STUDIES ON THE BENEFITS OF USING LINEAR MOTORS INSTED TO BALL SCREWS USED IN DRIVE OF THE MACHINE TOOLS

Prof. Dr. Ing. VELICU Stefan, drd. Ing. MIHAI Lucian, drd. Ing. Alexandru Velicu

Abstract: Linear drive technologies are steadily expanded in various applications, especially in industry, where high precision electrical direct drive systems are required. this paper analyzes on the benefits of using linear motors insted to ball screws used in drive of the machine tools Keywords: linear drive, linear motors, kinematic chains, machine tools, ball screw

INTRODUCTION Linear motors are used on a number of machine tools. What are they, where are they used and why? Now we will explain. Machine tool axes are still typically driven via a servo- motor-driven rotating ballscrew that engages with a static ball nut attached to a machine slide/moving element the conversion of rotary motion to linear motion. A linear motor has no rotating parts, the servo-motor components being effectively unwound such that the coil (primary section or forcer) and the magnets (secondary section) lie flat. The primary section is attached to the machine tool moving element, the secondary to the machine bed/structure. So, the rotary motion of a motor is effectively converted to linear motion by this unwinding.

Figure 1: Most machine axes are still driven via ballscrews, as on this Mazak CNC lathe

Figure 2: Linear motor diagram Due to their lack of multiple moving parts, linear motors hold out the potential for very high acceleration/deceleration (acc/dec) rates and rapid traverse rates, but the mass/inertia of the structure being moved is the limiting factor. German automation technology firm Siemens says its 1FN linear motor theoretically delivers velocities of up to 300 m/min and accelerations up to 45 G, although you won't see these realised on a metalcutting machine tool. But the rule for machine tool structures is that light ones can be accelerated faster and to higher speeds than can heavier systems. It is possible to increase the acc/dec and rapid traverse speed of a ballscrew system by increasing the ballscrew's thread lead (pitch); however, this has negative implications for positional resolution. NSK offers that its high lead (1632 mm diameter) design supports linear speeds up to 100 m/min.

Figure 3: A selection of ballscrews, as used in machine tools Rotating the ballscrew faster achieves the same end, but too high a rotational speed can cause a screw to whip or hit a resonant frequency, causing wild instability and vibration. This problem grows as the length of the screw increases. A solution here can be a rotating ballnut and motor assembly attached to the moving slide, with the ballscrew remaining static. Bearing firm SKF states that linear speeds of up to 110 m/min are possible here, and that such a solution is applicable to laser profilers and to machines for aluminium cutting.

Rotating ballnut solutions are not very common, but one such offering comes from laser profiler maker Bystronic, Switzerland. It uses a torque motor (rotary linear motor) to drive a ballnut along a static ballscrew on some of its machines to deliver 3 G acceleration and 120 m/min top linear speed. However, low mass and novel associated technology are important here. Profiling machines usually have lower masses to move than metalcutting machine, such as lathes and machining centres. Acc/dec rates for rotating ballscrew systems on lathes and machining centres tools can be up to 1.4 G, but mostly under 1 G (9.81 m/sec per sec), while rapid traverse rates can be up to 60 m/min on small machining centres, such as Yamazaki Mazak's 4800 400 mm2 pallet horizontal machining centre; and up to 30 m/min on Gildemeister's CTX beta 500 turning centre (65 mm bar capacity). In the case of Gildemeister, a direct comparison between ballscrew and linear motor performance can be made, because there is a linear motor option for the CTX beta 500. This offers rapid traverse rates of up to 60 m/min, from which it is possible to infer that the acc/dec rate is similarly likely to be double the ballscrew figure. But to continue with further comparison, ballscrews also wear, if the same part of the screw is used over and over again, while backlash exists, due to the number of mechanical interfaces between separate elements seen as reversal error when interpolating a circle in X and Y (the point where motion in X or Y changes from positive to negative). In contrast, linear motor systems have no backlash, while there's no wear for repeated travel over the same area although the linear guides that support the machine table or slide are still subject to wear, of course. Weaknesses of linear motors are that, because there is no possibility of applying mechanical advantage in the linear motor system, axis thrusts may be lower or linear motor power must be higher to achieve a similar thrust in any given comparison. Linear motors generate heat in the primary winding and so typically require water cooling; they are magnetic, so ferrous swarf will be attracted to the energised magnets; while there is a very strong attraction between the primary and secondary units, which causes extra downward force and so requires the motor to be located as close as possible to guideways. The guideways themselves will have to be larger than for an equivalent thrust ballscrew system to withstand this downward force the attractive force of a linear motor's magnets is typically three times greater than the thrust force. Regarding magnetism, a recent development by Siemens gets round this issue. Announced at an American manufacturing technology show last September was its 1FN6 model, claimed to be unique in the industry, having a magnet-free secondary track system and air-cooled primary section. The motors are said to produce thrust forces and velocities "equivalent to competitive models for light-duty machine tool, machine accessory and material handling applications".

Figure 4: Siemens 1FN6 model linear motor answers the magnetic criticism A final point to say about linear motors is that, in their rotary table incarnation (torque motors), they are exceedingly common on machining centres, even where all other axes are ballscrew driven. This is because they support not just very fast positional indexing of parts

on machining centres, but also high-speed continuous turning, thus supporting one-hit machining. So, to a few examples of linear motor machines. Machine tool companies such as Germany's Gildemeister AG (sold through DMG) and Trumpf; Japan's Citizen and Sodick; and US-owned MAG Group are just a few that apply linear motors in their machines. DMG makes CNC turning centres and all types of machining centres in the main; Trumpf makes laser profilers, plus punching and bending machines; Citizen is a sliding-head lathe specialist; Sodick makes both electro-discharge machines (EDM) and vertical machining centres; MAG Powertrain Ex-Cell-O is an automotive-focused machining centre maker, while MAG Cincinnati makes, among other machine types, large gantry milling machines for aluminium machining. It was in the automotive field, in the early 1990s, where linear motors first came to prominence, because they allowed a fast single-spindle CNC machine to compete with a slower dedicated machine having a product-dedicated multi-spindle head. With shorter product life cycles, the need to be able to reprogram machines/ production lines became essential. MAG Powertrain Ex-Cell-O's XHC series horizontal spindle machining centres are an example of a design aimed at this type of work speed of positioning is the real target here. In fact, Ex-Cell-O claims to be the first European company to introduce a high speed machining centre with linear motor technology, in 1993. In contrast, MAG Cincinnati's HyperMACH vertical gantry machining centres are aimed at high-speed machining of aircraft components, such as ribs, bulkheads, plate, frames, stringers and spars. X-axis lengths in excess of 9 m are supported. Sodick's machining centres are aimed at mould toolmakers, so the machining of hardened materials with an emphasis on high speed machining, accuracy and superior surface finish. On its EDM machines, linear motors are employed, in the case of die-sink, on the vertical Z-axis ram to support high-speed movement over very small distances, plus fine position resolution. Sodick makes its own linear motors, and so owns the technology and has a price advantage over those that don't. Japan's Fanuc similarly makes and uses its own linear motors in vertical machining centres and wire-cut EDM machines, but sells its technology to third parties, unlike Sodick. Gildemeister's use of linear motors, mostly on machining centres, but also on some turning centres, is aimed at overall performance enhancement in speed, accuracy and surface finish, but also lower maintenance costs/repair requirements have been cited as an advantage. It buys linear motors in very large volumes and so has higher purchasing power versus some others. Sliding-head lathes are used to turn long, thin parts whose cycle times are just a few seconds and fast slideway movements are helpful in minimising dead time/slashing cycle times and the smaller the part, the more important this becomes. Citizen's R04/7 machines (4/7 mm bar diameter) employ them in all axes X, Y and Z. Elsewhere, grinding machines, both cylindrical and surface/profile types, use linear motors. The former often to support X-axis following of, say, crankshaft pins orbiting about a centre of rotation; the latter to provide rapid table movement and reversal. SPEED IN PROFILE Laser profilers can cut thin material very fast, and so need high acc/dec and traverses to keep up. Trumpf's latest 7040 NEW laser profiler, with linear motors and lightweight carbon fibre travelling gantry housing the laser head, boasts axis acc/dec of 2.5 G in X and Y and 3 G in vertical Z. Maximum simultaneous axis speed (X-Y) is 304 m/min. Italy's Prima Industrie has married linear motors to a parallel kinematic axis arrangement, which sees its Syncrono laser profiler's head capable of 6 G acc/dec. Traditional machines (ballscrew or linear motor drive) employ serial kinematics each axis of motion is delivered by one motor/slideway moving in that same axis. In contrast, parallel kinematic motion in a given direction involves the simultaneous adjustment of several struts, which deliver resultant motion in a different direction to that which they themselve move. Such a system can give rise to an amplification effect, hence the 6 G achieved.

Conclusion: Let us consider the feed kinematic chain having as transformation mechanism a ball screw-nut mechanism as figure 5 shows.

Fig 5. Feed system driven a by electric motors

Fig 6. Mechanical structure with linear electric motor

Conventional Method

Linear Motor Servo Method

There are a few intermediates between motor and table. Instructions from the control takes some time to reach the table.
Chronic deterioration is inevitable

No intermediate between Linear motor and table. No time loss, resulting in accurate quick movement.
High-speed, high-accuracy and quick response are maintained

Thermal expansion Need to replace every 3 years to maintain original accuracy

No contact Original accuracy for ever No backlash Quick response

Over time, ball screws wear creating scrapped parts; but since linear motor drives is no contact system, they have also eliminated the possibility of scrap parts.

On the bed 1, on the bearings 2 and 6, the ball screw 3 is mounted. The electric motor 7 drives the ball screw (with pitch p) through a reduced composed by the pulleys 8 and 9 and a toothed belt 10. The nut 5, by means of support 4, displaces the slide 11 on the machine guides [2]. Linear motors consist of two parts a stationary track or platen and a moving forcer. They can be provided as a stand-alone linear motor assembly or as a complete stage built with a housing or enclosure with linear bearings, limit switches, cable track/carrier, protective bellows and linear encoder in a wide variety of lengths . In case of replacing the above system with one having a linear electric motor, the components mechanisms ball screw-nut, nut support, reducer and rotary electric motor are removed. The achieved mechanical structure is schematically presented in figure 6.

On the bed 1, the secondary is mounted, being formed in this case by two elements 2 and 3. The primary 4 is fixed on the saddle 5. The relative motion between primary and secondary leads to the properly positioning of the saddle. For motor cooling there is a special system 6.
The electric motors represent a modern solution for driving the feed and positioning kinematic chains in new and refabricated machine tools. By using these motors, the construction of the feed system is simplified by removing the rotary electric motor, couplings, mechanism for motion transformation (generally ball screwnut), and eventual speed reducers. Nowadays, there are linear electric motors that cover a great range of speeds having also some limitations regarding the developed forces. It is recommended their using in small and medium machines, existing the perspective of using them even in heavy machine tools It is strongly recommended the realization of a complete calculation from the static and dynamic point of views, on the basis of the technical documentation supplied by the motor producers. The cooling systems specific to these types of driving will be treated also carefully. Before the advent of practical and affordable linear motors, all linear movement had to be created from rotary machines by using ball or roller screws or belts and pulleys. For many applications, for instance where high loads are encountered and where the driven axis is in the vertical plane, these methods remain the best solution. However, linear motors offer many distinct advantages over mechanical systems, such as very high and very low speeds, high acceleration, almost zero maintenance (there are no contacting parts) and high accuracy

without backlash. Achieving linear motion with a motor that needs no gears, couplings or pulleys makes sense for many applications, where unnecessary components, that diminish performance and reduce the life of a machine, can be removed.

Linear motors provide unique speed and positioning performance advantages. Linear motors provide direct-coupled motion and eliminate mechanical transmission devices They offer substantial improvements over applications using ball screws, timing belts, etc. The rugged mechanical design provides accurate motion and precision positioning for hundreds of millions of cycles. Linear motors and stages are used in thousands of successful applications worldwide. At the end we can say that Linear motors provide the following advantages: 1. High repeatability resolution to 0.000004 inch (0.1 microns) this makes sure all parts produced are accurate and identical 2. Highly accurate to 0.0001 inch/ft (2.5 micron/300 mm) provides precise machine operation for precision parts.This numers can not br achived with lead screws and gears, 3. No backlash direct drive has no backlash such as with lead screws, gears, etc. this improves the accuracy of the part or operation 4. Faster acceleration from 1 to over 10 Gs (98 m/s), this leads to shortened cycle times and improved productivity. This numers can not br achived with lead screws and gears, 5. Higher velocities speeds to over 300 inches/second (8 meters/sec) to position the payload faster. This numers can not br achived with lead screws and gears without other desavantages, 6. Long term reliability only two parts with only one moving part this leads to simplicity and improves the applications reliability 7. No wear or maintenance no contacting parts, thus reducing component friction and wear like the sistems with lead screws and gears,. 8. Ease of installation linear motors are designed to allow for alignment tolerances. Misalignment produces no degradation of performance The disadvantage with linear motors is they are not inherently suitable for use in a vertical axis. Due to its non-contact operation, if the motor were shut down, any load that is been held vertically would be allowed to fall. There are also no failsafe mechanical brakes for linear motors at present. The only solution that some manufacturers have achieved is by using an air counterbalance. At the end we can do this comparation:

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