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Non-stiction Air Cylinder Actuators

Airpot Corporation announces the addition of a position sensing option to its popular line of Airpel non-stiction air cylinder actuators. The company offers non-contact electronic switching sensors from Sick, Inc. using state-of-the-art GMR technology. The addition of GMR sensing technology to the Airpel non-stiction cylinder line offers OEM designers an easy-to-install, secure, and reliable solution.

For customers desiring electrical output of piston position, most Airpel models are offered with an optional switch-activating magnet on the piston, as well as one or more option aluminum tracks measuring 9.51mm wide and 6.83mm high, attached to the cylinder. The tracks are specially designed for easy, secure mounting of the Sick, Inc. position sensors which are offered separately.

The sensors operate at 10-30 V DC and have repeatability of less than or equal to 0.2mm. Airpot stocks popular models of these extremely reliable GMR sensors with PNP or NPN output, along with matching accessory extension cables available in 2 and 5 meter lengths. OEM designers are assured safe and accurate feedback. A magnetic field has secondary maximum levels that can cause double switching behavior in Hall Effect and reed sensors. But GMR (Giant Magneto Resistive) technology is based on the measurement of the average strength of the magnetic field. This gives GMR sensors some important advantages over other types of sensors. GMR sensors greatly reduce the potential for troublesome double switching ensuring better accuracy. GMR sensors do not need to be adjusted to magnetic field polarity.

With its compact profile, the GMR sensor chip is encased in a small, rugged plastic shell. The entire sensor can fit in a common soda straw less than 1.25 inches long. There is a small LED window in the shell to allow visible indication of the switching signal. Installation is easy, secure and user friendly. The Sick, Inc. GMR sensor is specially shaped to allow for easy installation in the Airpel T-slot aluminum track. The track comes permanently bonded along the entire length of the cylinder in the location desired when ordering sensor-ready Airpels.

www.airpot.com

::Design World::

Chicago Hosts 2008 Manufacturing Technology Show

This year’s International Manufacturing Technology (IMTS) Show, sponsored by the Association for Manufacturing Technology (AMT), will take place September 8 – 13, 2008 at the McCormick Place in Chicago, IL. More than 1,500 companies will exhibit new machine tools, controls, computers, software, components, systems, and processes.

The show is organized in pavilions according to product category. These include Abrasive Machining/Sawing/Finishing; Controls & CAD/CAM; EDM; Gear Generation; Machine Components/Cleaning/Environmental; Metal Cutting; Metal Forming & Fabricating/Lasers; Quality Assurance; and Tooling and Workholding Systems.

Be sure to visit the IMTS 2008 Manufacturing Business and Technology Forum – “Where Technology and Business Connect.” It brings together experts from the industry to give you the most useful and up-to-date technical information available on how to improve your production and operations; and how to solve your manufacturing challenges. The sessions complement what you see on the exhibit floor.

The following are a few companies that will be exhibiting at the show.

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Sapphire and ruby orifices maintain calibration

Needle valves let you easily dial in a required flow, but they can also cause problems because the customer can change those settings in the field. This can upset the calibration of the device. The alternative is to choose a fixed flow valve that cannot be altered.

Bird Precision routinely recommends flow guides and repeatable sapphire and ruby orifice retrofits to achieve the ideal flow. Often the fixed orifice can be installed directly into the manifold, which reduces the number of fittings required. With Sapphire and Ruby Orifices, the material is a cost-effective man made product. Because it is next to diamond in hardness, wear is minimal. The material is also chemically inert even to acid at elevated temperatures, so corrosion is not an issue, and it will keep its calibration even in the harshest environment.

Bird Precision offers a unique series of laser drilled, wire lapped Ruby and Sapphire orifices. Orifices and filters are packaged in a variety of stainless, brass, and plastic  – fittings, connectors, and inserts. They have extreme chemical and wear resistance and ensure precise, dependable control with even the most harsh liquids and gases.

Booth 4821
Bird Precision
www.birdprecision.com

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Energy efficient gearmotor

Among many other products, Baldor Electric Company will display the Dodge QUANTIS GOLD, a C-face energy efficient gear motor. It combines Dodge QUANTIS ILH (In-Line Helical) and RHB (Right Angle Helical Bevel) C-face gear motors with Baldor Reliance Super-E Premium Efficient Motors for an energy efficient gear motor package. Motor and gearbox combinations to 10 hp are pre-selected.

Both QUANTIS ILH and RHB reducers have a NEMA clamp-collar design, foot mounted housing configurations, standard inch output shafts, nitrile input and output lip seals, A1 mounting, and Mobilegear 600 XP 220 oil.  In addition, the RHB unit offers flange mounted housing configurations and tapered hollow bores with twin-tapered bushings.  These reducers offer greater torque density in a compact housing.

Baldor Reliance Super-E Premium Efficient Motors are manufactured with rolled steel and cast iron construction that meets or exceeds NEMA Premium efficiency levels and offer TEFC enclosures for all standard industrial applications in dusty, dirty and humid environments.  These motors, 1800 rpm, 60 Hz, with voltages from 230 V to 460, are inverter capable and are suitable for use on inverter drives in variable torque and 20:1 constant torque applications. 

Booth 4117
Baldor Electric Company
www.baldor.com

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Multiple product highlights

HEIDENHAIN CORPORATION’s IMTS show product highlights include recent entries into the control market. Also included will be the company’s latest digital readout (DRO) – the versatile ND 500 system – coupled with an LS linear scale. Many new touch probe options will be on display, such as the TS 444 battery-free infrared probe, the TS 740 probe, and the UTI 192 interface box which allows for probe integration to non-TNC controls.

HEIDENHAIN will also feature the DIADUR®, a significant metal etching process invented by the company in 1950.

Booth D-4419
HEIDENHAIN CORPORATION
www.heidenhain.com

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Actuator suits clean room requirements

The CGL15N/CGL20N Actuator from THK America, Inc., has a clean, corrosion resistant, and long–term maintenance-free design and is ideal for clean room environments.

For low particle generation, it features a seal mechanism and a full size cover. AFE-CA grease reduces dust. The actuator’s Ball Screw and LM Guide come THK AP-C treated for high corrosion resistance. THK Caged Technology employs a synthetic resin cage with a curvature that cradles each ball and separates it from the next one. The spaces between the rolling elements retain grease and act as a lubrication system.

The CGL15N/CGL20N not only provides low dust generation, but also high-speed capabilities. It is compliant with ISO 14644-1 Class 4 (equivalent to FED209D Class 10) at 2,000 [mm/s].

Booth D-4217
THK America, Inc.
www.thk.com

::Design World::

PBC Linear Unveils Custom Products at IWF 2008

Rockford, IL – - PBC Linear has recently attended the International Woodworking Machinery and Furniture Supply Fair (IWF) in Atlanta, GA. Exhibiting our most exciting new products: Uni-guide, linear actuators, and Integral V™ Technology (IVT), PBC Linear was met with a great deal of enthusiasm as to what it can offer the woodworking industry.

Showing off the highly customizable Uni-guide linear slide system with a variety of different vices, PBC Linear gave the program new light as a made to order product. Custom applications exhibited include an angle-lock vice, a power-driven vice, and modular-clamp vice.

The new line of PBC Linear actuators were shown as two different gantries: an XY gantry with both the MT and PL series operating, and an XYZ gantry not only exhibiting the actuators, but the new Integral V technology (IVT) as well. The new line of Linear Actuator Technology (LAT) is an ideal solution for the woodworking environment due to its ability to handle debris and because it is sealed against contamination design.

Finally, the Integral V Technology (IVT) was also on display. Exhibited as an XYZ gantry system, the Integral V appeals to the woodworking industry by providing a cost-effective, easy to use, completely customizable linear guide solution that could function in a debris heavy environment.

www.pbclinear.com

::Design World::

Cylindrical Voice Coil Actuator

VISTA, Calif. – BEI Kimco Magnetics introduces a new compact sized, high force, cylindrical Voice Coil Actuator in response to market demand for improved consistency and precision in valve control and beam steering applications. Typical uses include analytical/test and measurement equipment for the pharmaceutical, R&D, laboratories, and medical industries.

Designed with high force sensitivity in a lightweight housing, the new actuator provides extremely fast control of valve opening and closing, thereby increasing throughput for OEMs looking to improve production and reduce product time to market. Used in conjunction with a high performance motion controller or other device, the actuator is capable of providing precise positioning, velocity, and acceleration in applications where exacting precision is critical.

The new actuator is available in small sizes from 1-inch OD to 1-1/2-inch OD for installation into products with tight space constraints. Features include stroke lengths ranging from 0 to 1.27 mm, force versus position curve characteristic, continuous force of 1 to 5 N, cog and hysteresis-free operation, and tight tolerances. The unit can be ordered in a variety of materials, allowing the OEM to select an actuator that is compatible with the type of sample being tested at the final point of use.

www.beikimco.com

::Design World::

Optical Positioning System Features Zero Translation

Developed for precision optical positioning applications, the LFA-1012 Linear
Focus Actuator features a zero-translation tangential flexure for high-speed
travel. The clear aperture, 10 mm (0.394 in.) stroke length, and standard 12
mm optics mount (or an optional DIN mount for use on microscopes) make this
linear focus actuator ideal for optical focusing, scanning, interferometry,
surface structure analysis, disk drive testing, autofocus systems, confocal
microscopy, biotechnology, and semiconductor test equipment.

A frictionless, closed loop, non-contact sub-micron resolution linear displacement
sensor – having high bandwidth and low noise – assures high responsiveness
and ultra precision.

Equipment Solutions, Inc. (ESI)

www.equipsolutions.com

::Design World::

Hollow Rotary Actuators

Each actuator in the DG Series of hollow rotary actuators has a repetitive position accuracy of 15 arc-seconds and a total backlash of 2 arc-minutes because of its integrated high rigidity cross-roller bearing structure. A hollow through hole of sufficiently large diameter helps reduce the complexity of wiring and piping.

The DG 200 has a frame size of 7.87 in. (200 mm) with an internal
hollow diameter of 3.94 in. (100 mm). It develops 440 lb-in. (50 Nm) of
torque at a speed of up to 110 rpm available for positioning larger
inertial loads.

ORIENTAL MOTOR, USA CORP.

www.orientalmotor.com

::Design World::

Linear Actuators Bring Flexibility to Packaging

The packaging industry is in the midst of change, shifting from pneumatics to electromechanical actuation for motion and positioning functions.  Multiple factors are fueling this trend and continue to add to its momentum.

Cost and regulatory requirements are two primary concerns for today’s machine tool designers.  For cost control, the current buzzword is “lean,” which for the packaging industry heavily favors processes that require minimal setup time.  One of the best ways to reduce setup time is through the use of flexible components and equipment.

Environmental concerns place new emphasis on emissions, which puts pneumatics under scrutiny because lubricated air is often exhausted to the atmosphere.  In addition, the demand for quieter operation is driving the change to alternate technology and components.

Whether specifying, designing, or selecting machinery, answers to several questions will determine which technology is most appropriate:
— Will increased flexibility actually be exploited? 
— Are there environmental issues to be addressed? 
— Are the necessary resources and skills available to implement a new technology?
— What are the costs for each approach, what is the return on investment for each, and what are the overall benefits?

Haydon Non-captive Hybrid Linear Actuator provides varying stroke dependent only on the length of lead screw passing through the motor. Photo Courtesy of Haydon Kerk Motion Solutions.

Pneumatics – A proven technology
A pneumatic cylinder uses pressure differential to move a piston.  That differential is either air versus air that is typically supplied as pressure versus atmospheric pressure, or air versus mechanism, such as supplied pressure opposed by a mechanical spring.

With sufficient pressure and volume, pneumatics can move exceptionally fast and supply high force.  If the actuator uses a spring return, the actuator moves when air pressure is applied.  When the pressure is removed, a spring pushes the actuator back to its original position while exhausting the previously supplied air.  When air is used for the return force, it offers a greater degree of control over the motion, but because of the larger volume of air required, it must be exhausted in both directions.

Most often, a pneumatic actuator moves to a hard stop, either the limit of the cylinder stroke or an external stop.  Positional accuracy is determined by the tolerances of the stop location.  Changing the travel requires either replacing the cylinder or relocating the external stop. 

The benefits of pneumatics include:
Speed – pneumatics react quickly
Simple – the mechanisms themselves are not complex, although the applied technologies are cutting edge
Reliable – although simple, these devices are robust
Extensive knowledge and supply bases in the packaging industry
The limitations of pneumatics include:
Inflexible – changeover is expensive, which is the biggest reason for the move to electrical actuation.
Environmental contamination – lubrication is required for maximum life and performance.  Lubrication is often added to the air supply.  Therefore, unless special components or filtration is used, lubricant can enter the atmosphere wherever it is exhausted.
Noise – a pneumatic actuator’s exhaust air can be forceful and loud. 
High Energy Consumption – pneumatics require compressors to create an ongoing supply of pressurized air. Compressing air is a less efficient method of converting electricity into motion.  Air pressure must be maintained if sustained force or position is required, making it necessary to run the compressors when pressure must be maintained. 

Electromechanical actuation – a rising star
Electromechanical actuation with a rod-type actuator uses a rotary motor turning a screw to move a nut to extend a telescopic rod.  Physically and functionally a rod-type actuator is very similar to a pneumatic cylinder.  The big difference is that the motion is not “on-off” like pneumatics.  Through motor control, the position of the actuator rod can move to any position throughout its stroke, limited only by the resolution of the motor/screw combination.  Velocity and acceleration can be similarly controlled.

Haydon Captive Hybrid Linear Actuator provides precise positioning using step-motor technology.  Photo Courtesy of Haydon Kerk Motions Solutions.

Though an actuator may have a stroke of 12 in. (300 mm), it can easily be instructed to move to any distance within that range, with an accuracy of ± 0.025 in. (0.64 mm) or better.  An encoder on the motor or in the actuator provides position feedback.  Alternately, motion control can come through a stepmotor that counts steps of rotation.  A homing routine establishes position.

The benefits of electromechanical actuators include:
Flexible, programmable positioning
Clean – there are no emissions
Maintenance-free – can outlast the machine in which installed
Quiet
Lower energy consumption – power need only be applied to make a move and when turned off will maintain position and force
Some drawbacks of electromechanical actuators include:
Culture change – new skills and tools are needed within packaging to operate
Indirect setup – changes are accomplished by running a motor.  This requires input to a control
system.
Speed – pneumatic cylinders can respond faster
Initial cost – in many applications, electro-mechanical actuators will cost more than a pneumatic
cylinder of equivalent stroke and force

The impact of sensors
The changes in packaging operations are built upon the availability of low cost, high speed, reliable computing capability and sensor technology.  Operators no longer need to make decisions.  All the knowledge is pre-programmed, sensors know what is coming, and the line “knows” what to do.  Even motor technology has the intelligence to receive a command, take action, and confirm whether the action was successful. 

The same sensing and controls can be applied to pneumatics, but pneumatics remain an on-off technology.  The motor and screw combination in a linear actuator can take the information and use it. 

Alternatives to pneumatic cylinders
Rod-type linear actuators are obvious candidates to replace pneumatic cylinders due to their physical similarities.  There are other forms of linear actuators that look different but offer the same opportunities with alternative forms. 

Rodless actuators take a form that might be classified as a compact slide, with the motion generated by a motor turning a screw or a belt.  These are not telescopic but instead are more of a transport mechanism positioned above or below the workspace or pathway. 

The non-captive linear actuator uses a non-rotating screw driven through an internally threaded hollow rotor motor.  These compact units produce surprisingly high actuation force.

The common element of all these options is easily programmable motion.  All can be used in an intelligent process that detects the product requirements and adjusts automatically to the situation.  Lot sizes of one can be accommodated without a changeover or additional set up.  All can be pre-programmed for a variety of configurations so that changeover requires the press of a button.

Points to consider
When comparing the technologies, there are few absolutes.  Generally, pneumatics has the speed advantage.  Force capability comes down to size with pneumatics, where motor driven actuators have the additional elements of electrical and mechanical efficiencies.  Linear actuators are the clear leaders for accuracy, especially if stopping short of full stroke.  Travel life or cycle life varies widely with both technologies; analyze closely as the cost implications can be great.

Familiarity with a technology strongly influences its perceived complexity.  If designing from the ground up, the tasks should be similar.  A redesign to switch from pneumatics will usually be straightforward and involve different controls and the removal of some manual stops and adjustments.  Increased electrical resources will be required but this should be offset by reduced air requirements.  Initial set up will likely take longer for programming an electromechanical process. 

ET Series Electrothrust Cylinder servo-motor driven actuator provides high thrust loads in a conventional telescopic configuration.  Photo courtesy of Parker Hannifin Corporation.
 
But once the system is complete and a good user interface established, process changes or additions are easy.

The big question mark comes when deciding how much of this new flexibility will be used.  It is wonderful to have the flexibility provided by automation.  But without the appropriate feeding processes, output processes, and a manufacturing mix that can exploit the capability, the benefits are few.  Providing the sophisticated input and output may be the greatest challenge of enhanced production flexibility.

ER Series Electric Rodless Cylinder has a guided carriage that is particularly well suited to transport mechanisms.  Photo courtesy of Parker Hannifin Corporation.

Cost
Purchase price is unlikely to be the determining factor, although pneumatics is likely to cost less based on hardware.  The simplicity of a pneumatic actuator gives it a cost advantage.

First time implementation of an electromechanical system can be costly because of the need for new resources, new knowledge, and the learning curve. The process starts at the design phase and continues through the supply chain, operations, maintenance, and customer training.  But once the investment is complete, it should be less costly to operate from both a labor and energy standpoint. 

Electromechanical systems reduce or eliminate downtime for additional savings.  As product mix increases and inventory levels drop, productivity measurements rise and cost savings grow.

Other demands such as environmental requirements still might justify a change of strategy.  Building a new line using electromechanical actuation will be a good choice because the initial investment should be comparable and the future capability will be more flexible and versatile.

Specification
The application will set the direction from the outset.  It will lay out all the performance and operational goals and should include information that defines the associated input and output processes and materials.  This is the point to consider future possibilities, as it will naturally define a technology path.  Prospective suppliers will critique the specification and offer options that may not have been considered.  Their responses will alert you to risks and opportunities and will give you insight to the suppliers’ capabilities, creativity, and willingness to provide the best product. 

Supplier Selection
A supplier’s prior experience, references, and empirical product data are valuable.  Product specifications in electromechanical components can be deceiving.  A good supplier will understand and articulate the features, benefits, and trade-offs of various options.  Training, design support, and service are as important as performance.  Reliability is very important.  Often, equipment is specified at peak capability but should be down-rated for normal use.

Prototype and Testing
With custom equipment, it may not be possible to prototype the system but it is still valuable to test the claims against the specification.  With a well-written specification, it’s possible to simply test critical features.  Isolate those parameters that represent new challenges, such as response time, positional accuracy, force-speed capability, or efficiency.  Work with the supplier to come up with a meaningful way to validate them.  The information may include data from equipment built for other applications.

A cautionary note about reliability and life:  be very careful about accelerated life testing.  Many electromechanical components do not behave in a linear way when speed, load, and duty cycle are varied.  In an accelerated test, friction, heat, and lubrication breakdown can cause premature failure that would never occur in normal use.  If an accelerated test is used, a positive outcome is likely valid but a failure is often inconclusive.

Opportunities
Imagine that each product manufactured carries a bar code or RFID tag that is read as the item travels into the packaging line.  Sensors know when each item reaches a station and have adjusted appropriately.  Conveyer track widths adjust, case packer strokes change, and the output is directed like trains in an automated freight yard, while the customers’ preferred transportation companies pick up the products recently completed.  Product is gone within hours, not warehoused for weeks or months.  Electromechanical actuation has established its value and those companies who have embraced it are already seeing the benefits.

Kerk Motion
www.kerkmotion.com

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Pneumatics with proportional control

Pneumatic actuation, and its role in motion control, has generally been quite simplistic but at least one company is working to change that.  Enfield Technologies, in Trumbull Connecticut, enables precise motion control and programmable positioning by applying proportional control to pneumatics.

Proportional control means that the output of a system is directly related to the input. System inputs include both a target value (set-point command), which is the desired result such as position, pressure, flow rate, or force level; and the real-time measurement of actual progress toward that goal (sensor feedback signal).

With proportional control, the output can be any interim value within a fixed range.  For example, an air cylinder can be positioned anywhere between fully retracted and fully extended.  In another example, a tank’s pressure can be maintained anywhere between vacuum and full line pressure.  Proportional control is a cost effective way to create flexible systems with dynamic control.

Pneumatics is viewed as on or off, with positioning characterized by hard stops.  Attempts to provide proportional pneumatic control using solenoid technology have been slow and relatively imprecise according to Enfield.  Thus, Enfield uses fast-response voice-coil technology, which is three- to seven-times quicker than solenoids, along with special valves, drives, and controls to make rapid adjustments to the air pressure for fast, accurate positioning anywhere within the total range of motion.

Voice coil actuators take their name from loudspeaker technology that uses a fluctuating current to cycle an electromagnetic coil (voice coil) back and forth through a flux field created by a permanent magnet. 

The amplitude and frequency are defined by the input signal, thus moving an attached cone to generate sound waves.  Enfield’s voice coil-type actuated valves distribute the air pressure to opposing sides of pneumatic cylinders, rapidly cycling to constantly update the forces necessary to reach or hold the desired position. 

While more common proportional systems rely on two or more “on-off” solenoids to do the switching, voice coil-type actuated valves require only a single element to provide bi-directional and variable volume flow. 

Used with closed-loop feedback, that system can achieve positional accuracies of ±0.032 in. with ±0.005 in. repeatability.  Though not as accurate as electro-mechanical actuation where ±0.001 in. can be readily achieved, this is an exceptional capability for variable position pneumatics.  Force and linear speed are limited only by the amount of air available and the choice of pneumatic cylinder.  It is possible to generate thousands of pounds of thrust with only 50 to 100 psig air pressure.

The air used to provide power must be exhausted.  The location and conditioning of the exhaust may be critical due to noise and environmental constraints.  Like any other prime mover, quick moves demand adequate power.  In the case of pneumatics, that means air pressure and volume.

For more information on Enfield Technologies go to www.enfieldtech.com

::Design World::

SKF® CAR Series Linear Actuators

SKF® “CAR Series” linear actuators can easily be equipped with a wide range of specialized components to deliver custom solutions for industrial applications. These compact and robust actuators benefit from high-efficiency SKF ball screw, sturdy gearbox assembly, and high-quality DC or AC motors contributing reliable performance and extended service life.

The actuators in left- and right-hand models are available in three standard sizes (CAR 22, CAR 32, and CAR 40) with load capacities up to 6000N, stroke lengths up to 700mm, and full-load speeds up to 40mm, depending on type. They can be specified with 1, 2, or 4 gear ratios and AC or DC motors, among other options.

Several special versions expand application capabilities and potential. Specific models feature an onboard feedback potentiometer to indicate current actuator position, incorporate a gearbox input shaft allowing for connection to external drive sources, or eliminate motor and gearbox entirely to allow for direct-drive operation by the ball screw and highly accurate positioning and efficiency.

www.skfusa.com/linearactuators

::Design World::

Explosion-Proof Linear Actuators

ELZex Series modular linear actuators meet European ATEX 95 explosion area testing certification for caustic environments.

Their heavy duty, rodless design is belt-driven and features the industry’s only anti-static HTD (High Torque Drive) belt on the market. These linear actuators improve safety and health protection of workers at risk in explosive atmospheres, including single-axis automotive paint booths and dual-axis pick-and-place gantry environments.

Nook Industries
www.nookindustries.com

::Design World::

Animatics’ Harmonic Linear Drive

Santa Clara, California - Animatics Corporation, through OEM Dynamics Linear Division, has expanded its product line into the Linear Actuator market with the release of the Harmonic Linear Drive Series.

The Harmonic Linear Drive™ (HLD) is an innovative linear belt drive solution providing high accuracy and low cost without the need for a gearhead or brake. Instead of using a fixed belt to move the load, the HLD uses a recirculating belt, folded back upon itself and routed over subtly different diameter pulleys yielding gear reduction by way of the Harmonic Drive Principle, without the cost or backlash of a separate gearhead (see animation at www.oemdynamics.com).

The HLD is available in standard stroke lengths from 100mm to 3200mm and equivalent pitch ratios from 2.5mm/rev to 12.5mm/rev. Custom strokes are available. These fully integrated units are shipped with the patented Animatics SmartMotor technology to provide an all-in-one Closed-Loop Brushless Servo Motor, Drive Amplifier, Optical Encoder, I/O, Field bus option, belt actuator and bearing support.

The HLD60 produces standard thrust up to 450 Newtons, with an average moment loading of up to 150Nm. Each unit provides a near Zero Backlash solution with bidirectional repeatability approaching 60µm and unidirectional repeatability of less than 20µm.

www.animatics.com

::Design World::