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Precision Engineering
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ball nut, and pinions are the highest contributors to the low stiffness of a stage Low stiffness reduces frequency response and increases settling times Maintenance and life expectancy In brushless linear servo motors, there is no contact between the two working members Therefore, they have an extremely long, virtually maintenance-free life The non-contact design eliminates lubrication and periodic adjustment to compensate for wear Rotary driven mechanisms require regular lubrication and occasional replacement due to wear Clean room and vacuum applications Since the coil assembly and the magnet assembly of linear servo motors do not make any contact, they are ideally suited for clean room and vacuum applications The main advantage of the linear servomotor is that the electromagnetic force directly engages the moving mass with no mechanical connection There is no mechanical hystersis or pitch cyclical error There are many types of linear motors, including stepper, DC brushed and brushless servo, inductance and AC Synchronous Only a few have become economically viable Brushless DC (also known as AC Synchronous) linear motors have found the widest acceptance in industrial applications because of their superior performance in precision positioning applications with a high thrust, velocity and efficiency In order to control the AC synchronous linear motor, a variable frequency power supply is used to monitor the progress of the magnet so that the coil polarity can be switched in time to accelerate the system The linear synchronous motor is reasonably efficient and quite powerful Furthermore, the coils can be positioned to optimize their effect on the magnet by predicting the acceleration of the magnet Brushed motors should not be used due to the problems associated with brush wear and heat generation at the interface Stepper motors cannot be tuned to the load or position feedback easily applied (Figure 538) This limits them to very light loads and low speeds, usually less than 20 lbs The open loop configuration also means that the stepper motor has a low servo stiffness The platen type linear motor requires a precise air gap (Figure 539) The magnet track is usually left exposed while the forces between the stator and armature are fairly high Induction motors do not use magnets
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Fig 538: A linear stepping
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motor [16]
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Fig 540: A linear induction Fig 539: A platen type linear
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motor [16] motor [16]
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and are not as efficient as brushless motors because they consume more power (Figure 540) The physical size and the forces are large, and the system requires a complex cooling arrangement Figure 541 shows the typical concept of a linear motor machine whose schematic arrangement is given in Figure 542 Generally, the arrangement for the linear motor system in an ultra-precision and high-speed machine is relatively simple A comparison can be made with the lead screw or ball
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Fig 541: The typical concept of a linear motor machine in a large mould and die machine tool [19]
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Fig 542: The linear motor method for high-speed feed [19]
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Precision Engineering
Fig 543: The high-lead ball screw method for high-speed feed [19]
screw system shown in Figure 543 A lead screw or ball screw system is usually driven by a low inertia high speed servo motor The tubular linear motor also has only two components, the rod and the forcer (Figure 544) The system has a symmetric design, large air gap, enclosed magnets and coils and integral heat sink fins which provide the system with additional advantages such as simple installation and noise-free operation Figure 545 shows a two axis linear stepper motor gantry stage designed for applications requiring a compact dual axis linear motion device The full step resolution is 25 m (0010 inch); however, when microstepped, step sizes as small as 1 nm (000004 inch) can be achieved This system is usually used in laser marking applications, pick and place, inspection systems, rapid prototyping, medical testing equipments, parts transfer and textile machines
Fig 544: A tubular linear motor [16]
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