APEX Remote Control
Rotzler

Together with defortec, Rotzler Holding has developed a new generation of optional wireless and wired remote controls for controlling everything from winches to complete recovery systems (winches, cranes, outriggers, etc.) that function reliably in the most extreme environmental conditions. These remote controls are part of the new ROTZLER APEX platform for control systems. The remote controls must be able to be operated easily and without errors under direct sunlight in the desert, in the pouring rain in the mud and at double-digit sub-zero temperatures in the Arctic. The wireless and wired devices guarantee users a high degree of flexibility in handling.

The new generation of remote controls  is also designed to take Rotzler's variability into account: from the simple single remote control, which can operate one cable winch, to the dual remote, which can operate up to two winches simultaneously, to the multi-remote, which can map complex operating and interaction scenarios.

 

Two factors were essential for a successful, well-functioning product: firstly, the ergonomics and housing of the remote controls, and secondly, an intuitive and state-of-the-art interface that makes the complex interaction scenarios easy to handle.

Despite the ambitious project time of just six months, the development included both the design of the housings and the design of the interface for all three device sizes. This enables consistent and user-friendly operation across the entire product range.

 

The focus of development was on operating the cable winches under the most extreme conditions: direct sunshine in the desert, in the pouring rain in the mud and at double-digit sub-zero temperatures in the Arctic. From -40°C [-40°F] to +70°C [+158°F], the devices must work reliably and be easy to operate.

This requires outstanding ergonomics and intuitive, error-free handling - even with Arctic Gloves. In addition, the enormous spread in the temperature range not only demands the highest leak tightness requirements for the housing, but also special materials and highly sophisticated solutions for the technical components.

Due to the predicted quantities, additive manufacturing was considered, and a special plastic that can be processed stereolithographically is used for the housing. On the one hand, this saves Rotzler the tool costs that would otherwise be incurred in injection moulding production, and on the other hand, the targeted, load-induced wall thickness optimization makes it possible to create a robust, lightweight product for extreme applications. Softer, shock-absorbing parts improve the grip and contribute to the robustness of the remote controls - after all, the devices have to withstand drops from a height of one meter without damage - at any temperature. These could be integrated directly using 3D printing.

Heated displays and batteries ensure functionality under polar conditions, large joysticks can be used safely even when wearing gloves, so touch displays are not used. Instead, the buttons are arranged around the display and display the function shown in the interface. In the largest version, the multi-version, up to six functions can be controlled simultaneously - which is reflected in the large display and the corresponding six toggle-buttons. The other versions with a smaller range of functions are housed in smaller housings and use smaller displays. In all cases, however, brackets protect the buttons from fatal false triggering, for example due to falls.

When operating winches and recovery systems, there are many parameters to keep an eye on, not just the tensile forces, but also loads, angular effects, etc. The interface had to reflect all of this and at the same time lead to a seamless product experience. The highly sophisticated development of the user interface for the winch remote control is explained in detail here.