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DC-Motors
No cogging torque
Smooth position and speed control
Very low rotor inertia
Dynamic start-stop operation
FAULHABER S/G
Low torque ripple and high efficiency
Wide operating temperature range
Low current and starting voltage
FAULHABER SR
Powerful rare-earth magnets
Wide operating temperature range: -30 °C to +85 °C (optional -55 °C to +125 °C)
All-steel housing with corrosion-resistant coating
Extremely compact and lightweight design with integrated encoder
FAULHABER CXR
Highly dynamic performance due to a low rotor inertia
Shockproof all-steel housing with corrosion-resistant coating
Powerful rare-earth magnet
Wide operating temperature range: -30°C to +100°C (optional -55°C)
Durable graphite commutation
No cogging
Very high power density
FAULHABER CR
Best dynamic performance due to a low rotor inertia
Extremely wide operating temperature range -30 °C to 125 °C (optionally -55 °C, winding up to 155 °C)
Highest power density
FAULHABER SR-Flat
Extremely flat design. Lengths ranging from 6 mm to 19 mm
4-pole design
Minimal moment of inertia
Integrated spur gearheads of minimal length with high gear ratio are available
Available with integrated optical encoders
Brushless DC-Motors
High efficiency slotless design
High-torque or high-speed with small size and low weight
Highly dynamic acceleration and deceleration
Available with a wide range of sensor options or sensorless
FAULHABER B-Micro
Extremely compact design. Diameters ranging from 3 mm to 5 mm
For applications where space is very limited
2-pole design with medium to high speeds
Matching, highly compact gearheads available
Matching speed controllers available
FAULHABER B
High density ironless system FAULHABER winding
Digital or analog hall sensors available
Extremely smooth speed control
Sensitive positioning control
FAULHABER BHx
Large power up to 96 W in small diameter
High speed close to 100'000 min-1 (BHS version)
Huge impulsive torque > 30 mNm (BHT version)
Very dynamic and responsive with low inertia
Low vibration and low noise, suitable for handtools
Optional integrated encoder
FAULHABER BX4
High torque and speed rigidity thanks to 4-pole technology
Position control in extremely confined installation spaces thanks to optional analogue Hall sensors
Modular, diameter-compliant mounting concept for high-resolution magnetic and optical encoders
Versions with integrated Speed or Motion Controllers available
High reliability and long service life
Dynamically balanced rotor, quiet running
FAULHABER BP4
High-power motors with maximum torque
Continuous output from 133 W to 150 W
Outstanding ratio of torque to weight and size
Very high efficiency of up to 91 %
Fully integrated analogue Hall sensors and matching encoders, gearheads and controllers are available
For dynamic start/stop operation
FAULHABER B-Flat
Electronic commutation using three digital Hall sensors
Precise speed control
FAULHABER BXT
External rotor motors with very high torque
Continuous output up to 100 W
Flat design for space-critical applications. Length range of 14 to 21 mm.
Matching optical and magnetic encoders, gearheads and controls available
14-pole construction
Motors with integrated Electronics
Integrated drive electronics
Extremely compact
Very robust construction
Integrated current limiting
Control parameters can be tuned to the application
FAULHABER BRC
Programmable motor characteristics through integrated speed controller
Outstanding reliability, long service life
Wide, more linear speed/torque range
Smooth running
FAULHABER BX4 SC
Speed control in tight installation spaces; thanks to optional analogue Hall sensors, also available in the low speed range from 50 min-1
Modular, diameter-compliant mounting concept with integrated current limitation
Simple and convenient programming using the Motion Manager and programming adapter
FAULHABER BXT SC
High torque and speed rigidity thanks to 14-pole technology
Speed control in tight installation spaces; thanks to the high number of poles of the motors, also available in the low speed range from 200 rpm
Second shaft end available in sizes 32 and 42 mm
FAULHABER B-Flat SC
Extremely flat design. Lengths ranging from 10 mm to 22 mm with speed controller already integrated
FAULHABER B Cx
Wide speed range from 1 to 14,000 min-1
RS232 or CANopen interface, adapter for connection to USB interface
Compact mounting concept with integrated current limitation
Minimal wiring requirements
Smooth running operation
FAULHABER BX4 CxD/Cx
FAULHABER MCS
Maximum torque in compact installation space
Interfaces: RS232, CANopen, EtherCAT, configuration via USB
Optionally available with protection class IP 54
Standardised plug and connection cable concept
Can be universally used in slave or stand-alone operation
Extensive protective and diagnostic functions, local status LEDs
Linear DC-Servomotors
Excellent force to volume ratio
No residual force present
Non-magnetic metal housing
Compact and robust construction
No lubrication required
Simple installation and configuration
Extremely low rotor inertia
High power density
Long operational lifetimes
Wide operational temperature range
Ideally suited for micro-stepping applications
High force output
Backlash free
Nanometer resolution
Precision Gearheads
Available in a wide variety of reduction ratios
Zero backlash versions are available
Available with a variety of shaft bearings including sintered, ceramic, and ball bearings
Available in all plastic or metal versions
Use of high performance plastic and ceramic materials
Modified versions for extended temperature and special environmental conditions are available
Custom modifications available
Spur Gearheads and Spur Gearheads zero backlash
Available in a wide variety of reduction ratios including very high ratios
Linear Components
Customized versions with special lubrication for extended application areas
High positioning accuracy thanks to considerably reduced play
Lead Screws and Options
High resolution of up to 40 000 steps per rotation (corresponds to a 0.009° angle resolution)
No pull-up resistors are necessary at the outputs because there are no open collector outputs
Symmetric switching edges, CMOS and TTL-compatible
Different resolutions, according to type, from 16 to 10 000 pulses, are available for standard delivery
Various resolutions available as standard feature
Also available as Line driver version
Index channel for referencing a rotation of the drive shaft
Flexible customer-specific modifications including custom resolution, direction of rotation, index pulse width and index position are possible
High signal quality
Minimal wiring requirement
Absolute angle information directly after power-on
No referencing necessary
Enhanced control characteristics even at low rotational speeds
Flexible customisation of resolution and direction of rotation is possible
Precise and dynamic control
Flexible configuration for different motor types
Configuration via USB interface adapter
Easy to use Motion Manager software
Flexible reconfiguration capacity
Minimal wiring required
Parameter setting using FAULHABER Motion Manager software and USB interface adapter
Controlled via RS232, EtherCAT or CAN interface
Parametrization with "FAULHABER Motion Manager" software and USB interface
Simple start-up
Transfer of real-time data
Optimal signal power without cable-related interference
Pre-assembled system cables – Fast and easy wiring, error-free connection, innovative and time-saving connection solution for devices
Simple and fast connections with various connection options
Fast data connection between defined devices
Adapters with plug-in or screw connectors
The coronavirus and the disease it causes, COVID-19, have the world on edge. The number of people who have fallen ill and who have tested positive for the virus continues to rise. To slow the spread of the pandemic, measures – some of which are very drastic – are being taken around the world. At the same time, laboratory and diagnostic capacities are being created and expanded to allow tests to be analyzed faster and to perform research using antibodies and immunity data to help develop vaccines.
The need for ventilation systems around the world has increased rapidly in a just a very short time, with many countries currently stocking up and expanding their capacities. To ensure the supply with oxygen, so-called CPAP (continuous positive air pressure) machines are being used in non-invasive cases to support breathing.
Personal protective equipment (PAPR)
Respiratory protection is an especially important part of personal protective equipment. After all, the virus spreads through respiratory droplet transmission. Closed PAPR systems (powered air-purifying respirators) provide ideal protection for medical personnel. Wearable ventilation systems provide filtered, contaminate- free air via a fan.
An expansion of testing capacities is considered an important part in the fight against COVID-19. The more tests that are performed, the more that is learned about the virus. For people experiencing potential symptoms of COVID-19, it's critical that these individuals have access to quick, accurate testing resources to confirm the suspected diagnosis, and also to identify an effective prognosis.
Point-of-care (PoC) analysis
If results need to be available promptly so that decisions can be quickly made in, e.g., intensive care units, outpatient departments or doctors' practices on the basis of laboratory values, so-called point-of-care test are called for. These are used to detect parameters such as heart enzymes and blood values on-site or can be used with PCR tests to quickly verify the presence of pathogens like SARS-CoV-2 on swabs.
Infrared thermometry
Shown in simplified form, a lens in an infrared thermometer focuses the thermal energy of an object, e.g., a building, a person or an animal, onto a detector. The associated thermal radiation is converted into electrical signals and ultimately into an image or a numerical value. Thus the operator of the device can quickly identify the temperature in a room, or in the case of COVID-19, the detector can indicate an elevated temperature or fever of an infected individual.
The tasks of analytical devices and machines used in laboratories are becoming increasingly sophisticated. Precision and speed are important requirements despite the compact dimensions. FAULHABER with its wide variety of dynamic miniature and micro drives offers custom-made solutions.
Surgical robot
After taking over industry, robots are now conquering the medical sciences. The advantages are obvious: absence of fatigue, maximum precision and speed, optimum ergonomics. Experts see their use as the next evolution in the treatment of patients. Already today, robot systems are used in a number of surgical applications, such as in orthopaedics, in neurology or in cardiothoracic and ENT surgery.
Countless samples are tested daily in analytical laboratories. The benefits of automation in this area is obvious: They make it possible to achieve faster results, higher throughput, fewer errors and lower personnel costs. In order to ensure smooth operation, high dynamics and precision are extremely important for the drive systems.
Myoelectric prosthesis
Tie shoelaces, fold bed linen, tear open a bag of crisps – the list of things that are difficult to do with one hand goes on and on. People with a congenital amputation or who have lost a hand due to an accident are confronted with such obstacles every day. To make daily life easier, the British company Steeper developed the Bebionic myoelectric hand prosthesis.
Factory Automation & Robotics
Various actuators and sensors are integrated in automated manufacturing applications. The linking together of these components and the commissioning of the systems must take place simply and quickly. FAULHABER drive systems can be configured conveniently and integrated easily and securely using standardised interfaces.
The central technical element of our modern world is the microchip. From the coffee machine to communication satellites, there is practically nothing that would function without it. Thus, the manufacture of microelectronic components is a key technology par excellence. Motors from FAULHABER play a role in all important steps here – from the processing of the silicon crystal to the assembly of PCBs.
Picker robot TORU
Microdrives and Motion Controllers from FAULHABER are what make the TORU picker robot from Magazino so versatile. With an eye to the constantly growing sector of online retail, logistics and material flow are coveted playing fields for technical progress – with the goal of increasing effi ciency through automation and digitalisation.
Small parts gripper
A small gripping system that is both quick and powerful – up to now, that was often only possible with pneumatics. Because with compressed air, large amounts of pressure can be conveyed virtually without any time lag. A compressed air supply requires a complex infrastructure, however, and having to provide it for every production step is diffi cult and expensive.
Precision Monitoring & Measuring
Accuracy and resolution in the micrometer range as well as exactly reproducible test procedures are required in modern measurement and testing technology. Here, FAULHABER drive systems provide precise control dynamics and a high power density in a minimum amount of space.
The miniaturization trend extends across all industries; however, the ever-decreasing product sizes are a challenge to the automation technology, e.g. when it comes to accurately applying the correct amount of soldering paste, adhesive, lubricant, potting material or sealant.
Broadband seismometers
Imagine a bar that extends from Zurich to Tokyo, more than 10,000 kilometres. Now someone in Tokyo slides a piece of paper beneath it. The seismometer at the Zurich end then reacts and precisely indicates the minimal change to the inclination angle.
Test systems for car doors
Product life cycles are becoming shorter in all areas of industry. New products appear on the market faster and faster. This trend is particularly evident in the automotive sector. While not so long ago it still took seven to eight years before a vehicle was ready for production, today it is just two-and-a-half to three years.
Industrial machines are becoming ever more complex with regard to functionality and design, while their size remains the same. FAULHABER motion control systems provide the full range of functions of complete positioning systems with minimum space and wiring requirements.
ViscoQuick
From smooth and creamy to light and fluffy to thick and sticky – with foods, our mouthfeel provides reliable information about consistency. Spit out or swallow? We make this decision in just a fraction of a second. In industry, one would gladly have decisions that could be made as quickly and easily. In many sectors, viscosity tests are necessary during production in order to define and maintain optimum process parameters.
Sensor Screwdriver
Every handyman intuitively knows how to tighten a screw: according to feel. In the hobby room, this is generally sufficient for achieving the correct amount of tightening torque. In industrial production, on the other hand, the demand for secure screw fixing is much greater because the intention is to ensure that the end product remains functional until the end of its service life.
Laser beams can melt and even vaporise metals highly efficiently and very precisely. For this reason, they are increasingly used as a tool for joining components, namely for welding and soldering e.g. in the automotive industry. Normally, laser devices – like conventional welding torches – have a single focal point or "spot".
In space or in civil aviation – the components used in this environment are subjected to extremely high mechanical stress but must still operate perfectly. FAULHABER drive solutions function reliably in a vacuum and at extremely low temperatures, and ensure safety and comfort for air travel.
Mars Rover
2020 is the year of the next Rover mission to Mars. The main payload of the Russian Proton rocket: the ExoMars Rover, developed by the European and Russian Space Agencies (ESA & Roskosmos). The plan is for the vehicle to be equipped with nine measuring instruments. Including one that will be mounted on a two-meter mast on the rover.
Cabin equipment
In 2011 there were 15,556 passenger planes and almost as many private jets in operation worldwide. If predictions prove correct, this figure is set to double in the next fifteen years. At the same time there is a marked trend towards equipping aircraft cabins with additional features that provide comfort at the push of a button. This will require an increasing number of small electric motors which, of course, must be as reliable, light and powerful as possible.
Control rocket fuel valves
Amid tightening budgets, space agencies are increasingly looking to the commercial space sector to provide the launch vehicles of the future. Some companies now offer highly reliable and economically viable launch vehicles which can send a large variety of payloads into Earth orbit.
Adjusting optical lenses for zooming and focusing or the adjustment of mirrors in laser applications require maximum precision in the smallest possible installation space. Here, FAULHABER drive systems provide full functionality in compact form.
What is going on in the neighbourhood? We all want to know, whether we admit it or not. Applied to the whole of humanity and Earth, the question is: What is going on in the Milky Way? We know surprisingly little about this, because we literally have a hard time seeing the wood for the trees. But the MOONS project initiated by British astronomers aims to change this.
Pulsed-laser beams
If you turn on your pocket torch for just a second and point it towards the sky, your beam reaches all the way to the moon. How fast would you need to switch the torch on and off in order for the beam to be shorter than the thickness of a human hair? It's not something you could accomplish with your thumb, that much is certain.
X-ray optics
When Wilhelm Röntgen discovered and investigated the X-ray in the late 19th century, he was one of the few pioneers in the field who routinely used protective lead shields. He may not have known the precise reasons why, but he suspected that this kind of radiation was not good for human health – and his suspicions were well founded.
Camera, Audio & Data
Speed and flexibility are particularly important factors in film recording and everyday TV business. Drive technology for modern camera technology is therefore subject to specific requirements. FAULHABER drive systems convince with their dynamic movement and compact power combined with minimum mass and maximum efficiency.
Modern electronic cameras are opening the door for totally new photographic possibilities, both for photos taken in situ and for post image processing. By combining the high resolution and rapid shot frequency that can be achieved nowadays with a "rotating turntable", so-called panorama shots can easily be compiled. The basis for this, along with a top-quality photographic device, is optimal camera or lens focusing over the swivel range.
Camera set up
In the rugged environment of the ocean, making brilliant films is far from easy. To shoot the "OCEANS" documentary, French film company "Galatée Films" therefore required some advances to be made to existing camera technology. The challenge of creating the necessary camera stability to ensure shudder-free images could be shot from a permanently shaky surface was a particularly difficult task for the developers.
Scientific analysis and development often means having to overcome extreme conditions in order to obtain data. FAULHABER drive systems operate with extreme precision and absolute reliability even in the most inhospitable environments.
Charging robot
While electric mobility is becoming ever more popular, there is still room for developing functional standard technologies in some areas. One such example is the way cars are charged: nobody wants to see streets littered with charging stations. And while inductive charging is largely hidden from view, it comes with some significant disadvantages.
Electronic Partner for Individual Climbing (EPIC)
Typically when climbing, it is essential to have a belayer. Provided that he does not make a mistake, the climber's fall will be arrested by the rope after one or two meters. Since the climber mostly takes care for his own self-interest, the occasions when this happens are few and far between.
Energy kites
An innovative approach, which harvests wind power through the use of comparatively small turbines by means of steerable kites, is setting new standards. Microdrives support the fully automatic control of the kite.
Modelling & Prototyping
The fundamental requirement placed on models and prototypes is always replication in true-to-scale miniaturisation with the highest possible accuracy with regard to shape, function and technical equipment. As compact drive solutions, FAULHABER drive systems ensure prototypical, precise movements.
Driveless Racing Car
Driverless driving is a topic which is currently attracting a great deal of attention from experts and media alike. Driverless racing cars have now competed against each other for the first time in "Formula Student Driverless" in August 2017 in the "Formula Student Germany" competition at the Hockenheimring (Baden-Württemberg).
Visit the most diverse regions of the world in just a single day: explore Las Vegas, the Alps or the Norwegian fjords in only a few hours − it is possible in the Miniatur Wunderland. Located directly along the Elbe river in Hamburg's Speicherstadt (traditional warehouse district), it features the largest model railway in the world and is one of the most exciting tourist attractions in Germany.
Commercial Vehicle Replicas
True to the original replicas of commercial vehicles not only gladden the heart of any model car collector but also find increasing use as simulation vehicles for high-quality industrial products – provided, that is, they match the form, function and technical specifications of the original as closely as possible.
Electronically controlled movements can be found almost everywhere. The huge variety of miniature motors mirrors the broad spectrum of potential applications. In the field of miniature drives in particular, FAULHABER offers a range of powerful standard products that can easily master tasks in everyday applications.
It goes without saying that the bicycle is a part of locomotion culture in Germany. 97 percent of people in Germany can ride a bike. They use bicycles not only for bike tours in their free time but also on a daily basis for shopping or commuting to work. Due to rising petrol costs and the constantly congested roads at peak times, residents of large cities in particular see the bicycle as a true alternative to the automobile.
Kinetic sculpture "Project Anthozoa"
Flowing, living movement without cogging torques, a strictly linear force-current ratio, high dynamics, exact position control: thanks to these properties, the linear DC-servomotors from FAULHABER are ideal for micropositioning tasks – or for bringing a fascinating work of art to life. The kinetic sculpture "Project Anthozoa" – a collaboration between MKT AG, flying saucer GmbH and FAULHABER.
A combination of exercise, relaxation and a sporting challenge - these are the things that motivate golfers when they step onto the green. The golfer's most important companion is a lightweight and manoeuvrable golf trolley. The latest models assist their owners as E-caddies, like the TiCad Liberty, the premium golf trolley from manufacturer TiCad.
Find answers to frequently asked questions, specific information about your products and their usage, downloads like the Motion Manager or special PLC configuration files.
Application Notes for Drive Electronics
Application Notes are available for the Speed Controllers, Motion Controllers V 2.5 and Motion Controllers V3.0. Most of the Application Notes for a specific platform will also address the integrated Speed- or MotionControl Systems.
Drive Electronic FAQ
In case of any odd behavior of your drive you might want to check this section. We are updating the questions and answers whenever we come across an interesting answer in our daily support.
The download section collects some files like Programming examples, the latest controller firmware and its version information. If we do have a beta-version of our controller firmware we will publish it here too. You can also find the latest Motion Manager here.
Documentation for Drive Electronics
The operating instructions and manuals for our extensive range of electronic products.
Find additional information about gearheads and their application. If you need assistance during commissioning of any of these motors try and contact our support here.
Gearhead FAQ
In case of any odd behavior of your gearheads you might want to check this section. We are updating the questions and answers whenever we come across an interesting answer in our daily
Application Notes for Encoders & Sensors
Application Notes are available for different types of our encoders and interfaces like digital hall, incremental encoder or the absolute encoder.
Encoder FAQ
In case of any odd behavior of your encoder you might want to check this section. We are updating the questions and answers whenever we come across an interesting answer in our daily support.
Documentation for Encoders
Find the explanations to use and understand our datasheets. This is single document which collects all the technical information as given in our catalogue.
Find additional information about Linear Motors or Stepper Motors and their application. If you need assistance during commissioning of any of these motors try and contact our support here.
Motor Application Notes
Application Notes offering in deep information beyond the datasheet are available for some of our motor series.
Documentation for Motors
Find the explanations to use and understand our datasheets. This is single document which collects all the technical information as given in our catalog.
Motor FAQ
In case of any odd behavior of your motor you might want to check this section. We are updating the questions and answers whenever we come across an interesting answer in our daily support.
Download white papers and technical articles for support documentation and overview information about coreless (brush) DC motor technology and FAULHABER stepper motors.
Are you looking for additional information? Learn more about our innovative market solutions, read our company magazine "motion", flip through our latest catalog or obtain additional technical information.
FAULHABER Catalogue / Shortform
On more than 650 pages, FAULHABER presents the most comprehensive portfolio of highly developed miniature and micro drive technology that is available from a single source worldwide in the new 2020 – 2021 catalogue.
FAULHABER motion
The FAULHABER motion is the company magazine from FAULHABER with interesting stories about applications with FAULHABER products, technology articles, product news, and much more. The FAULHABER motion is published twice a year and is delivered to customers and interested parties free of charge.
FAULHABER Market solutions
Each customer has specific needs and requests that should be acknowledged. With our established and comprehensive knowledge of markets, we can offer you the best and most appropriate products, services, and solutions that can effectively and efficiently be used in your market.
In this document you will find detailed explanations of the technical information provided for the various drive components, calculation examples and detailed descriptions concerning the design of motors, gearheads, linear components, encoders and drive electronics.
Product Conformity
Information and documents on the conformity of the FAULHABER product line with respect to currently applicable directives and regulations as well as ISO certificates available for download.
REACH stands for "Registration, Evaluation, Authorisation and Restriction of Chemicals" and took effect on 1 June 2007 with regulation (EC) no. 1907/2006. REACH is a regulation of the European Union adopted for the purpose of better protecting human health and the environment from the risks that can arise from chemicals.
Directive 2011/65/EU of the European Parliament and the Council on restricting the use of certain hazardous substances in electrical and electronic devices (the so-called RoHS directive) regulates certain conditions for bringing electrical and electronic devices into circulation.
FAULHABER declares with the EC Declaration of Conformity that the products listed here fulfill the essential protection requirements defined within the directive mentioned in each case.
For FAULHABER, quality assurance is not just a technical certification but also an employee philosophy. An atmosphere of solution oriented cooperation and dialog contribute to the total quality consciousness that is embodied by each and every employee in our Group.
The term 'conflict minerals' refers to the metals tin, tungsten, tantalum and gold, from the Democratic Republic of Congo and its neighbouring countries. These metals are also referred to as the 3TG. Trading 3TG from the Democratic Republic of Congo and its neighbouring states enables armed conflict and human rights abuses.
FAULHABER Motion Manager
The "FAULHABER Motion Manager" software provides the user with comprehensive support for start-up and configuration of FAULHABER drive controls. The graphical user interface makes uniform and intuitive procedures possible independent of the device family and interface used.
The operating instructions and manuals for our extensive range of electronic products including our drive systems with integrated electronics are available for download. Current instruction manual versions are available in our product selector in the download area of the respective product.
FAULHABER - the international specialist for high-quality drive systems, values the high-quality materials and sophisticated technology from its suppliers. What is important to us as an innovative company is a well-organised and efficient supplier management consisting of the following processes:
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FAULHABER press area
About FAULHABER
DR. FRITZ FAULHABER GMBH & CO. KG (DE)
FAULHABER MINIMOTOR SA (CH)
FAULHABER MICROMO LLC (USA)
FAULHABER PRECISTEP SA (CH)
FAULHABER Motors Hungaria Kft. (HU)
FAULHABER Motors Romania S.R.L. (RO)
FAULHABER Drive System Technology (Taicang) Co. Ltd. (CN)
FAULHABER Benelux B.V. (NL)
FAULHABER France SAS (FR)
FAULHABER Austria GmbH (AT)
FAULHABER Polska sp. z o.o. (PL)
FAULHABER Asia Pacific Pte Ltd.
FAULHABER Malaysia Sdn Bhd (MY)
FAULHABER Italia S.r.l. (IT)
FAULHABER GROUP
FAULHABER Worldwide
E-mail encryption
eCommerce Frequently Asked Questions
Climb without belayer partner
Typically when climbing, it is essential to have a belayer. Provided that he does not make a mistake, the climber's fall will be arrested by the rope after one or two meters. Since the climber mostly takes care for his own self-interest, the occasions when this happens are few and far between. However, the belayer must always be vigilant when professional climbers are carrying out corrosion protection work, maintaining telecommunication masts, constructing overhead cable systems or working on crane booms. Anyhow, it was until recently. Now, a leading manufacturer of fall protection has brought the first automatic belayer onto the global market. The specialists have worked closely with a young Munich based company. With the aid of the fallback system the climber can safely climb without a second person. Here, two powerful DC-Micromotors play a key role.
The story of the electronic belay partner EPIC (Electronic Partner for Individual Climbing) began seven years ago at the University of Regensburg. Florian Widmesser, engineering student and enthusiastic climber, developed the concept of automatic securing as part of his thesis. Even at this stage, the drive specialist FAULHABER (cf. company box) was assisting the inventor with motor expertise. Widmesser founded Auroco GmbH together with business studies graduate Jan Lohse in 2011. With the idea to bring fully-automatic rope protection for industry and leisure climbing onto the market, both founders approached Skylotec. The company from Neuwied is among the leading manufacturers of personal protective equipment for fall and fallback systems in the area of sport and industry. A year later, the first prototype emerged and the reliability of the newly-developed securing technology was confirmed with DEKRA certification in 2014. The company has now undergone significant growth due to crowd funding and an outstanding reaction to the product. Use of the devices in practice and sales for different application areas are currently on Skylotec's priority list.
Safety for lead climbing, second climbing and abseiling
EPIC is the first automatic fallback system for climbers that can handle lead climbing, second climbing and abseiling mechatronically. What these terms mean: during lead climbing, the climber attaches the rope to a carabiner about every two meters when ascending. The belayer stays at the bottom and holds the rope. If the climber slips, he will only fall down to the next carabiner. During second climbing, the climber follows a rope that has already been secured further up on the climbing route and is pulled upwards by the belayer.
These tasks are now assumed by the automatic climbing assistant. For lead climbing, the device is secured at ground level. During stationary use such as on a climbing wall, the device can be secured to a wall using screws or click closures. A clamping device is available for mobile use. The fallback system can be fastened to any fixed structure such as the base of an electricity pylon.
This brick-sized device controls the rope using two motors.
Two motors control the rope
This brick-sized device, which is designed for mobile battery operation, controls the rope using two motors. One winds up the rope, the other assumes the brakes. When inspecting a radio mast or a crane boom, the user can extend the safety rope via EPIC and can draw it in again via a remote control command. This is important in order to prevent a slack rope and therefore keep potential fall heights to a minimum. During second climbing, i.e. when the climber is following the suspended rope, he can choose whether the motor should tighten the slack rope by command or automatically. Users always use a remote control, which is easily attached to their arm. The rope can therefore be blocked at any point in order to work or take a break. The second person can now also perform work within ear shot - and react in the event of an emergency.
When abseiling, the brake automatically unwinds the rope from the pulley at a defined speed, and the climber can abseil easily. However, the brake motor is also responsible for securing. In the event of a fall, a sensor transmits an emergency signal to the securing device within 30 milliseconds, which then operates the brake.
Of course, the developers do not rely on a single system. Instead, the securing is designed to have multiple redundancy. In the event of a fall, the EPIC blocks the rope using three sensors and an independent, redundantly operating centrifugal brake. If the user is suspended helplessly after a fall or is even unconscious on the rope and has to be rescued, the colleague can trigger automatic abseiling using a second remote control. If a second remote control is not to hand, an emergency release can also be activated using a rescue key. This mechanism functions independently of the electronics and is triggered directly on EPIC by a second person.
Excessive speed as a challenge for drive technology
The high speed which acts upon the rope motor in the event of a fall was one of the challenges that needed to be met by the drive technology. Up to 25,000 revolutions per minute could destroy a winding mechanism with less quality within an extremely short time. Andreas Eiler, who is responsible for looking after Auroco at FAULHABER, explains. "A powerful motor provides the power for abseiling and braking. It bears the weight of the climber with its static torque rating."
Perfect function of the drive components is a matter of life or death as far as the automatic safety partner is concerned. The DEKRA certification proves that the drives also work under the harsh conditions that are usually the case when climbing. Neither strong vibrations nor extreme temperatures adversely affect function. The device is certified for industrial use in accordance with EN 341 as an abseiling device for use in combination with PPE to prevent falling. With SKYLOTEC and using the already existing manufacturer's sales network, both founders have now begun to conquer the market. The first interested parties did not come from the usual sports climber customer group, but from the industry. There are more than 300,000 electricity pylons in Germany alone, which have to undergo regular maintenance. There are also increasing numbers of systems that are difficult to access such as crane booms. The companies can significantly reduce their costs for the prescribed securing with EPIC. Because the person who was previously almost solely responsible for securing their climbing partner can now also carry out work within ear shot. This increases efficiency. Climbing halls and high rope courses also are potential customers, and the company is working hard on developing the device for sports climbing. Furthermore, work is being done on a Smartphone app which will record and analyse the kilometres climbed, speed, elevation in metres, energy consumption, fall height, number of falls and also load values. Jan Lohse is convinced: "Our device will radically change the face of both sports climbing and professional climbing." The small DC-motors, which control the rope, contribute to this significantly.
The EPIC solution is a fully automatic, electronic rope safety system. The device is battery operated and, thus, suitable for mobile use. The climber controls it remotely and is always 100% secured.
Auroco GmbH
www.auroco.de
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