spur and ultra-polymer planetary stages in very compact designs for extremely high torque-to-size ratio geared solutions.

Other products include novel incremental and absolute encoder feedback devices that may be assembled directly on the front motor shaft or rear gearbox shaft in space saving designs that help to complete highly integrated mechanical solutions for miniature power transmission.

The new device may be useful to replace potentiometer based angle encoders by combining motor and position feedback in a single component or for low cost servo feedback in linear and rotary actuators. Absolute position feedback is also extremely useful for machine homing. The innovative multi-turn option includes an integral rechargeable battery that maintains full position information for up 20 hours if machine power is removed.

Rotalink designs and manufactures a wide range of gearboxes in planetary and spur gearbox designs that feature optional steel and/or polymer gears on sintered or ball bearings. The range also includes unique ovoid style gearheads that  include a combination of spur gears for the input stages and planetary gear assemblies for the output stages. These are also available  in a choice of steel or ultra-polymer materials. The flexibility available from these options  allow customers to match their exact application requirements without cost compromise.

Rotalink also manufacture incremental encoder feedback devices as well as speed controls and motion controls including the innovative Red Drive - a powerful DC motor drive for motors up to 200 Watts which features drag-and-drop flow chart programming for motion control with incremental encoder feedback.

These innovative absolute encoders are included in Rotalink's new and revised full range catalogue which details three new ranges of DC motor technologies ( rare earth, heavy case and brushless) as well as several new gearbox lines and a brushless version of Rotalink's Red Drive motion controller.

The long life RE series motors are available in diameters of 15, 24 and 30mm with nominal voltages of 12 and 24 VDC. Through the range, maximum motor power is from 2.0 W to 29 W and maximum stall torque from 9 to 299 mNm.

These new motors are sourced from global distribution partners as a part of Rotalink's strategy to maintain competitive pricing for commodity components and combine them with its own innovative designs for gearbox, motor feedback and motion control technologies to enable low-cost miniature rotary power transmission solutions up to 28 Nm and linear motion solutions to 50 N.

Rotalink's manufactured range includes planetary and spur gearbox designs that feature a selection of steel and/or polymer gears on sintered or ball bearings in a wide choice of output torque ratings. The range also includes unique ovoid style gearboxes that combine spur gears with ultra-polymer planetary stages for extremely high torque output  in very compact designs. This flexibility allows customers to exactly match their performance requirements from motor type through to performance characteristics without compromising cost.

Rotalink also manufacture incremental and absolute encoder feedback devices along with speed controls and innovative motion controls including Red Drive - a powerful DC motor drive with drag-and-drop flow chart programming for motion control including encoder feedback for motors up to 200 Watts.

The RE series motors are included in Rotalink's new and revised full range catalogue which includes two other new DC motor ranges ( heavy case and brushless) in addition to  several new gearbox lines and new absolute encoders, and a brushless version of Rotalink's Red Drive motion controller.

Like its brushed servo counterpart, the modular design concept includes the separately supplied SA1 serial port adapter to program the controller with the free-of-charge Red Drive PC-based graphical software. For fast and cost-effective OEM product development, the microprocessor chip is available separately, allowing the full board version with its integral servo drive to be used in the design and pre-production phases with the IC version incorporated in the final machine for full production. This option also enables the customer the flexibility to choose and design-in the optimum power components and I/O requirements for the application.

The BLDC10A Brushless Red Drive is easy to program using a drag and drop flowchart programming method which eliminates the complexity typically associated with many other motion controllers available today. The Windows™ program allows scaling of encoder and gearbox resolution into meaningful units at set-up along with I/O interfacing assignment. Set-up also includes simply entering catalogue values for motor stall-torque and no-load speeds for automatic tuning. Homing, limits and reset inputs can also be set.

The sequential graphical programming format requires little training or specialist motion control knowledge. The programmer simply creates then drags and drops function blocks in a sequential order with relevant values. Separate subroutines can be included in the program to call specific functions at any time on input states or as a part of the program flow. Program functions include incremental and absolute distance moves, acceleration, speeds and wait times in addition to maths and variable calculations. In all, the Red Drive's EEPROM memory storage can handle repeatable sequences of more than 100 functions and drives may be easily linked through I/O for multi-axis set-ups. An A safety input may also be configured to shutdown the drive for emergency measures.

Up to 8 of the 27 I/O points may be assigned to 5V analogue inputs with the remaining available for digital I/O interfacing at 5V TTL levels. All I/O is connected to the BLDC10A via a IDC type connectors using space saving flat cable assemblies or crimp connectors with standard wiring. The 4-pin encoder connection uses a snap-lock header connector, and motor, power and hall sensor connection is via convenient screw terminals. The SA1 RS232 serial adapter board is interfaced via a 14-way header and only needs to be connected to the drive when programming and is therefore useful for production environments or security minded OEM applications where access needs to be restricted.

Rotalink's product range is based on low-cost, volume sourced motors from global partners which are integrated with specialist in-house designed and manufactured power transmission components and controls. These include innovative miniature gearboxes using the latest materials technology, novel incremental and absolute feedback components and motion controls like the new BLDC10A Red Drive which together realise cost competitive solutions for small and large volume users alike.

Crewkerne UK – June 2010: A new and revised full range catalogue from Rotalink includes several new products and additional technical information aimed at making an informed selection for highly cost competitive  miniature power transmission systems and controls. The new resource covers performance specifications for three recently added DC motor technologies (rare earth, heavy case and brushless) as well as several new gearbox lines along with a  completely new section on DC motor control - including new absolute encoders and a brushless version of Rotalink's flagship motion controller, Red Drive.

The new catalogue reflects just how busy Rotalink have been over the past two years -   developing and improving a complete range that allows its customers the benefit of volume sourced and low-cost DC, AC and stepper motor technologies from global partners which are integrated with in-house designed and manufactured miniature gearboxes, motor feedback components and motion control technologies.

Rotalink's strength and expertise lies in adapting advanced materials technologies into its own innovative designs for miniature gearbox and associated components to realise leading-edge and cost effective solutions for miniature power transmission systems up to 28 Nm torque and to 150 W shaft power. With its own manufactured range of planetary and ovoid style gearboxes that include a flexible choice standard or enhanced polymer gears with sintered or ball bearings, it is possible to exactly match a customer's specification without cost compromise. Furthermore, the choice of advanced materials and Rotalink's unique ovoid gearboxes with spur/planetary output stages can yield extremely high torque in space restricted envelopes and are a perfect solution where miniaturisation in design or maximising power to size is of prime importance.

By adapting these same gearbox designs with Rotalink's space saving  incremental or absolute encoder feedback devices, and by adding speed or positional motion control, Rotalink provide a complete single-source service for miniature linear or rotary power transmission systems at costs which are much less than its competitors.

The new catalogue includes complete specification information for three recently introduced DC motor technologies; high power brushed DC motors with neodymium rare earth magnets, heavy case low inertia brushed DC motors, and  low cost brushless DC motors complete with hall effect sensors for commutation.

 Also, recently launched and available for the first time in the new catalogue is a brushless version of the Red Drive programmable motion controller for up to 10A output from a 12 – 24 VDC source with up to 27 configurable analogue and digital I/O points for comprehensive machine control interfacing.

For each of the DC, AC and Stepper motors section in the new catalogue,  a detailed selection guide is included with technical assistance information available such as countermeasures for EMI  and a discussion on customisation options for DC motor gearbox applications. Engineers and designers involved in miniature power transmission systems will find Rotalink's new catalogue an invaluable resource.

Rotalink's new catalogue is available in  hard cover or downloadable PDF from the www.rotalink.co.uk website or by contacting the Rotalink sales office on +44 (0) 1460 72000.

Crewkerne UK – June 2009: Focus International is a leading fibre optic lighting company specialising in large projects such as museums, shopping centres and corporate buildings. When a challenging project for a large illuminated sign for an historic building required complex and high speed synchronised switching, they found a competitive solution using Red Drive servo controllers with brushed DC motor/encoders and gearboxes from miniature power transmission and controls specialist Rotalink.

Fibre optic technology lighting creates spectacular effects and is becoming increasingly popular with proven benefits of high efficiency and low energy consumption as well as guaranteed intrinsic safety with no electrical hazard as only transmitted light reaches the target area. For Focus International, each project is unique and, as the industry does not generally have standard equipment, involves the careful and specialist design of three main components to achieve the desired balance of illumination and intensity - the light source containing the lamp with optical modifying components and controls - fibre optic bundles to transmit the light - and the light fittings that direct the light onto the subject and its surrounding space.

For this project, the synchronised high speed switching pattern was produced using twelve identical light sources, each with a motorised aperture disc that is rotated to allow or restrict the light path into its corresponding fibre optic bundle. Each light source disc was controlled by a Red Drive and driven by a Rotalink supplied brushed DC servomotor fitted with a high ratio spur gearbox with position feedback from a rear motor mounted, 48 pulse-per-rev, dual channel optical encoder. Synchronisation between each axis was simply achieved by interconnecting the Red Drive’s built-in and fully programmable I/O to trigger pre-programmed move sequences, with a master Red Drive interconnected to the main switch.

Focus International had considered using DMX Controllers for this application but the stage lighting industry’s standard protocol is found to be overly complex to program and expensive for such customised multi axis motion control based lighting systems.

Red Drive with its inherent low cost and straightforward drag-and-drop flowchart programming was an attractive alterative that could be quickly integrated into the application. The credit card sized controller was easily installed in the light source housing and its EEPROM memory allowed the complex motion sequences to be stored for a fit-and-forget and standalone solution. Furthermore, as Rotalink also design and manufacture a wide range of motor technologies, gearboxes and ancillary components, they could provide the complete power train system. In addition, the Crewkerne based specialist also helped with motor sizing and application calculations – further reducing development time and design costs.

As the Windows™ programmable Red Drive scales the encoder and gearbox resolution into meaningful units at set-up, actual move distances and speeds matched the fixed 90 degree angular aperture rotation. PID servo tuning was taken care of by simply entering catalogue values for motor stall torque and no-load speed. The set-up also included assigning each of Red Drives’ complement of nine user-definable digital input and outputs, and linking the homing and reset inputs which were called from subroutines in the flowchart based program.

Red Drives’ graphical drag-and-drop programming methodology allowed Focus International to quickly program acceleration, move and dwell parameters that created the desired lighting effect – and at this point, the subroutine feature allowed a variety of subtlety different move profiles to be evaluated with easy retrieval for final use. It was also possible to select alternative move and lighting sequences using Red Drives’ variable and loop commands to provide different lighting effects from input states to highlight various areas of the sign for different purposes.

Since its recent launch, the Red Drive has significantly flattened the entry level costs for integrated digital servo amplifiers or intelligent drives. For this application, each light source was fitted with 1A Red Drive and power transmission components for less than £90 representing a considerable saving over standalone digital drives and conventional servo gearheads.

Together with Rotalink’s competitive range of DC motors and gearboxes, and with a 10 A current capability, Red Drive allows OEMs to create mechatronic positioning systems with up to 10 Nm torque economically and with a significantly improved time to market. Other features such as newly introduced analogue inputs that can be used with potentiometers to give positional feedback make the Red Drive an even more sophisticated and flexible motion controller for DC servomotors.

Following the success of this project, Focus International is now using Red Drive for other lighting projects involving fully synchronised colour filter discs for even more spectacular effects.

Crewkerne UK – March 2009: Rotalink Limited, the leading miniature power transmission systems and controls specialist, has launched a new presentation folder to support its specialist ‘centre of excellence’ Design & Supply Services to OEMs.

The folder summarises the Crewkerne based manufacturer’s design philosophy which embraces a well-informed awareness of the substantial opportunities offered by today’s materials and technologies in combination with an extensive range of core catalogue products which can be imaginatively repackaged into motion and position control sub-assemblies. Together these factors help reduce volume purchase and prototype development costs, improve quality, and minimise time-to-market.

Rotalink’s Design & Supply Services for OEMs is well established and led by experienced, multi-disciplined engineers backed by the latest 3D modelling software and in-house prototyping facilities. An Express 3D CAD file service is also available to help customers visualise new designs and quickly integrate application-specific assemblies into their own CAD systems using digital prototyping techniques - helping to further reduce time-to-market by resolving design issues before prototype manufacture.

Rotalink’s extensive core product range includes AC and DC miniature motors, encoders, gearboxes and ancillary power transmission components, as well as motion control products such as the Red Drive - a powerful motor driver with on board encoder feedback handling and innovative drag-and-drop flow chart programming for motion control of DC motors up to 200 Watts. Red Drive is available as a PCB or as a chip option for integration directly into the customer’s application.

The new presentation folder forms part of Rotalink’s Design & Supply Services to OEMs proposal process. The informative document is also available as a PDF download from here.

Crewkerne UK – October 2007: To help speed and simplify the design visualisation process for its customers, Rotalink Limited have recently announced an Express 3D CAD file service for application-specific assemblies from its wide range of miniature motors, encoders, gearboxes, and transmission components.

After finalising the application evaluation, Rotalink aim to provide a 3D space model file within 24 hours that details all the essential mechanical and electrical interfacing information for the recommended product. The product can then be quickly assessed within the customers’ CAD system and any design issues resolved with minimum delay. 3D files include mounting holes, drive shafts, output gears, pulleys, connectors and if necessary, application customised features.

3D CAD software with built-in “digital prototyping” is now the leading and indispensable technique for design visualisation. With definite product development time and cost savings, such software is available from several companies, each with its own merits. However, whilst many common “commodity” design components such as bolts and bearings are integrated with these CAD software systems, design engineers often have to spend a significant amount of time creating 3D models for specialised components like motor gearboxes by tediously reworking manufacturers 2D drawings supplied in brochures or from website downloads.

The new service was introduced after several instances where Rotalink was able to quickly provide 3D CAD files specific to the customers’ application by referencing its own extensive design library to compile the virtual assembly. Whereas this simple but extremely effective process may prove difficult for a distributor who must contact his component supplier or suppliers and wait for action, Rotalink’s in-house design and manufacturing strengths make the process very straightforward.

Rotalink’s engineering team uses Autodesk® Inventor CAD software for design and production with many productivity enhancements and is able to output 3D space models in the STEP Application Protocol 203 file format which is universally accepted by all major 3D CAD software systems.

ISO 9001 registered Rotalink supply a broad range of AC, DC and stepping motor technologies plus gearboxes, drives, controls and power transmission equipment from its design and manufacturing facility in Crewkerne – UK.

Smaller than a credit card, Rotalink’s Red Drive DC motor controller - with motor, gearbox and encoder – requires no complex programming to control all the variables associated with rotational or linear movement. Its simple Windows-based drag-and-drop flowchart style interface uses real world values such as seconds, revolutions and gearbox output rpm to control speed, acceleration, position, dwell etc., and to manage digital I/O connections for interaction with limit switches, sensors, LEDs, relays and similar signals.

Red Drive’s flowchart programming approach eliminates much of the complexity typically associated with motion control systems. Dragging readily understandable flowchart blocks for start, accelerate, compare, wait and so on onto a work area allows program structure to be established within minutes. With a click and drag, blocks are easily moved, added or deleted, repetitive sequences readily identified and grouped into subroutines, and variables manipulated for calculations and loop control. And, with no need to resort to Basic or C, programming is simplified and engineers have a single consistent development environment in which to work.

Initialise

The cornerstone of any Red Drive program is the motor set-up definition. In a single dialog box, the programmer specifies motor, encoder and gearbox information directly from the appropriate catalogue pages. Only output shaft load torque, global failsafe requirements and digital I/O pin assignment – which are inputs, which are outputs – need application-specific settings.

Output shaft load torque is used in conjunction with the speed feedback setting specified in several motion control blocks – move, accelerate, decelerate. Together they smooth acceleration and deceleration, and ensure actual motor speed is as close as possible to programmed speed. Speed feedback also helps detect if the unit is blocked, protecting the motor from overheating and hence the system from damage.

Once these parameters are set, the programmer can set a calibrated home position. Movement in Red Drive is specified in absolute values and a known start point is essential to ensure the system always starts from the same position. For example, connecting an input pin to a micro switch at the extreme end of a linear system’s travel, or an optical sensor on the final output stage of a rotary system, allows repeatable zeroing of the system. If relative positioning is required, say in a pumping system, a Reset Home block does exactly what it says on the tin.  

Move 

Once initial conditions have been specified, implementing a profile is simply a matter of dragging a sequence of move, accelerate and decelerate blocks into the program. Step parameters are set in real world values such as rpm and seconds. Context sensitive tool-tips help the programmer with parameter selection, whilst comprehensive checks and fail-safes built into the software trap many simple errors.

Movement accuracy is assured by combining soft start/stop with user programmable acceleration sequences, simplifying power management in high-torque applications and eliminating overshoot and jerk. Specifying a final position in acceleration or deceleration blocks eliminates any discrepancy in motor performance created by variations in output load that may be present in a particular application.

Organise

Red Drive has 128 simple variables that can be set, incremented, decremented and checked, opening ways to improve readability and reduce memory usage where repetitive sequences occur. To build a simple loop the programmer needs only to drag the blocks required to set initial value, increment and check end condition around a sequence to execute it n times. With 64 variables stored in EEPROM, recovery from power failure is simplified and long-term statistics can be logged – even over the life of the end product.

Repeated sequences that do not lend themselves to loops can be quickly selected and dragged between a subroutine start/stop pair. The result can be called from anywhere within the program. And, with variables global to the program, simple parameter passing can be emulated, further increasing flexibility.

Interact

With pin connections identified at program set-up, a decision block can check the state of input pins at appropriate points in the program to establish whether a particular sensor or relay has tripped before initiating a set of actions. Examples include pushing the start button or arrival of the next item on a conveyor belt. To trigger an external action such as actuating a relay, or signaling information to the operator, a set output block for the pin is all that is needed. Connecting two or more controllers together with input/output signals enables multi-axis systems to be developed quickly and easily.

Over 100 command blocks can be stored in Red Drive’s on-board EEPROM, enabling complex motion sequences to be programmed. The on-board RS232 serial interface allows the program to be uploaded to the controller at any stage. Transfer typically takes less than a minute, speeding prototype development and allowing the latest product version to be installed on the shop floor immediately prior to test and ship.

Red Drive, motor, gearbox and encoder packages cost significantly less than £100 in quantity. Add a compelling drag-and-drop flowchart methodology that simplifies programming, slashing development times, and Rotalink has virtually flattened the entry barriers to flexible digital drive systems. Available with most of the company’s DC motors and gearboxes, it allows engineers to develop powerful systems with up to 10Nm of torque that outperform many, more expensive, stepper motors.

The dual channel encoder’s 48-line quadrature output gives 192 positions per revolution, indicating minute steps at the gearbox output when multiplied by the gearbox ratio. Integrated circuitry operates from a standard 5V supply, uses long-life optical components and provides Schmitt triggering to directly drive CMOS/TTL logic.

The single channel encoder provides a lower-cost option when directional of rotation is not critical. Operating from 3.8V to 30.0Vdc supply voltages, this magneto-resistive encoder outputs 24 pulses/revolution at the supply voltage level, making it suitable for interfacing with TTL and CMOS devices.

The encoders are fully compatible across Rotalink’s range of DC motors - delivering up to 150 watts of power - and interface with its wide range of gearboxes.

Digital incremental encoders can capture motor speed and distance travelled with precision, making them ideal for an extremely diverse range of control applications. Typical uses include coil winding, security camera pan-and-tilt mounts, robotic pick-and-place systems, advertising and lighting displays and similar indexing/positioning devices. Other applications include vending machines; dosing/metering pumps requiring air and/or liquid valve control; analytical instrumentation and other applications where low cost and maximum performance are required.

• Motor, gearbox, encoder and drive package under £100.

10 November, Crewkerne, UK - - - Rotalink has virtually flattened the entry barriers to flexible digital drive systems with the launch of Red Drive. Smaller than a credit card, Red Drive - in conjunction with a dual channel encoder - can control a wide range of DC motors and gearboxes with up to 10A output current, allowing OEMs to create electromechanical positioning systems quickly and economically.

Motor, gearbox, encoder and Red Drive packages cost significantly less than £100 (in quantity). When combined with Rotalink’s simple drag-and-drop flowchart programming methodology that slashes development time, sophisticated control systems are now within easy reach.

Measuring just 46 x 63 x 24mm, Red Drive lets the user control all variables associated with rotational or linear movement, such as speed, acceleration, position, dwell etc. Ten digital I/O connections allow interaction with limit switches, Hall effect sensors, LEDs, buzzers and similar signals – and with other Red Drive controllers to create multi-axis control systems.

No complex programming is required. Windows-based Red Drive software provides an extremely easy to use interface for defining all aspects of the controller. Dragging readily understandable flowchart symbols such as start, accelerate, compare, wait and so on onto the work area allows program structure to be established within minutes. Repetitive sequences can be readily grouped into subroutines and variables provide for simple calculations and loop control.

Step parameters can be set directly from catalogue values, in real world values such as rpm and seconds, or as interactions with I/O signals. Context sensitive tool-tips help the programmer with parameter selection, whilst comprehensive checks and fail-safes built into the software trap many simple errors. Soft start/stop combined with user programmable acceleration sequences simplify the management of high-torque applications.

Over 100 commands, including subroutines, can be stored in the on-board EEPROM enabling complex motion sequences to be programmed. Program transfer through the serial interface to the controller typically takes less than a minute allowing shop floor installation of latest version into final product immediately prior to test and ship.

“Until now, there was simply nothing available at this price and flexibility in this power range anywhere,“ states Melvyn Hazell, Rotalink’s Managing Director. “Red Drive systems fill this gaping void in DC motor control, making this unique and flexible controller the most cost effective way of accessing a dc servo system.”

The launch of Red Drive makes Rotalink a one-stop-shop for complete control systems. Available with most of the company’s DC motors and gearboxes, it allows engineers to develop powerful systems with up to 10Nm of torque that outperform many, more expensive, stepper motors. In addition, its simple programming makes it a compelling design tool, allowing a machine to be exhaustively tested to its limit at the development stage.

• First planetary/spur gear combination in compact ovoid format offers massive torque.

June 16, Crewkerne, UK - - - Rotalink, a world-leader in the design and manufacture of miniature transmission products, has launched two highly cost-effective planetary/spur gearboxes. Fabricated from advanced materials, dedicated gear profiles enable these unique compact units to deliver a massive 10 Nm of flexible torque at a highly competitive cost, significantly enhancing market opportunities for original equipment manufacturers. Key to the massive torque available in the planetary output stage is Rotalink’s unique gear tooth design, which also minimises noise and backlash. Power transfer to the stainless steel output shaft is maximised by the wide choice of ratios available in the spur input stage - up to 12800:1 - coupled with low friction standard front ball race and nylon or steel ball race rear bearings. The zinc-plated pressed steel case’s standard 4-point fixing gives OEMs solid but flexible fixing options.

Gearboxes are the Type 230, delivering up to 5Nm through input ratios from 25:1 to 1000:1, and the 260 delivering up to 10Nm through input ratios from 50:1 to 2000:1, both with alternative input ratios available up to 12800:1.The units are rated at 80°C at the gear case and are available with ac, stepper or dc motors, single or dual line encoders are optional across the range. With the introduction of these miniature gearboxes, Rotalink has successfully used its state-ofthe- art design capability and strategic manufacturing and sourcing to deliver the compact, costeffective product essential to 21st century motion control, automation and system integration OEMs. Typical applications include peristaltic pumps, dispensing equipment, vending machines and similar dosing/metering systems where air and/or liquid valve control is required; analytical instrumentation, semiconductor manufacturing plant and other applications where low cost and maximum performance are required.