iTRAK Intelligent Track Systems

Source: Rockwell Automation
ITrack bucket image

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.


  • 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

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
SAP Material Number or KMAT Number Marketing Description Technical Description Catalog String 1
PN-585036 iTRAK 5730 Starter Kit Small iTRAK 5730 Starter Kit Small, 600 mm straights, 5 movers, with control panel 2198T-SK-06-05
PN-585037 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
 50mm 100mm 150mm
50mm 88 N* 185 N* 265 N*
100mm 176 N* 370 N* 529 N*
150mm 265 N* 555 N* 793 N*

*Peak Force; Cont Force: 46...417 N