Miniaturized linear motion

Test and measurement, semiconductor, and precision CONTENTS

medical applications are pushing the envelope of mod-
ern motion designs. In these and other applications, Rotary
actuators —
compact linear motion designs are being leveraged to Electromagnetic
deliver accurate movement. motors paired
with rotary-to-
linear converters

Integrated
stepper-
leadscrew
actuator
advantages

Compact linear motion comes in myriad Coreless micromotors address some of A few notes on
forms — traditional rotary micromotors the limitations of iron-core dc motors. miniature slides
paired with miniature rotary-to-linear Only the copper coil moves — the and guides
converters, direct-driving linear motors, magnets do not. A tiny ø38-mm version
pneumatic cylinders, and piezomotors that can output 100 W of power. These
output linear force. These linear motion coreless micromotors are suitable for Miniature
pick-and-place, avionics, and compact
designs satisfy myriad design requirements,
designs necessitating high precision. linear motors
shrinking overall machine footprint (as in
pick-and-place robotics and medical devices),
reducing power consumption, and boosting • MOTOR: The proportionality of dc
precision. motor output speed to applied voltage, Linear
current and torque output linearity, and piezomotors
Rotary actuators — output predictability by stall torque and no-
Electromagnetic motors paired load speed alone all simplify the application
with rotary-to-linear converters of dc-motor-based linear actuation. Miniature
Miniature linear actuators — rotary step Myriad options exist: Brushed iron-core pneumatic
or brushless dc motors connected to rotary- motors, brushed ironless motors, brushless linear actuators
to-linear devices — are designed to deliver micromotors, and permanent-magnet
up to several Newtons of force, typically over brushless motors used for microstepping.
2 to 200-cm travel lengths. Only mechanical Simplicity and low cost are the key
devices such as leadscrews or belt drives strengths of brushed iron-core motors. Iron-
capable of maintaining the required level core construction delivers high torque and
of accuracy are paired with such motors in rigidity, though the heavy armature limits
exacting miniature applications. rates of acceleration. What’s more, when the
motor’s brushes pass over each commutator
1
motors paired with rotary-to-linear…1
Rotary actuators —Electromagnetic

Hall-effect sensors or even analog

sensors for sinusoidal commutation
is usually required for turning the
motor phases on and off at the
correct times.
Electronically commutated
permanent-magnet step motors
are yet another option for small
Integrated stepper-leadscrew

precision installations. 12 pole

actuator advantages … 2

pairs on the rotor (and stator)

is common; one, two, three,
and even five-phase motors are
possible. These are highly suitable
Brushless dc motors are not speed for applications requiring wide
limited by mechanical commutation speed ranges, holding power even
subcomponents. Actuators based on when de-energized, and frequent
this motor type incorporate drive stopping, starting, and reversing.
electronics, leadscrew, and in some Microstepping is possible with
cases, a nut and gearbox. motors of sufficient angular
accuracy and a drive designed to
continuously vary winding current
Miniature linear

(for dividing full steps into smaller

motors …3

segment, small voltage spikes result. This compounds discrete steps.) That said, surgical applications and pick-
regular mechanical wear. Motor designs employing an and-place robotics that cannot tolerate slight performance
ironless setup (with skewed-wound coils) are stiffer and variations due to thermal effects might not be suitable uses
generally more efficient thanks to a lighter rotor. Faster for these motors.
accelerations are possible, and cogging is eliminated —
useful features in miniature precision machinery employing • SCREW OR BELT: Conversion of rotary to linear
linear motion. movement with a leadscrew often uses balls that roll through
A few notes on miniature

Brushless motors must overcome starting friction as the mechanism’s load zone to eliminate sliding friction between
slides and guides … 3

well as dynamic friction defined as mNm/rpm; viscous nut and screw. For miniature applications, precision-machined
ball-bearing friction and Eddy currents cause these losses. steel screws are used for their accuracy. Backlash — the play
However, brushless commutation both necessitates and between nut and screw — depends on the ball size and groove
benefits from electronic control, typically in the form of geometry. Preloading (to negative clearances) can keep backlash
pulse-width modulation. Closed-loop control with digital below 0.05 mm or better. In other designs where lighter loads
are moved, some leadscrews utilize
plastic drive nuts, which maintain
Integrated stepper-leadscrew actuator advantages precision by automatically
Step motors paired with leadscrews are an indispensable miniature linear-actuator adjusting for wear, and reduce
combination, largely because actuators with these subcomponents are well-suited for overall design weight and power
positioning tasks. consumption.
piezomotors… 3

All step motors turn a discrete amount for each pulse of electrical input, which is a mode An alternative to actuators
of operation widely leveraged in myriad applications. Certain miniature linear actuators take employing rotary-to-linear
this a step further by integrating the leadscrew into the step motor rotor. In these designs, screws is synchronous (toothed)
Linear

the rotor’s permanent magnets follow the motor’s sequentially energized coils to concurrently belts. These are used in some
advance the screw’s mechanical nut via the screw’s thread along the working linear axis. In miniature linear-motion
other setups, the leadscrew’s nut (instead of the screw) is integrated into the rotor to enable applications where high speed
linear advancement. Both types eliminate the need for mechanical couplings between motor (to 30 cm/sec) is priority.
and leadscrew; zero-backlash gearboxes and quadrature magnetic encoders can then be Advances in material science
integrated where required. and belt-tooth geometry analysis
Miniature pneumatic
linear actuators … 5

Miniature actuators integrating step motor and leadscrew are commonly found in have spurred designs capable
laboratory, X-Y table, and optical positioning applications. (with closed-loop control)
of generating relatively high-
2
 motors paired with rotary-to-linear…1
Rotary actuators —Electromagnetic
or a screw’s linear bearings
support a moving carriage.
Capacity depends on
motor torque capacity,
screw diameter, and the
application’s inherent
amount of pitch or roll.

actuator advantages … 2
Integrated stepper-leadscrew
Miniature linear motors
Linear-motor designs abound.
In one miniature iteration, three
coils position a shaft packed
Permanent magnets with permanent magnets.
for positioning Driven by a servocontroller, the
PMDC motors are shaft is positioned with almost
useful for positioning zero residual static force — a
and other precision suitable mode of operation
applications; stepping for micro-positioning. As in
often offers sufficient larger designs, feedback is
trackability, and provided by a linear encoder or

slides and guides … 3

A few notes on miniature
inherent detent toque Hall-effect sensors. The latter
is useful where power reduces design cost as well as
is at a premium. size, with some housings 10
cm3 or smaller. The elimination
of static force (associated with
precision linear motion: Glass fiber or aramid reinforcements traditional rotary-motor types) and linearity between
extend life and ensure stable belt length for precision; current input and output force make these motors suitable
modified trapezoid, curvilinear, and customized tooth for micropositioning.
profiles allow for no-slip positive pulley engagement. The main advantage of linear motors is their direct
driving of attached loads, which eliminates the lost
• SUPPORTS AND ACTUATOR STRUCTURES:

motors …3
Miniature linear
Rod and rodless screw-based actuators exist.
Applications positioning small or pivoting loads often A few notes on miniature slides
use rod-type electric cylinders, especially if the load is
otherwise supported. Here, an electric motor rotates the and guides
screw and advances a car; where needed, intermediary Common miniature slides and guides are designed
gearboxes match motor output to required linear speed to deliver 3 to 1,000 cm travel lengths, depending on
and thrust. Positioning actuators (often for conveyed actuation method. To sufficiently support the load over such
items) can move and stop loads in various positions travel lengths, the primary linear motion device can require
with accuracy to ±0.010 mm. For fragile loads, controls supplemental load support in the form of slides and guides.
piezomotors… 4
Linear
also ensure gentle decelerations. Finally, these actuators Here, mechanical subcomponents are precision machined;
can guide loads in isolated environments, as the rod can aluminum alloy structures boost rigidity and reduce weight.
extend into a space while the cylinder main and motor Some miniature linear stages have one guide and one
remain outside. bearing instead of two; elsewhere, miniature slides may
One potential concern when utilizing leadscrews incorporate friction-free surfaces in lieu of rolling elements.
in precise miniature applications is that imbalance of Where accuracy trumps the aim to reduce friction,
the rotating component can transversely excite natural miniature guides utilizing rollers are often preloaded.
system frequencies. Therefore, turning shaft supports Positive clearance is eliminated for zero or even negative
linear actuators … 5
Miniature pneumatic

often consist of bidirectional bearings at each end where values with rollers that are larger than the guide’s roller
possible. Setups with one free (unsupported) end are less channels. The rigidity and accuracy of such setups is
stiff and typically less accurate. indispensible in applications such as wafer welding and
In contrast, rodless actuators provide support and probing (during final testing.)
positioning from one compact design. Here, a belt
3
motors paired with rotary-to-linear…1
Rotary actuators —Electromagnetic
Integrated stepper-leadscrew
actuator advantages … 2

Piezomotors
are suitable for
nano-positioning
applications.
Miniature linear
motors …3

motion and accuracy degradation

of intermediary mechanical
devices. Typically, linear motors
for compact designs move loads of
10 N or more over 4 to 1,000 cm
A few notes on miniature

travel lengths.
slides and guides … 3

Accelerations commonly reach

7 g with sufficiently stiff framing
with smooth motion even at low
speeds. In some designs, one
unit can support multiple cars to
simultaneously position multiple
loads. Top speeds exceed 900 cm/
sec; thrust depends on motor size.

Linear piezomotors
Focusing, adjustment, and
piezomotors… 4

For micron-positioning accuracy, some tubular

inspection in medical and linear motors use permanent magnet thrust
electronics machinery are rod paired with a primary mover. The high
applications for which piezomotors cost of the magnets is less of an issue in smaller
Linear

are suitable, thanks to this type designs. This electrically commutated linear dc
of motor’s ability to deliver sub- servomotor delivers precise linear motion.
micrometer positioning — even
down to a few nanometers in
some designs. For example, in a
measuring application, piezomotors might slowly move piezo stepmotors. The former sometimes come in stacked-
Miniature pneumatic
linear actuators … 5

objects past machine vision set up to record their geometry. crystal designs that generate motion in a way that resembles
Delivered travel lengths are typically 2 to 40 cm. the operation mode of a traditional solenoid — with
Four linear piezomotor types exist: Single-element, stroke direction in line with crystal polarization — useful
flexure-guided, standing-wave piezomotors, as well as for dispensing applications. In contrast, standing-wave
4
 motors paired with rotary-to-linear…1
Rotary actuators —Electromagnetic
piezomotors are suitable for longer strokes: Piezo crystals Traditional miniature servopneumatic actuators deliver
vibrate ultrasonically to advance a screw that translates accuracies to 0.20 mm or better — sufficient for numerous
attached loads. Stepmotor designs activate a series of positioning applications. They move loads to 500 cm/sec
crystals through various positions to walk loads forward; without inducing shock in the load or machine. Challenges
speeds to 100 cm/sec make this design useful in tiny include stick-slip behavior and degraded speed consistency
robotics, unmanned drones, and fine-tuned positioning when carried loads vary. Even so, 20-g acceleration exceeds
applications. Visit www.accelacomm.com/jaw/micromo-piezos- that of certain electromechanical linear designs, which is

actuator advantages … 2
Integrated stepper-leadscrew
motion/9/50196544/ for more information on miniature useful for particularly quick or short linear strokes.
piezomotor technologies. An alternative design is miniature pneumatic
motors. Capable of 30 mN-m or more at 5 to 60,000
Miniature pneumatic rpm (depending on the miniature gearbox fitted to
linear actuators the design) these are driven by air pumped through a
Miniature pneumatics are manufactured in several rotary series of vanes.
designs. Prime fluid-power generation is based on the © Penton Media Inc. 2013
conversion of compressed air into mechanical power for
the linear translation of loads. Actuators leveraging this
means of operation excel in positioning of light loads
over multiple stops, particularly when equipped with
digital sensors and valves or sensors that linearly vary
output signal with piston movement.

slides and guides … 3

A few notes on miniature
motors …3
Miniature linear
piezomotors… 4
Linear
linear actuators … 5
Miniature pneumatic