Lifting heavy, large-diameter weights with precision can be challenging in a manufacturing or test environment. Traditionally the form factor of mechanically coupled linear stages such as Motorized BiSlide® Parallel-Coupled Linear Stages could possibly interfere with the payload or surrounding equipment.

In this case study, we explore how Electrically Parallel Coupled BiSlide® Stages solved a customer challenge involving 200 lbs loads, independent stage placement, and easy operator control—all while staying cost-effective.

The customer required a system that could:

Lift a payload of disk-shaped weights of 50–200 lbs

Maintain level lifting across multiple Z stages

Allow payloads to rest safely between stages

Operate safely with interlocked motion

Be easy to control without a computer

Mechanical coupling can block payload access and reduce flexibility—electrically coupled stages solve this issue.

Velmex Application Engineers designed a system using multiple independent BiSlide® linear stages, electronically synchronized via the Velmex VXC-2 Pulse & Direction Motor Controller.

Key Advantages:

• Independent, Synchronized Z Stages

  • Motion is electronically synchronized, not mechanically linked

  • Payload can safely rest between stages

• Scalable Load Capacity

  • Each BiSlide® supports 100 lbs vertically

  • Two stages lift up to 200 lbs. safely

  • Additional stages can be added for heavier loads

• Safe Operation with Interlocks

  • Z-axis locked out unless X-axis is at home position

  • Prevents collisions and unsafe lifting

• Flexible Layout

  • Each stage can be positioned independently

  • Maximum cable length of 30 meters provides flexibility

• Operator-Friendly Control

  • Digital joystick allows movement without a PC

  • Side-mount kit keeps controller organized and accessible

Multiple synchronized motors allow load sharing and precise, independent stage motion—no belts or mechanical linkages required

Velmex Inc. uses genuine Leadshine motors on BiSlide® assemblies because Leadshine has earned a reputation for delivering exceptional motion quality, reliability, and control accuracy in precision linear motion systems.

BiSlide® stages are often used in metrology, test, and automation environments where smooth motion, high holding torque, and long-term stability are just as important as raw power. Leadshine’s closed-loop stepper technology allows Velmex to provide servo-like performance without the cost, complexity, or tuning burden of traditional servo systems, making them ideal for precision linear stages that must perform reliably over thousands of cycles.

1. Closed-loop control ensures synchronized lifting
Each Z-axis stage must move at exactly the same rate to prevent binding, tilting, or uneven loading of the payload. The VML-232-PDCL 14-bit encoder continuously monitors position and speed, allowing the motor to automatically correct for any lost steps or load disturbances. This ensures that both stages remain electronically locked together, even under changing load conditions.

2. Excellent low-speed performance for vertical lifting
Heavy vertical motion requires smooth, stable movement at very low speeds. The iCS-2313 is specifically optimized for low-speed operation below 60 RPM, eliminating cogging, vibration, and step jitter. This is critical when carefully lowering a 200–300 lb payload onto an air-bearing spindle.

3. High torque in a compact NEMA 23 package
With 1.3 N·m of torque, the VML-232-PDCL provides strong holding and lifting capability while keeping the motor size small. This makes it easy to integrate into BiSlide® Assemblies without increasing system size or mass.

4. Soft-start behavior protects mechanical components
The motor’s soft-start feature prevents sudden jumps when power is applied, which protects lead screws, bearings, and mounted loads from shock. This is especially important when large vertical loads are present.

5. Perfect compatibility with the Velmex VXC controller
The VML-232-PDCL supports Pulse & Direction (PUL/DIR) control, which matches the output of the Velmex™ VXC synchronized motion controller. This allows multiple motors to be driven in parallel with precise timing and repeatability.

6. Built-in I/O and diagnostics for industrial systems
With digital inputs, an optically isolated output, and RS-232 communication, the VML-232-PDCL integrates easily into safety interlocks, homing systems, and diagnostic tools—supporting the customer’s requirement for axis lockouts and system monitoring.

Why this matters for electrically parallel BiSlide® systems

Electrically parallel coupled systems depend on motor accuracy and feedback integrity rather than mechanical linkages. By using closed-loop motors, Velmex ensures that each BiSlide® stage:

• Shares load evenly

• Moves in perfect synchronization

• Maintains alignment over time

• Recovers automatically from disturbances

This combination delivers a system that is as stable and accurate as a servo-based solution, but at a much lower cost and with far less setup complexity—making it ideal for heavy-load, high-precision BiSlide® applications like this one.

• Eliminates mechanical couplings that block payload access

• Supports 2–100+ stages, expanding load capacity

• Provides flexible stage placement to fit unique geometries

• Offers precise, synchronized motion for heavy or awkward payloads

By leveraging electrically parallel coupled BiSlide® stages with multi-synchronized motors, this solution provided the customer with safe and repeatable lifting for heavy loads, while offering flexibility in stage placement to accommodate large or uniquely shaped payloads. The system also featured intuitive, operator-friendly controls, allowing easy operation without a computer. Additionally, the design delivered a cost-effective, scalable solution that could be expanded or adapted for future requirements.

Electrically coupled BiSlide® stages provide a flexible, scalable solution for heavy load automation.