Synchronous Controllers (Electronic Shaft or Gearbox) for
 Synchronization of Speeds, Events, Positions, Print Marks

* = instant stock availability

General Information

All synchronization controllers shown on this site operate according to the Master- Slave principle. Where the Master can freely move with any motion profile under control of any remote speed reference, the synchronizer will control one or several Slaves to exactly follow the Master motion in terms of position and speed. 
The control is based on incremental position feedback by means of encoders on both sides. Many applications just use a measuring wheel with encoder instead of a Master drive. It is possible to preset every speed or gear ratio by means of  adjustable  impulse scaling factors.

All units can accept marker pulses from the encoders and from remote proximity switches or photocells, to automatically produce the correct position with pitch or cycle related applications. motrona synchronous controllers can operate with any kind of speed variable drives (AC- inverter, DC, Servo or hydraulic type) that follow to a +/-10V speed reference signal. The extremely fast position control loop provides excellent performance even with highly dynamic applications

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Application Examples (movies):


Film 01
Synchronization of product position with machine cycle

Film 02
Synchronization of a punch roll with pre-printed cardboard

Film 03
Synchronization of individually driven printing screens with a textile printing machine

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BY340* and BY641:
Low-cost Synchronous Controllers for Synchronization
of one Follower Axis

[PDF manual]

• New series of compact synchronous controllers, built into a standard 
  DIN housing and designed for front panel mounting
• Since most affordable in price, these units are also suitable  for use 
  with small machines and limited budgets.
• Full angular and positional control with adjustable gear rations and maximum 
  accuracy by 300 kHz of feedback frequency at a control loop cycle of only 250 μsec.
• Manual and automatic facilities to adjust the phase or relative position 
  between Master and Slave
• Easily operated by means of the front keys or the front thumbwheel switches, 
  or via PC and serial link.
• PROFIBUS communication is possible with use of the PB251 gateway 
  (see accessories)
• With use of SM300/SM600 brackets also suitable for DIN rail mounting 
  (see accessories)

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MC700* Motion-Controller with Firmware BY701*: 
Excellent Multi-Drive Synchronization with Use of Physical or Virtual Master Axis

[PDF manual]

• MC700 is a universal motion controller for 1 to 4 axis, programmable for multiple motion applications by simple download of the corresponding function firmware 
  (see “SUPPORT”).
• With use of our BY701 firmware this unit provides excellent solutions with all kinds of multi-axis synchronizing applications.
• Numerous possibilities for control of relative phase, position, index and print mark evaluation
• Optional operation modes with either a real physical master or an embedded virtual master axis and programmable master speed profiles
• Cascading output for extension to an unlimited number of follower axis
• The MC700 hardware is a black-box unit for cabinet mounting. 
  Remote control and communication facilities via external operator terminal, serial PC communication, CANBUS,  PROFIBUS etc. (see also Accessories)

Controller for Flying Operation (Flying Saws, Shears, Punchers etc.)

* = instant stock availibility

Application examples (movies):

Film 04 (Flying Saw)
Steel profile plant, cut-to-length of steel tubes

Film 05 (Flying Saw)
Cut-to-length of aluminum plates

Film 06 (Flying Saw)
Cut-to-length of steel profile

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Motion-Controller MC700* with Firmware FS701* for
Flying Saws, Flying Shears, Machining “on the fly”

[PDF Manual]

• MC700 is a universal motion controller for 1 to 4 axis, programmable for multiple motion applications by simple download of the corresponding function firmware.
• With use of  firmwares FS701 or CT702 (see SUPPORT) this unit provides excellent solutions with all kinds of flying cut-to-length systems as well as with applications like labeling, printing, punching, sealing etc.
• Functions and properties are very similar to the FS340 controller described below.
• The range of functions includes extended possibilities with evaluation and blanking of print marks, floating print mark registers and more
• The MC700 hardware is a black-box unit for cabinet mounting. 
  Remote control and communication facilities via external operator terminal, serial PC communication, CANBUS,  PROFIBUS etc. (see also Accessories)

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FS340 * /FS641: Compact and Low Priced Motion Controller 
for Machining “On The Fly” like Flying Shears, Saws, Punchers, Cutters etc.

[PDF Manual]

• New stand-alone precision controller for the specific motion profile of Flying Shears and Saws
• Also most suitable for smaller machines with limited budget, due to a very competitive price
• Self-optimizing polynomial speed profile to ensure extremely smooth motion and gentle tool treatment for best service life
• High accuracy and repeatability, even with high line speeds, due to a 300 kHz frequency range of the incremental encoder inputs
• Continuous closed-loop position control with only 250 μsec of cycle time, therefore outstanding dynamic features and high cutting precision even during changes of the line speed
• Suitable for operation with all electric or hydraulic 4-quadrant drives providing a +/- 10V  speed input
• Instantly ready for use, with easy setup and commissioning via Windows PC software (freeware), resulting in successful machine operation within shortest time
• The controller can be operated by means of control keys or thumbwheel switches on the front side, as well as by remote operation terminals or by serial link
• Direct PROFIBUS access is possible with use of gateway model PB251
  (see Accessories)
• Compact DIN housing for front panel mounting
• Optional assembly to DIN rails with use of the mounting supports SM300/ SM600(see Accessories)

Controllers for Rotating Cross Cutters (Paper, Corrugated Board etc.), 
for Rotating Punchers and other Rotary Operations

* = instant stock availibility

Cut-to-Length
Application  Example (Movie):

Film 07 (Rotating cross cutter)
Cut-to-length of corrugated cardboard

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New universal Motion-Controller MC800 with an integrated tandem drive-controller, flexible input configuration for sensors and adaptive interface structure. With firmware CT803 suitable for rotating processes.

[Datasheet PDF]
[PDF manual]

The Multi-Axes-Motion-Controller MC800, a successor of the proven MC700, is convincing by its higher bandwidth and a more flexible bus architecture. A  special feature of the MC800 is the integrated tandem drive-controller. This enables to reach the acceleration requirements of  heavy loads by splitting the necessary power to two independent drives.

• Suitable for incremental encoders or sensors with RS422 output or 10 to 30 V HTL output (differential signals A, /A, B, /B)
• Freely combined with standard SinCos sensors or SinCos encoders with 1 Vpp (format sin+, sin-, cos+, cos-)
• Four fast interrupt based HTL NPN/PNP inputs for control commands
• Two 14 bit analogue inputs with  ±10 V, as well as two similar analogue outputs
• OnBoard interfaces: Ethernet TCP/IP, CANOpen, Modbus RTU, RS232/RS485 interface
• Optional interfaces: e.g. Profinet, EtherCAT, Profibus DP, DeviceNet etc.
• Snap-on module for standard DIN rails (35 mm C-profile)
   
• Synchronous process during penetration of the tool and length dependent speed outside this phase
• Optimizing polynomial speed profile to ensure extremely smooth motion and gentle tool treatment for best service life
• High cutting precision, even at high line speeds, due to a max. 2 MHz feed-back frequency of the incremental input or 1 MHz of the SinCos input
• High dynamic response by means of short cycle time (300 μse), therefore accurate cutting results also during change of line speed
• Suitable to operation with all 4-quadrant drives providing a standardized drive communication bus (e.g. SerCos II) or a ±10 V speed input
• Easy setup and commissioning by use of the Windows based operating software (freeware), resulting in successful machine operation within shortest time
• The controller can communicate with external operation terminals as well as HMI via standardized factory communication bus (e.g. Profinet)
   

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Motion-Controller MC700* with Firmware CT703* for
Rotating Cross Cutters and other Rotary Operations

[PDF Manual]

• MC700 is a universal motion controller for 1 to 4 axis, programmable for multiple motion applications by simple download of the corresponding function firmware.
• With use of the CT703 firmware (see SUPPORT) this unit provides excellent solutions with all kinds of rotating cut-to-length systems as well as with applications like rotary labeling, printing, punching, sealing etc.
• Functions and properties are very similar to the CT340 controllers described below.
• The range of functions includes extended possibilities with evaluation and blanking of print marks, floating print mark registers and more
• The MC700 hardware is a black-box unit for cabinet mounting. 
  Remote control and communication facilities via external operator terminal, serial PC communication, CANBUS,  PROFIBUS etc. (see also Accessories)

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CT340 * /CT641: Compact and Low Priced Motion Controller
for Rotative Machining, Rotating Cross Cutters, Rotary Punchers and Other Intermittent Operations

[PDF Manual]

• New stand-alone precision controller for the specific motion profile of rotative cutting or printing rolls, e.g. for cut-to length or intermittent printing of paper, corrugated board and synthetic materials
• Also most suitable for smaller machines with limited budget, due to a very competitive price
• Speed profile with synchronous operation during tool engagement and asynchronous speed while the tool is free, automatically optimized to the actual length setting
• Self-optimizing polynomial speed profile to ensure extremely smooth motion and gentle tool treatment for best service life
• High accuracy and repeatability, even with high line speeds, due to a 300 kHz frequency range of the incremental encoder inputs
• Continuous closed-loop position control with only 250 μsec of cycle time, therefore outstanding dynamic features and high precision even during changes of the line speed
• Suitable for operation with all 4-quadrant drives providing a +/- 10V  speed input
• Instantly ready for use, with easy setup and commissioning via Windows PC software (freeware), resulting in successful machine operation within shortest time
• The controller can be operated by means of control keys or thumbwheel switches on the front side, as well as by remote operation terminals or by serial link
• Direct PROFIBUS access is possible with use of gateway model PB251 
  (see Accessories)
• Compact DIN housing for front panel mounting
• Optional assembly to DIN rails with use of the mounting supports SM300/ SM600(see Accessories)

Controller for Rotary Shears and Eccentric Shears, 
for Use with Cut-to-Length Lines in Coil Steel Industry

* = instant stock availibility

Film 08: Rotary Shear and cut-to-length line

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MC700* Motion-Controller with Firmware CT701*: 
Outstanding Performance with Rotary Cut-to-Length Shears

[PDF Manual]

• MC700 is a universal motion controller for 1 to 4 axis, programmable for multiple motion applications by simple download of the corresponding function firmware.
• With use of our CT701 firmware (see “SUPPORT”) this unit provides excellent solutions with all kinds of guillotine cutters and rotary eccentric shears needing a cosine-compensated speed profile during the penetration of the tool.
• Extremely smooth motion  to protect  mechanical solution, by self-optimizing polynomial speed transitions
• High cutting accuracy, even during line acceleration and at high speeds
• Programmable cosine-compensated speed profile
• Special torque control features to master the impact load when cutting hard materials like stainless steel etc.
• Special profile features to avoid deadlock between tool and material
• Embedded virtual master axis (selectable)
• Black-box unit for cabinet mounting.
• Remote control and communication facilities via external operator terminal, serial PC communication, CANBUS,  PROFIBUS etc (see “Accessories”) 

Controller for Tubular Bag Packing Machines (Pillow Type Packing)

* = instant stock availibility

Application Example (movie):

Film 09 (Tubular Bag Machine)
Packing and sealing of choco bars

Motion-Controller MC700* with Firmware TB701*: 
Perfect Solutions for Control of Tubular Bag Packing Machines (Pillow Packing)

• MC700 is a universal motion controller for 1 to 4 axis, programmable for multiple motion applications by simple download of the corresponding function firmware.
• With use of our TB701 firmware (see SUPPORT) this unit provides simple but perfect solutions with most types of tubular bag type packing machines.
• The controller provides full speed and position control of all drives involved 
  (feed-in chain, foil drive with or without print mark evaluation, sealing roll drive)
• This system is able to achieve very high sealing rates, due to excellent dynamic performance of the controller (adequate servo drives assumed)
• The tubular bag controller is able to detect missing products, missing or wrong print marks and even wrong position of shifted products. In every of these cases the drives will respond correspondingly.
• Extremely soft and still highly dynamic motion profiles provide best accuracy and protection of mechanics, even with high speeds and sealing rates
• MC700 hardware.is a black-box unit for cabinet mounting. 
  Remote control and communication facilities via external operator terminal, serial PC communication, CANBUS,  PROFIBUS etc. (see also Accessories)

Controller for Winding, Wire Traverse and Tension Control
(Winding Calculator, Tension Controller)

* = instant stock availibility

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Motion-Controller MC700* with Firmware WR701*: 
Compact and Advantageous Solutions for Many Common Winding Applications

• MC700 is a universal motion controller for 1 to 4 axis, programmable for multiple motion applications by simple download of the corresponding function firmware.
• With use of our WR701 firmware (see SUPPORT) this unit provides advantageous solutions with many common applications of winding, rewinding, traverse and tension control.
• Different from most other winding controls, the principle of this system is not based on torque control, but uses high-precision speed control with special real-time diameter calculations. For this reason the controller provides superior features with fast start-stop-start cycle on rewinding machines,  and also  with applications requiring low tension or even tension-free winding characteristics
• Black-box unit for cabinet mounting.
• Remote control and communication facilities via external operator terminal, serial PC communication, CANBUS,  PROFIBUS etc (see “Accessories”) 

Motion Controller for Intermittent Printing, Label Printing,

Rotary Punching etc.

* = instant stock availibility

Application Example (movie):  Film 10 (Label Printing) Intermittent printing of bottle labels

Motion Controller MC700*: Compact and advantageous solutions for many applications  
in the field of Printing, Punching, Labeling

• MC700 is a universal motion controller for 1 to 4 axis, programmable for multiple motion applications by simple download of the corresponding function firmware.
• motrona has developed motion control firmware for many typical applications in the field of printing, punching and labeling. Our solutions are proved and tested and immediately ready to work.
   

Please ask our engineers for your specific application.
They will will be happy to advise you.