iTRAK Intelligent Track Systems

A Modular, Scalable Linear Motor System to Increase Flexibility

Revolutionizing the design and build of track-based industrial motion control for packaging and material handling, iTRAK® combines linear and rotary motion. The result is a flexible, fully integrated motion solution that helps you get more from your machines.

Track System Revolutionizes Motion Control

The iTRAK Intelligent Track System is one of the most innovative motion solutions in the market today. This system is a modular, scalable, and linear motor system. It allows for independent control of multiple movers on straight or curvilinear paths. Gone are the rotary driven chains, belts, and gears of the past. iTRAK replaces hardware with simple, effective software profiles that redefine speed and flexibility in automation.

Benefits:

  • Increased production rates – 50% or more
  • Lessened downtime for changeovers
  • Reduced machine size
  • Shorter runs can still be profitable
  • Lowered periodic maintenance

iTRAK Track Systems are available as the iTRAK 5730 Small Frame and the iTRAK Medium Frame to help ensure you get just the right size for your application.

iTRAK 5730 Small Frame

The iTRAK 5730 Small Frame is designed with a reduced footprint for smaller machines. The 50 mm pitch makes it ideal for primary packaging applications such as flow wrapping, end-load cartoning, and form, fill, seal pouching. The iTRAK 5730 small frame also easily integrates into system architecture, providing analytics that help optimize energy consumption, monitor the wear on parts and reduce downtime.

The iTRAK 5730 also features integrated safety, such as safe torque off and Safe Stop 1, at a SIL 3, PLe safety rating. Creating safety zones increases safety without compromising productivity. They allow motion to continue outside of the safety zone, even after there has been a trip inside the safety zone. Features include:

  • Minimum mover pitch: 50 mm
  • Tool face diameter: 420 mm
  • Transverse width: 130 mm
  • Forces: 100 N peak; 36 N continuous
  • Speed: Up to 5 m/s
  • Payload: Up to 4 kg, higher kg at low speed
  • Position loop rate: 250 us
  • Repeatability: +/-0.01 mm
  • Maximum system size: 64 logical sections, 128 movers
  • Rail design: stainless steel
  • IP Rating: IP66 with infield cover

The iTRAK 5730 Small Frame is currently available as engineered to order. It will be available as a standard product in June 2020.

Get Moving With the iTRAK Small Frame Starter Kit!

Want to do some testing? The iTRAK 5730 Small Frame starter kit makes it easy to test before implementation. This plug-and-play kit allows you to test iTRAK intelligent track systems before redesigning your machine. Starter kits are available in two sizes:

  • Small: 600 mm straight track with 5 movers
  • Large: 1200 mm straight track with 10 movers

The control panel includes:

  • Compact GuardLogix® controller 5069-L3100ERMS2
  • Safety I/O: 5069-IB8S, 5069-OB16
  • iTRAK power supply 2198T-W25-ER
  • Kinetix® 5700 DC bus supply, 2198-P031
  • Kinetix 5500 line filter, 2198-DB20-F
  • PanelView™ 5510 HMI 2715P-T7WD
SAP Material Number or KMAT NumberMarketing DescriptionTechnical DescriptionCatalog String 1
PN-576800 iTRAK 5730 Starter Kit Small iTRAK 5730 Starter Kit Small, 600 mm straights, 5 movers, with control panel 2198T-SK-06-05
PN-576804 iTRAK 5730 Starter Kit Large iTRAK 5730 Starter Kit Large, 1200 mm straights, 10 movers, with control panel 2198T-SK-12-10

iTRAK Medium Frame

The iTRAK Medium Frame is designed for larger systems. It can be designed as large as 100 m in length with 250 movers. It’s well-suited for applications with heavier payloads, such as automotive assembly or higher weight product packaging. Features include:

  • Minimum pitch: 66…75 mm
  • Tool face diameter: 600 mm
  • Transverse width: ~250 mm
  • Speed: Up to 5 m/s
  • Payload: Up to 40 kg
  • Position loop rate: 1…2 ms
  • Repeatability: +/-0.03 mm
  • Maximum system size: 256 sections, 250 movers
  • Rail design: tooling steel
  • IP Rating: IP65

Forces by Motor Module Size

Motor
Module
Mover Magnets
50 mm100 mm150 mm
50 mm 88 N* 185 N* 265 N*
100 mm 176 N* 370 N* 529 N*
150 mm 265 N* 555 N* 793 N*
*Peak Force; Cont Force: 46...417 N

Want to discuss how independent cart technology can help you move smarter?

Resources

Check out all the software, firmware, documents and training you need to make the most of your independent cart technology investment.

Modernize Machine Design

The iTRAK Intelligent Track System presents an opportunity to revolutionize machine design in a way that has not been seen in decades. Watch the way machine designs have changed from mechanical line shafts to electronic line shafts and finally to independent mover technology. This video shows how the mixture of continuous and intermittent motion, direct drive motion control, and high-performance servo control can combine to increase throughput, reduce changeover time, and reduce overall machine size.

Part of a Safer Machine

Independent cart technology is a great start to designing a safer machine. It controls each cart independently with either built-in anti-collision or pre-programmed libraries to prevent damage to products. Track segmentation allows you to create safety zones enabled by our safety products or independent cart technology integrated safety. We’re combining safety and productivity and bringing it to the next level.

Need a Custom Solution?

iTRAK intelligent track systems can be engineered to order. Examples of engineered to order projects include:

  • Liquid cooled motor modules
  • 45° and 135° curves
  • Heavy payload movers
  • Large radius curves
  • And more!

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How May We Help You?

Rockwell Automation and our partners offer exceptional knowledge to help design, implement, and support your automation investment.

iTRAK can be configured to suit specific application needs

The iTRAK System consists of:

  • iTRAK Linear Modules
    • Each iTRAK Linear Motor is a self-contained multi-phase motor module and ready to use out of the box with no moving parts subject to wear
  • iTRAK Curve Modules
    • iTRAK Curve Motor Modules work seamlessly with Linear Motor Modules and the standard iTRAK Movers
  • iTRAK Movers
    • iTRAK Movers are available in different sizes and designs or can be customised to meet precise application needs. The motion of the Mover is tracked using an absolute encoder integrated within the iTRAK Motor Modules
  • Power and Control Module
    • Each iTRAK Module contains its own drive which requires power and communications. The Power and Control Module (PCM) provides these necessary functions in a centralised module
  • iTRAK and Integrated Architecture
    • The iTRAK System really excels when it is combined with Integrated Architecture. Integrated Architecture enables end users and machine builders to respond to dynamic demands

iQFlex exploits MagneMotion flexibility and scalability

This integrated platform streamlines IMA Automation’s design and programming activities, while its customers benefit from minimised installation and start-up times, coupled to reduced maintenance, changeover and training.

Described by IMA Automation as the next step in motion control, independent cart technology replaces mechanical systems with simple, effective software profiles – redefining speed and flexibility in automation. With MagneMotion on board, the iQ FLEX’s versatility makes it ideal for multiple industries and assembly applications, such as those for medical devices, automotive and electronics products.