Solutions for long-range linear motion

Short-range linear motion of machine tools is often achieved using ballscrews and nuts, but this design can become problematic as travel length increases. In a typical ballscrew-and-nut drive, the nut is fixed to the moving table. As the screw rotates, the nut translates along the axis of motion. In this configuration, the servomotor directly sees the rotary inertia of the screw. Rotary inertia is the resistance of the servomotor rotor and attached screw to rotational acceleration.

As the desired motion elongates, so does the screw. As the screw length increases, so does its rotary inertia. As its rotary inertia increases, the acceleration achievable by the limited motor torque decreases. In the traditional ballscrew-and-nut design, long motions have low accelerations. In addition, as screw length increases, the screw becomes thin and flexible, and, without support, the screw can begin to whirl like a jump rope. However, it is difficult to support the screw and still allow the nut to pass.

Courtesy of Atlanta Drive Systems

Figure 1. A rack-and-pinion drive for a linear axis.

For these reasons and others, fixed-nut, rotating-screw designs are practically limited to about 4 ‘ of travel. If the desired motion is longer, another solution is needed. In machine tools with long travels, two basic designs are common: rack-and-pinion and linear drives.

In a rack-and-pinion drive, the servomotor is attached to the small pinion gear, and the teeth mesh with the teeth on a long-toothed track—the rack (Figure 1). The rack is often fixed to the machine base, and the servomotor and pinion are mounted to the moving component. As in a gear, motion quality is directly related to teeth quality.

A common problem in these types of drives is backlash, a pause in motion caused by the clearance between teeth when the direction of motion is reversed. In addition to backlash being reduced by improving the precision of the teeth, it can be reduced by using a spring-loaded split pinion. In this design, the pinion is split into two parts: one side in contact with the rack in the direction of forward motion and one side in contact with the rack for motion in the opposite direction. The preload between the two parts is set with a spring, and the spring’s force is greater than the operating force, so contact is never lost in either direction.

Backlash can also be removed by using two servomotors, loading two pinions against each other. The advantage of this design is the preload is programmable. In most cases, the positional feedback for a rack-and-pinion drive is a rotary encoder on the servomotor. Such systems can have intermediate gears to increase the transmission ratio, making the servomotor insensitive to the inertia of the moving axes or cutting forces.