Smart drive.

With its new DualGear, FAULHABER presents a high-performance drive system which combines tried-and-tested BX4 and GPT technology in a single, well thought-out unit. Developed for the demands of modern conveying systems, the DualGear provides high dynamics, robustness and precision in a compact, diameter-compliant design.

The DualGear drive system has been specifically designed for applications in conveyor belts as well as in compact wheel drives of autonomous logistics systems. Especially in intralogistics environments where space is limited, the system offers a high-performance and economical solution. A particular advantage is its versatility: Two synchronous movements can be realised with one drive. This reduces integration effort significantly, while at the same time optimising installation space and system costs.

Powerful combination of BX4 and GPT Technology.
The new drive system combines two high-performance partners in a compact unit: the powerful and dynamic brushless 32 mm motor from the tried-and-tested BX4 family and two diameter-compliant mounted, robust metal planetary gearheads from the GPT series at both ends of the motor.

The BX4 base motor for the DualGear combination is available in two motor lengths with 42 mm and 68 mm. This allows the drive system to be flexibly adapted to different performance and installation space requirements. Hall sensors with sine/cosine output signals enable precise detection of the rotor position for exact commutation and positioning. In combination with an external motion controller, accurate positioning movement is possible, resulting in a drive system that combines torque and maximum accuracy with a compact design.

In this combination, the GPT planetary gearheads are available with up to three stages, which enables exact dimensioning with respect to speed and torque requirements. The components have only welded joints to ensure reliable and durable construction without the use of adhesives.

Upgrade for Conveying and Intralogistics Systems.
Modern conveying and logistics systems require dynamic, durable and integratable drive solutions. The DualGear meets these requirements thanks to its robust design, high control accuracy and long service life. The possibility of realising two synchronous, powerful movements with just one drive and a central control, creates new approaches for efficient, simple system architectures in the next generation of conveying and intralogistics systems.

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Robotics: Ready for the next generation.

Into the future of drive technology with new dimensions and features for robotics.

Human-like movements place extremely high demands on precision, force and dynamics––from delicate grip movements to powerful, coordinated joint movements. This is where the FAULHABER BXI steps in. The internal rotor motor of the 9317 BXI G series combines robustness and exceptional compactness and defines new standards for integrated drive systems in robotics. With a maximum torque of up to 20 Nm, it enables dynamic movements, fast reaction times and a highly precise movement control.

The motor covers a voltage range of up to 50 V and, thanks to the available interfaces and an installation length of just 34 mm, is easy to integrate in existing system architectures. The BXI is thereby especially well suited for applications in which every millimeter, every gram and––above all––high power density are decisive, e.g., as a compact joint drive in humanoid robots.

Maximum performance with minimum space requirements.
The drive system forms a functional unit made up of motor, integrated stepped planetary gearhead and high-resolution encoder. Its special strength lies in the systematic integration: maximum performance with minimum space requirements. The flat aluminum housing offers corrosion resistance and also supports optimized thermal dissipation. The internal rotor construction with 21 pole pairs, grooved stator and iron-core winding ensures a low cogging torque and a high torque density. The integrated absolute encoder with 15-bit SSI, line driver and compensation algorithm performs the precise positioning, is resistant to interference and makes a significant contribution to the reliability and accuracy of the entire system.

Perfectly matched to the overall system.
In combination with the FAULHABER MC5010 Motion Controller, an optimally matched overall system is created for torque-sensitive and highly precise positioning tasks. At the same time, motor and drive are reliably protected, while commissioning is particularly simple and efficient thanks to the Motion Manager software. The FAULHABER BXI thus offers a high-performance, future-oriented solution for demanding robotic applications in which innovation, application and new technology interact seamlessly.

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Co-operation leads to smallest intelligent motor!

The two companies, Dr. Fritz Faulhaber GmbH & Co. KG from Schönaich, (D), and Technosoft SA from Neuchâtel (CH), have combined their skills and knowledge to produce one of the world’s smallest intelligent motors for speed and position control with EtherCAT com-munication, which complies with CoE (CAN application protocol over EtherCAT).

The motor is based on the highly successful 32....BX Brushless DC 4-pole technology Servomotors using the FAULHABER® ironless stator system and a dynamically balanced rotor, resulting in a no-cogging output, which is ideal for low inertia loads.

The controller is of modular design and compact construction, for high reliability, and incorporates the iPOS4808 controller which utilises Technosoft’s MotionChip™ technology and offers 7 I/Os. The configuration, tuning and local programming of the iPOS drive can easily be done using Technosoft’s powerful graphical platform EasyMotion Studio. The position sensor is absolute single-turn providing 4096 counts per revolution for accurate speed and position control, down to 5 arc minutes.

Alongside the EtherCAT version, there are two CAN versions: the standard CANopen protocol, in accordance to the CiA 301, 305 and 402 profiles, and the TMLCAN protocol. The Technosoft Motion Language (TML) opens the possibility to use the powerful motion controller, allowing it to operate as an independent intelligent device (e.g., customise any homing routine to match the application needs). Stand-alone single or multi-axis applications with communication between drives (without the need of a CAN master) are possible, while various types of CAN masters are also supported with an extended set of Technosoft Motion Control Libraries.

This intelligent motor has a maximum speed of 6000 rpm and a stall torque of 97 mNM, which is achieved from a motor with a diameter of 32 mm and the maximum length of the integrated unit is a mere 92.8 mm. The controller is housed in an oblong, which is 46.5 mm x 67 mm, with a depth of 26 mm. There are six families of Faulhaber gearheads that are available for fitting to the motor, depending on the requirements of the application.

An intelligent motor can be used in many applications, but it has been developed for medical analysis and dosing machines, pick and place and welding robots, instrumentation and optical equipment, unmanned military vehicles, packaging bottling and labelling machines.

The world´s smallest brushless motor with integrated motion controller

The well-known BX4 family of brushless DC servo motors from Faulhaber has an innovative new member. With a 22 mm module, the 2232/2250...BX4 CSD/CCD is the world´s smallest brushless motor with integrated motion controller in uniform-diameter construction. It combines all the advantages of BX4 technology in a tiny package: long service life, high non-cogging torque and freedom from adhesives. This makes them ideal for use in demanding application areas such as robotics, automation, medical technology, specialty machinery and the aerospace industry.

The drives are based on proven their motion control systems. With their compact, uniform-diameter construction and suitable gearing combinations, they provide the ideal drive solution for a wide variety of applications. The drives have serial RS232 or CAN interfaces and can be configured using FAULHABER Motion Manager 4.4 software. Additional features of the new drives further expand their scope of use: a wide temperature range of -25 to +85 °C, thermally allowable continuous current up to 0.69 A, and flexibly configurable speed in the range of 5 to 8000 rpm. The units are also available with customer-specific software on request.

All products with integrated electronics have automatic peak and continuous current limitation to protect the motor and the electronics. Operation of the motor and the electronics from separate supply voltages is possible as an option.

The new drives are available in two motor lengths (32 and 50 mm) with a rated voltage of 24 V DC. Outstanding features of these innovative new products are an extremely flat torque versus speed curve and an excellent torque to volume ratio, with torque output of 18 to 35 mNm.