Linear motors or pneumatic slides?

Readers of CONTROL DESIGN magazine chime in with their preferred choices, some suggested application strategies, and how much of an issue reliability, maintenance and cost should be.

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E MAKE PACKAGING EQUIPMENT and use pneumatic linear slides. They've been pretty accurate and we know how to support them. One of our new engineers is all about linear motors and feels we'll have a big improvement in accuracy and reliability, simpler maintenance and increased machine uptime if we re-design. What do you think? -- A CONTROL DESIGN magazine reader


Stick With Pneumatics

It's true that a linear motor and especially a linear servo motor would give increased accuracy and might even reduce maintenance downtime. But these benefits will come at significantly increased cost and increased difficulty of troubleshooting when something finally does go wrong. So, do you need the increased accuracy and is the present level of reliability unacceptable?

For simple stop-to-stop motion, it is virtually impossible to beat air-operated linear slides. The only time I would look at electric motor solutions is when there's a need for precise control of speed or endpoint, especially if these parameters need to be changed by software, or where other considerations such as sanitary or cleanroom environment or lack of an air source preclude use of pneumatics.

Kim Ground, Senior Automation Engineer
Surface Finishing Technologies, Clearwater, Fla.

Choose What's Simpler
Linear motors are going to improve your machine's performance in areas or accuracy, speed and flexibility. As far as reliability and simpler maintenance are concerned, there's more to it than a simple component replacement.

If done properly, the linear motor solution will provide simpler maintenance and greater reliability because of the significantly more advanced diagnostic features associated with servo drives. In the event of a problem, the faults generated should pinpoint exactly what happened, and what the corrective action is. With a pneumatic slide, all you know is that it didn't get there in time.

If the application is not done properly, the more complex servo system will baffle the typical maintenance electrician, and the machine might sit idle until you, not your customer, ends up fixing it. There's not a lot involved,from a technical standpoint,to a pneumatic slide, and that helps the untrained technician. Overall, you need to ask yourself which one presents a bigger problem for you: the machine not performing its function, or an external force preventing your machine from performing its function.

Lastly, be careful not to open a Pandora's Box by making the upgrade. You'll need to look at the mechanics of your machine before attempting such an upgrade. Linear motors have the potential to introduce a significantly higher amount of stress and strain to your machine due to the higher velocities and acceleration/deceleration rates. Cable tracks and other wire-management devices will need to be examined for higher velocities and higher fill ratios. Safety systems, panel layouts, etc., will also need to be revisited.

I agree with a move to linear motors from a performance point of view. However, if it is not something that your company can execute or support properly, it might not make sense.

Jason Christopher, Controls Designer
Liberty Precision Industries, Rochester, N.Y.

Do Your Homework
When faced with the decision of choosing between linear motors or pneumatic slides, the first step should be to identify the specific application where the actuator is to be used. Then consider requirements for speed, accuracy, and flexibility. Finally, evaluate performance vs. cost. Select the technology that best fits the application and budget at hand.

Traditionally, linear motors are very accurate with a premium price tag, while pneumatic rodless actuators are affordable with limited flexibility and accuracy. Additionally, linear motors provide higher speeds, which translates to more cycles per minute, and can accelerate heavier loads than pneumatics.

Kjell Lyngstad, Market Segment Manager
Bosch Rexroth Pneumatics, Lexington, Ky.

Linear Is a Viable Replacement
Linear motors and linear stages can accelerate rapidly,as much as 10 g with speeds to 200 in./sec. Linears provide repeatability ranging 1-25 ?m and accuracy of 10 ?m. What performance is needed and what improvements are you trying to attain?

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