Linear

Engineering Actuator
Operation Rod Type or Rodless?
Rod Type actuators are similar in configuration to a NV Series
hydraulic or pneumatic actuator and are preferred
3 2
when you need to position an externally supported
load, move a load that pivots, retrofit a hydraulic or
pneumatic actuator, or have “reach in requirements”. 4

EC and NV electric actuators (see the NV series figure,

7
right) use leadscrews (1) to convert rotary motion into 10 11
linear motion. The motor (2) is mounted to the
bearing housing (3), and the motor’s power is
transmitted to the screw through a gear, or timing-belt
reduction (4). The screw turns and moves the drive
nut (5), which is connected to a guide flange (6). The 1 5 6 9 8
guide flange keeps the nut from rotating, by sliding
1. Leadscrew 4. Drive Train 7. Guide Cylinder 10. Rod End Housing
through the guide cylinder (7). The thrust tube (8) is 2. Motor 5. Drive Nut 8. Thrust Tube 11. Rod End
threaded on to the nut, and is supported by the sleeve 3. Bearing Housing 6. Guide Flange 9. Sleeve Bearing
bearing (9) in the rod-end housing (10). The load is
attached to the rod end (11).

Rodless actuators have a bearing support system and a and each end is connected to the connector bracket (5).
carriage that runs the length of the actuator. This type The connector bracket is connected to two bearing
of actuator is preferred when you need to save space by blocks (6) that ride on the recirculating ball-bearing rail
eliminating external guides and ways, when high speed (7) that is mounted in the guide cylinder (8). The
and long stroke lengths are needed, when the shortest carriage (9) is mounted to the connector bracket and
overall work envelope is needed, or when a multi axis the seal strip (10) runs between them. The connector
Cartesian System is required. bracket lifts the seal as the carriage moves, while roller
wheels (11) in the carriage push the seal back in place.
R2, R3 and R4 rodless actuators use a leadscrew or a
R2 actuators have no bearing blocks, but instead have
transport belt to convert the motor’s power to linear
roller wheels for bearing support (as seen in the figure
thrust. Pictured below is a belt-drive actuator. As in the
below). Four track-roller bearings run on two hardened
EC and NV actuators, there is a timing belt, or gear
and ground steel shafts, pressed into the extrusion.
reduction (1) between the motor (2) and the driven
Engineering

pulley (3). The transport belt (4) runs over two pulleys

4 11 9 5 10

R2A Carriage

6 7 8

1. Drive Train 5. Connector Bracket 9. Carriage Roller

2 Bearings
2. Motor 6. Bearing Blocks 10. Seal Strip
3. Transport Pulley 7. Linear Rail 11. Seal Roller
4. Transport Belt 8. Guide Cylinder Steel Shaft

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 Linear
Actuator Engineering
Rod Type or Rodless? Operation

Linear Modules are very efficient, high speed systems, the Thrust Rod (2). The Thrust Block is connected to
that have repeatabilities in microns. They are similar in one or two bearing blocks (3) that ride on a wide linear
configuration to the R-series Rodless actuator family, but rail (4), which is mounted to the base extrusion (5).
operate on a different principle. A linear motor converts The Thrust Rod runs through the Thrust Block and is
electric current directly into linear force. There is no mounted to brackets on either end of the base
rotary motion to be converted. Motor coils, hall effect extrusion. The motor wiring is housed in a cable track
sensors, and the linear-encoder read head are mounted (6) that flexes with the movement of the Thrust block.
in the Thrust Block (1), while permanent magnets are in

1 2

6 5
End View

1. Thrust Block 4. Linear Rail

2. Thrust Rod 5. Base Extrusion
3. Bearing Blocks 6. Cable Track

3 4

Engineering

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 Linear
Engineering Actuator
Operation Rotary to Linear Conversion
Linear motion systems driven by rotating electric motors Leadscrews
commonly employ one of three rotary-to-linear Screw-drive mechanisms, whether Acme screw or
conversion systems: ballscrew, belt drive, or Acme ballscrew provide high thrust (to thousands of pounds),
screw. but are often limited by critical speed, maximum
recirculation speed of ball nut circuits, or sliding friction
of Acme nut systems.

Ballscrew Ballscrew
The majority of linear motion applications convert
motor torque to linear thrust using ballscrews due to
their ability to convert more than 90% of the motor’s
torque to thrust. As seen below the ballnut uses one or
more circuits of recirculating steel balls which roll
between the nut and ballscrew threads. Ballscrews
provide an effective solution when the application
requires:
• High efficiency - low friction
• High duty cycle (> 50%)
• Long life - low wear

Acme Screw Acme Screw

The Acme Screw uses a plastic or bronze solid nut that
slides along the threads of the screw, much like an
ordinary nut and bolt. Since there are no rolling
elements between the nut and the leadscrew, Acme
screws yield only 30-50% of the motor’s energy to
driving the load. The remaining energy is lost to friction
and dissipated as heat. This heat generation limits the
Engineering

duty cycle to less than 50%. A great benefit of the Acme

screw is its ability to hold a vertical load in a power-off
situation (refer to the Backdrive specifications for acme
screw actuators). The Acme screw is a good choice for
applications requiring:
• Low speeds
• Low duty cycles (50%)
• The ability to hold position while motor power is off

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 Linear
Actuator Engineering
Rotary to Linear Conversion Operation

Timing Belt
Belt Drive systems offer many of the benefits of actuator and is attached to the carriage to pull it back
ballscrews, yet have fewer moving parts, and do not and forth along the length of travel. The carriage is
have the critical speed limits of leadscrew-driven supported by a linear bearing system to provide load
systems. They generally provide more linear motion carrying capacity. The neoprene belt is reinforced with
from the same motor movement, resulting in higher steel tensile elements to provide strength and minimize
travel speeds with minimal component wear. In belt stretch. Timing belt systems are a good solution for
contrast, this design results in lower repeatability and applications requiring:
accuracy. Thrust capability is also smaller compared to • High speeds
screw-drive systems due to the tensile strength limitation
of the transport belt. • Low thrusts
• High efficiency
The general configuration can be seen in the figure. A
toothed belt passes around a pulley in each end of the • High duty cycle

Belt Drive
Carriage and Linear
Support Bearings

Engineering

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 Linear
Engineering Technology
Comparison
Mechanical Drive Comparison
The following chart will help
pinpoint which linear drive
mechanism is right for your
application. IDC offers many
actuator options, such as brakes,
encoders, lubrication ports,
preloaded nuts, and precision
ground screws, that may help you
meet your specification. If these
standard options do not meet
your requirements, please contact
the factory for information
regarding custom solutions.

Considerations Acme Screw Ballscrew Belt Drive

Noise Quiet Noisy Quiet

Back Driving Self Easily Easily

locking backdrives backdrives

Backlash Increases with wear Constant throughout Can increase with wear
screw life or stretching of belt

Repeatability +/-0.005" to 0.0005" +/-0.005" to 0.0005" +/-0.004"

Duty Cycle Moderate High High
max. 60% max. 100% max. 100%
Engineering

Mechanical Efficiency Low High - 90% High - 90%

Plastic Nut - 50%
Bronze Nut - 40%
Life and Mechanical Shorter life due to Longer Longer
Wear high friction

Shock loads Higher Lower Low

Smoothness Smooth operation Smooth operation Smooth operation

at lower speeds at all speeds at all speeds

Speeds Low High Higher

Cost $$ Lowest $$$ Moderate $$$ Moderate

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 Linear
Technology Engineering
Mechanical Drive Comparison Comparison

Linear Motor Comments

Moderate Acme: Sliding nut design provides quiet operation.
Ball: Transmits audible noise as balls recirculate through nut during motion.
Belt: the neoprene cover of the belt provides damping of noise. The support bearings
will generate some noise.
Easily backdrives Acme: Good for vertical applications; vibration may cause position loss.
Ball: May require brake or holding device when no holding torque is applied to the
screw.
Belt: May require brake or holding device when no holding torque is applied to the drive
pulley.
Linear motor: Low friction system–backdrives easily.
Negligible Acme: Considered worn-out when backlash exceeds 0.020". Typically 0.006" when
shipped from the factory.
Ball: Typically constant at 0.006" (lead screw/nut only).
Belt: Typically at 0.010" when shipped. Can be adjusted to compensate for wear or
stretching.
Linear motor: with a preloaded rail there is zero backlash.
Best (microns) Linear motor: repeatability depends upon the encoder used. Sub micron possible.
High max. 100% Acme: Low duty cycle due to high friction from sliding surface design.
Ball: High screw efficiency and low friction allow high duty cycle.

Engineering
Belt: High efficiency provides low heating and high duty cycle.
Highest - 90-95% Acme: Low efficiency sliding friction surfaces.
Ball: High efficiency smooth rolling contact.
Linear motor: Efficient - no conversion needed between rotary and linear motion.
Longest life, least mechanical wear Acme: Mechanical wear is a function of duty cycle, load and speed.
Ball: Virtually no mechanical wear when operated within rated load specifications.
Belt: High efficiency contributes to long life. Drive belts can be easily replaced to
extend system life.
Linear motor: Limited by cable flex, and bearing life.
Highest Acme: Better suited because of larger surface area.
Ball: Brunelling of steel balls limits shock load capability.
Belt: Shock loads can cause fatigue and stretching of drive belts.
Smoothest Acme: At extreme low speeds, units have a tendency to stop/start stutter (due to
friction).
Ball: Generally smoother than acme through the entire speed range.
Belt: 180° engagement of belt provides continuous smooth contact throughout the
speed range.
Highest Acme: Extreme speeds and accelerations can generate excessive heat and deform the
screw.
Belt: Each revolution of the drive pulley provides several inches of travel. Speeds up to
120 in/sec can be achieved.
Linear motor: LM to 196 in/sec. LD to 394 in/sec.
$$$$ Highest

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 Engineering
Linear
Technology
Electric Cylinders vs.
Comparison
Hydraulics & Pneumatics
For many applications, hydraulic or pneumatic linear Or, when very light loads must be moved rapidly and
cylinders are a better choice than their repeatedly from one fixed location to another fixed
electromechanical alternatives. For example, when location, pneumatic cylinders may be the most
extremely heavy loads (>25,000 N [5,620 lb]) must be economical solution.
moved, hydraulic cylinders are usually the best solution.

Industrial Devices Hydraulic Pneumatic

Electric Cylinders Cylinders Cylinders
Installation All electric operation requires Requires expensive plumbing, Requires expensive plumbing,
simple wiring; directly filtering, pumps, etc. Must pay filtering, pumps, etc.
compatible with other close attention to compatibility
electronic controls. of components.
Precise Cost-effective, repeatable (to Requires expensive position Most difficult to achieve.
Positioning ±0.013mm [±0.0005in]), rigid sensing and precise electro- Requires expensive position
multi-stop capabilities. hydraulic valving to sensing and precise valving to
implement; has tendency to implement; has tendency to
creep. creep.
Control Solid-state microprocessor- Requires electronic/fluid Inherently non-linear,
based controls allow automatic interfaces and sometimes compressible power source
operation of complex motion exotic valve designs. severely complicates servo
sequences. Hysteresis, dead zone, supply control. Compressibility can be
pressure and temperature an advantage in open loop
changes complicate control. operation.
Speed Smooth, variable speed Difficult to control accurately. More susceptible to stick slip
capabilities from 0.5 to 1330 Varies with temperature and and varying load. Well-suited
mm/sec [0.02 to 52.5 in/sec]. wear. Stick slip can be a for high speed applications to 5
problem. m/sec [200 in/sec].
Reliability Repeatable, reproducible Very contamination sensitive. Very contamination sensitive.
performance throughout useful Fluid sources require Air sources require proper
life of product; little maintenance. Seals are prone filtration. Good reliability, but
maintenance required. to leak. Good reliability with usually many system
diligent maintenance. components are involved.
Power Virtually unlimited force. Most
Engineering

Up to 25,000 N [5620 lb], 3kW Up to 5,000 lbs. Typically used

[4 HP]. powerful. below 1 HP.
Cycle Life Up to millions of cycles at rated Dependent on design and seal Dependent on seal wear,
load. Easy to predict. wear; usually good. usually good.
Environment Standard models rated for -20° Temperature extremes can be Temperature extremes can be
to 160° F. Inherently clean and a major problem. Seals are a major problem. Seals prone
energy efficient. prone to leak. Waste disposal to leak. Air-borne oil can be a
is increasingly problematic. problem.

Safe Load Acme screw units are self- Complex back-up safety Complex back-up safety
Holding locking if power fails. Fail-safe devices must be used. devices must be used.
brakes available for ball screw
models.
Cost Moderate initial cost; very low Components often cost less, Components often cost less,
operating cost. but installation and but installation and
maintenance are increased. maintenance are increased.
Hydraulic power unit cost is Most cost-effective for low
high if not pre-existing. Most power, simple point-to-point
economical above 10 HP. applications.

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 Electric Cylinders vs. Linear
Technology Engineering
Hydraulics & Pneumatics Comparison

But when simplicity, flexibility, programmability,

accuracy and reliability are important and loads are
within the capacity of the technology,
electromechanical solutions often are the most
desirable.
Further, electromechanical systems are inherently
more compatible with today’s automation controls.

Engineering

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 Linear
Engineering Sizing
Calculations Move Profile
Rotary and linear actuator selection begins with the The Move Profile sketch contains some important
calculation of speed, thrust and torque requirements. In information:
order to determine the torque required, the acceleration
• Peak acceleration is the steepest slope on the curve,
of the mass being moved must be calculated. A “move in this case during t4 or t5.
profile”, or a plot of load velocity vs. time, is
sketched in order to simplify the peak acceleration • Maximum velocity is at the highest or lowest point
and peak velocity calculations. over the entire curve, here at the peak between t4 and t5.
• Distance is equal to the area under the curve. Area
above the time axis represents distance covered in the
Typical Machine Cycle positive direction, while negative distance falls below
Typical Cycle Time T Next Cycle this axis. The distance equation (1) is just a sum of the
areas of two triangles and a rectangle.
Velocity

V+
Trapezoidal and Triangular Profiles
V- Time
A couple of assumptions can greatly simplify the general
equations. For the Trapezoidal profile we assume
t1=t2=t3, and for the Triangular we assume t3=t4.
t1 t2 t3 t4 t5
Substituting these assumptions into equations (2) and (3)
yields the equations shown in the figure below.
For a given distance (or area), a triangular profile
requires lower acceleration than the trapezoidal profile.
(1) Total distance, dtot = vMAX t1 + t2 + t3
2 2 [ ] This results in a lower thrust requirement, and in turn, a
smaller motor. On the other hand, the triangular profile’s
peak speed is greater than the trapezoidal, so for
dtot
applications where the motor speed is a limiting factor, a
(2) Max velocity,
(
vMAX = t1 + t3
2
)+t 2 trapezoidal profile is usually a better choice.

vMAX Trapezoidal Move Profile

(3) Acceleration, a= tACCEL

v max
vAVE = dtot
ttot
The figure above is an example of a typical machine v avg t1 = t2 = t3 = ttot
a
cycle, and is made up of two Move Profiles; the first is Velocity 3
d tot
an example of a trapezoidal profile, while the second (in/sec)
Engineering

is a triangular profile. The horizontal axis represents vMAX = 1.5 dtot = 1.5 vAVE
time and the vertical axis represents velocity (linear or t1 t2 t3 ttot
T (time in sec)
rotary). The load accelerates for a time (t1), has a d
a = 4.5 tot 2
constant velocity or slew section (t2), and decelerates to (ttot)
a stop (t3). There it dwells for a time, accelerates in the
negative direction (t4), and decelerates back to a stop
(t5) without a slew region. The equations needed to Triangular Move Profile
calculate Peak Velocity and Acceleration for a general
trapezoidal profile are shown in the figure. A triangular Vmax
dtot
profile can be thought of as a trapezoidal profile vAVE =
ttot
where t2 = 0. a
Vavg t1 = t3 = ttot t2 = 0
2
Velocity
(in/sec) d tot
vMAX = 2dtot = 2 vAVE
t1 t3
ttot
T (time in sec)
4dtot
a= = 2vMAX
(ttot)2 ttot

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 Linear
Sizing Engineering
Move Profile Calculations

Example 1 Example 3
Calculate the peak acceleration and velocity for an This is an example of a case when triangular and
object that needs to move 30 inches in 2.5 seconds. trapezoidal move profiles are not adequate
Assume a Trapezoidal Profile. approximations. Assume a maximum actuator speed is 6
inches/sec. Sketch a move profile that will complete a
Solution
10 inch move in 2 seconds. What is the minimum
allowable acceleration rate in inches/sec2?
vmax
Solution

d tot= 30 in.
v
Triangular
Trapezoidal
Actual
2.5 sec. Required
Move

vAVE = 30 in = 12 in/sec
2.5 sec
t
d
vMAX = 1.5 t tot = 18 in/sec
tot
Triangular
dtot vAVE = 10 in = 5 in/sec
a = 4.5 (t )2 = 21.6 in/sec2 2 sec
tot
vMAX = 2 × vAVE = 10 in/sec (vMAX > 6 in/sec – too fast)

Example 2
Trapezoidal
Calculate, in radians/sec, the peak acceleration and
velocity for an cylinder that needs to move 5 revolutions vMAX = 1.5 × vAVE = 7.5 in/sec (vMAX > 6 in/sec – too fast)
in 0.4 seconds. Assume a Triangular Profile. These are too fast, so we need to find t1 as follows:
Solution

v max Required Profile

Engineering
dtot = vMAX ( (t +2 t )+ t )
1 3
2
5 revs
substitute (t1 + t3) = ttot - t2

d=
vMAX
( (t 2- t ) ) + t = t2
tot 2
2 tot + t2
2
0.4 sec. solving for t2,

× 2 = ( 10 in –
2 )
ttot
t2 = (vd
MAX
tot -
2
) 6 in/sec
2 sec
×2
dtot = 5 revs x 2π rad = 31.42 rad
rev t2 = 1.33 sec
vAVE = 31.42 rad in = 78.55 rad Now assume t1 = t3, so
0.4 sec sec
t1 = (ttot - t2)/2 = 0.33 sec.
vMAX = 2 vAVE = 157.1 rad
sec
Finally, calculate acceleration
dtot
a = 4 2 = 785.5 rad2 v
T sec a = MAX = 6 in/sec = 18 in 2
t1 0.33 sec sec

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 Linear
Engineering Sizing
Calculations
Thrust Calculation
Thrust Calculation Wactuator becomes important when the acceleration force,
The thrust required to move a mass a given distance (Wt/g)a, is a significant part of the thrust calculation.
within a given time may be calculated by summing all of For simplicity, start by neglecting this weight, and
the forces that act on the mass. These forces generally calculate the required thrust without it. After selecting
fall within the following four categories: an actuator, add its mass to the mass of the load and
recalculate. To make these equations clear, lets begin
• Gravity is important when something is being raised
with an example.
or lowered in a system. Lifting a mass vertically is one
example, as is sliding something on an incline.
Example 1
• Friction forces exist in almost all systems and must
be considered. We would like to move a 200 lb weight a distance of
10 inches in 2 seconds. The mass slides up and incline
• Applied forces come from springs, other actuators, with a friction coefficient of 0.1 at an angle of 45°.
magnets, etc., and are the forces that act on the mass
other than friction, gravity, and the actuator’s thrust. There is a spring that will be in contact with the mass
The spring shown in the figure below is an example during the last 0.5 inch of travel and has a spring rate
of an Applied force. of 100 lb/in. What is the maximum thrust and
velocity?
• Actuator thrust is the required actuator force, and is
what we need to determine. Solution
We need to look at the thrust requirement during
Fapplied
each part of the move, and find the points of
maximum thrust and maximum speed. Choosing a
trapezoidal profile we calculate that vmax is 7.5 in/sec
and the peak acceleration is 11.25 in/sec2 (see
Factuator WL Move Profile Section).
F friction
Acceleration Section:
Ma = 200 lb/386 in/sec2 × 11.25 in/sec2
= 5.83 lb
Fgravity
Fapplied = 0 lb
Ffriction = [200 lb × cos (45)] × 0.1 = 14.14 lb
The figure above shows a general case where the force
Fgravity = 200 lb × sin (45) = 141.4 lb
required by an actuator must be determined. All of the
above forces are included, and it is important to note Ftotal = 161 lb
that all of these forces can change over time, so the Slew Section:
Engineering

thrust must be calculated for each section of the move Ma = 0 lb (since a=0)
profile. The worst case thrust and speed required
should be used to pick the appropriate actuator. All of Fapplied = 0 lb
these forces added up (Σ) must be equal to mass × Ffriction = [200 lb × cos (45)] × 0.1 = 14.14 lb
acceleration, or: Fgravity = 200 lb × sin (45) = 141.4 lb
Ftotal = 156 lb
ΣF=m×a , or, (1) Deceleration Section:
Ma = 200 lb/386 in/sec2 × -11.25 in/sec2
= -5.83 lb
Factuator - Fapplied - Ffriction - Fgravity = ma = ( Wg ) a t (2)
Fapplied = K × x = 0.5 in × 100 lb/in =50 lb
(worst case)
Factuator = ( Wg ) a + F
t applied
+ Ffriction + Fgravity (3) Ffriction = [200 lb × cos (45)] × 0.1 = 14.14 lb
Fgravity = 200 lb × sin (45) = 141.4 lb
where Wt= Wload + Wactuator (4) Ftotal = 200 lb

Ffriction = µWLcosθ, and So the worst case required thrust is 200 lb. And
the worst case velocity is 7.5 in/sec.
Fgravity = WLsinθ

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 Linear
Sizing Engineering
Thrust Calculation Calculations

Actuator Mass Vertical and Horizontal Cases

In applications where the acceleration force, (Wt/g)a, In a vertical system, θ is 90°, sin90 = 1, and Fgravity is
is a significant part of the required thrust, the actuator equal to WL. Since cos90 = 0, Ffriction = 0.
mass must be considered in the thrust calculation. After
an actuator is chosen, the actuator weight (linear
inertia), Wactuator, is added to the weight of the load. WL
Wactuator can be determined using the tables and
equation in the actuator data section. To illustrate, we
Factuator = (Wt/g)a + Fapplied + Fgravity
will use the previous example.
1. The first step is to pick an actuator with the above Factuator = (Wt/g)a + Fapplied + WL
thrust and speed capability. One such actuator is an
EC3-B32-20-16B-12. This is an EC3 actuator with a
B32 motor, a 2:1 gear reduction, a 16mm lead In a horizontal system, sinθ = 0, so gravity would play no
ballscrew, and a 12 inch stroke. part (Fgravity = 0), and cosθ =1, so Ffriction would be equal to
2. The next step is to look up the effective Actuator µWL, or 50 lb.
Linear Inertia in the tables located in the particular
actuator section (do not include the “load” term in WL
the equation). An entry from this table can be seen
in the table below. The B32 motor inertia is 1.00 x
10-3 in-lb-sec2. The effective actuator weight, Factuator = (Wt/g)a + Fapplied + Ffriction
calculated from the table is 247 lb.
Factuator = (Wt/g)a + Fapplied + µWL
3. The final step is to add this weight to the weight of
the load, WL, and recalculate the peak thrust RMS Thrust
required for each section of the move profile (do
not add this weight to the gravity or friction For all Servo Motor applications, the RMS Thrust needs
terms): to be calculated. This thrust must fall within the
continuous duty region of the actuator. Use the
following equation when calculating RMS Thrust:
Acceleration Section:
Ma = 447 lb/386 in/sec2 × 11.25 in/sec2 FT ACC FT VEL FT DEC FT OFF

Thrust Profile
= 13.03 lb Move Profile

Ftotal = 169 lb
Slew Section:

Engineering
FT RMS
Ma = 0 lb (since a=0)
Deceleration Section:
Ma = 447 lb/386 in/sec2 × -11.25 in/sec2)
tA tV tD toff
= -13.03 lb
Ftotal = 193 lb
FT RMS = (FT ACC )2ta+ (FT VEL )2tv+ (FT DEC )2td+ (FT OFF)2toff
We can see from this calculation that the addition of
t a + t v + t d + t off
this extra “acceleration weight” increases the thrust
required during acceleration, but reduces the peak
thrust required during deceleration. The EC3-B32-20-
16B-12 will work in the application.

EC3 Cylinder Actuator Linear Inertia = [A + B*(stroke, in) + D]/C Motor Inertia (in-lb-sec2)
Leadscrew Ratio A (lb-in-s2) B (lb-in-s2/in) C (lb-in-s2/lb) D (lb-in-s2)
16x16 1:1 1.1909E-03 1.1760E-05 2.6039E-05 B32 1.00 E-03
1.5:1 7.4495E-04 5.2280E-06 1.1573E-05
2:1 4.7866E-04 2.7650E-06 6.1212E-06

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 Linear
Engineering Sizing
Calculations Loading Limitations
NORMAL FORCE: Fn = Fz
Yaw Axis
z SIDE FORCE: Fs = Fy
PITCH MOMENT: Mp = Fz (lx) + Fx (lz + dp) + Ty
ROLL MOMENT: Mr = Fz (ly) + Fy (lz + dr) + Tx
Tz YAW MOMENT: My = Fx (ly) – Fy (lx) + Tz

Fz
Carriage
Fx
Ty
• Tx
General loading condition applied at point
Fy
(lx, ly, lz) from center of the carriage.

lz

ly
lx dp or dr
Roll Axis
x
Pitch Axis
y

Rodless actuators have bearings designed to support The equations for pitch, roll, and yaw assume that the
significant loads, however actuator loading is limited, directions of the arrows in the figure are POSITIVE. If
and moment, normal, and side loads on the rodless the forces or torques in your application work in the
actuator and linear motor carriages need to be opposite direction, they are NEGATIVE and they should
evaluated. be entered as negative numbers in the formulas. The
same is true for the distances lx, ly, and lz.
Moment loads are rotational forces (or torques) which
are applied to the carriage assembly. They are defined as It is important to add the carriage to bearing distances,
Engineering

yaw, pitch, and roll and are measured in in-lb. dp (pitch) and dr (roll), in the roll and pitch moment
calculations above. These distances vary for each
To evaluate the actuator you have chosen, use the
actuator and are listed in the table below.
diagram above. The three forces (F) and the three
torques (T) are a general loading condition applied to Examples
the load a distance lx, ly, and lz from the centerpoint of To illustrate these calculations, refer to the facing page
the carriage. These forces may be due to gravity, which shows six typical rodless actuator orientations
friction, applied loads, and actuator thrust. Each of these and the equations for the calculation of moment, normal
forces may act at different points of application. For and side loads in each case.
example, gravity will act at the center of gravity of the
load, while friction and applied loads will act at the edge
of the load.

Table of Added Moment Distances (inches)

R2A Series R3 Series R4 Series Linear Motors
Screw Belt Screw Belt Screw Belt LM25 LM38
dp - pitch 1.822 1.575 1.68 1.10 2.42 1.90 2.60 3.23
dr - roll 1.11 1.11 2.76 1.97 3.94 3.06 2.60 3.23

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 Linear
Sizing Engineering
Moment Loading Calculations

Load and Cylinder Orientation

Note: THRUST = Factuator as
Fx explained on page K-12, equation (3)
WL

Fn = F z = W L
dp lz
Mp = Fx (lz + dp)
Fx = THRUST

ly
Fn = Fz = WL

Fx Mp = Fx (lz + dp)
WL Mr = Fz (ly)

Fz My = Fx (ly)
Fx = THRUST

lx Fz
Fn = F z = W L
dp
WL
lz Mp = Fz (lx) + Fx (lz + dp)
Fx = THRUST

Mp = Fx (lz + dp)
WL
lz Fx = THRUST
Fx dp

Engineering
lz

WL
Mp = Fx (lz + dp)
dp
My = Fx (ly)
ly Fx
Fx = THRUST

dr, dp Fy = W L

WL
Mp = Fx (lz + dp)
Mr = Fy (lz + dr)
lz
Fy Fx = THRUST

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 Linear
Engineering Sizing
Calculations
Loading Limitations
Dual Carriage Option
The a dual carriage option is available to increase pitch,
roll and yaw loading capability. This is generally needed
in vertical applications with heavy loads. To get the
most benefit from the extra carriage, the load should be d
distributed so that each carriage sees the same force.
The Dual Carriage option is available for both belt and
screw driven actuators. Follow the example in the figure RB
to calculate the required distance between the two
carriages with a given loading configuration. This Rodless Actuator,
distance must be added to the stroke length of the Dual Carriages
D
actuator. The option is specified as in the example
below:
R4B32-104B-96-PL-ADE RA FX

Dual Carriage Option

Note: The second carriage does not increase the thrust RA = R B = F X d
D
load capability.
Idler
An idler is a rodless actuator with its power transmission
parts removed and can be used in conjunction with a
R A = – R B = Fx ( Dd )
rodless actuator when roll, pitch or yaw moments are Example:
exceeded. It is dimensionally similar in an R2, R3, or R4
To support a 300 lb load located 10 inches away
actuator except it has no motor, belt or, screw. An idler
from the carriage of an R4 actuator, how far apart
is specified:
should the centers of the carriages be placed if
Rx-IDLER-Stoke Length (in)-ASE we know the maximum allowable normal load is
For example, an R3-IDLER-48-ASE is a 48-inch stroke R3 300 lb on each carriage?
idler with angle brackets, a single carrige and English It is assumed there is a rigid bracket between the
mounting dimensions. All idlers have the same load load and the carriages (weight of the bracket is
limitations as their actuator counterparts. included in the 300 lb) and that there are no
moment loads transmitted to the carriage.
Customer Options
Engineering

By changing the system design, and taking the loading Solution:

off of the actuator, sometimes a smaller actuator than It is a good idea to leave some safety margin so we
once thought can be used. Counterbalancing removes will use 150 lb as the maximum Normal Load on
the need for the actuator to do work against gravity. the R4 carriage (actual normal load is 300 lb).
External rail support removes moment loads that are
RA = 150 lb
too great for the actuator. This can be done with an IDC
Idler, or any number of off-the-shelf linear rails and D=?
bearings.
d = 10 in
Fx = 300 lb

RA = RB + Fx ( Dd )
D = Fx (d) = 300 lb (10 in)
RA 150 lb

D = 20 inches

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 Linear
Sizing Engineering
Duty Cycle Calculations

Duty Cycle is the ratio of motor-on time to total

Example:
cycle time and is used to determine the acceptable
level of running time so that the thermal limits of the V
motor or actuator components are not exceeded.
Inefficiencies cause a temperature rise in a system, and Move
when the temperature reaches a critical point, Cycle
components fail. Letting the system to rest idle during
the cycle allows these system components to cool. Duty 3 sec 1 sec
cycle is limited by Acme screw and motor thermal ON Time Off Time
limits. Use the following equation and example to
determine Duty cycle: Duty Cycle = 3 sec × 100
3 + 1 sec
Duty = ON TIME
× 100 = 75%
Cycle ON TIME + OFF TIME
Motor Type
Leadscrew Limitations
Electric motors incur heat losses via a number of paths,
Cylinders with Acme screws have sliding friction namely, friction, ohmic (I2R) losses in copper windings,
surfaces and are limited to a maximum 60% duty cycle hysteresis and eddy current induction in magnetic core
regardless of motor capability. The friction in the Acme materials, and proximity and/or skin effect in windings.
screw causes rapid heating, and continuous operation is As a result duty cycle can be limited by the motor
likely to end in a ruined nut or screw. For actuators with winding temperature limitations.
ballscrews the motor is the only duty-cycle limitation
when used within the listed speed vs. thrust curves in Step Motors
the catalog. Series wound motors (S23T, S32T, S42T, etc.) are rated
for 100% duty cycle, while the parallel wound motors
Acme screw limitations are shown in the catalog speed (S23V, S32V, S42V, etc.) are limited to 50% above 5 RPS.
thrust curves as a set of percentages. An example of an Duty Cycle percentages for Stepper motor actuators are
R3H-105A curve is below. If we wanted to run this listed as percentages on the speed thrust curve.
actuator at 6 in/sec and 25 lb thrust, it would be limited
to 60% Duty Cycle over any 10 minute period (1). If we Servo Motors
wanted to increase the thrust to 60 lb, this would drop Actuators using D, H and B Series motors must have
the duty cycle rating to 30% (2). their peak (Fpeak) and continuous (FRMS) thrust
Acme screw duty cycle is a function of Pressure and requirements determined to establish their safe
Velocity, so operation at very low speeds or thrusts may operation within an application. FRMS can be determined

Engineering
allow duty cycles above 60%. If an Acme screw is using the RMS Thrust equation in the Thrust Calculation
required and Duty Cycle requirements exceed 60%, section. Plotting FRMS on the actuator Speed vs. Thrust
please call the factory for a custom evaluation. If power- curve indicates the allowable Duty Cycle. For ball screw
off position holding is required, consider using a brake actuators, FRMS must fall within the continuous duty
on a ballscrew or on a motor. region, while for Acme screws it must fall in the 60%
duty region. Fpeak must fall within remaining operating
envelope. The speed vs. thrust curve below is an
mm/s in/s R3H-105A example of proper servo actuator sizing.
381 15

305 12
mm/s in/s R3B23-105B
Speed

305 12
229 9
(1) (2) 254 10
152 6 • • 30% 203 8
60% 10%
Speed

76 3
152 6
VMAX

0 102 4
15 30 45 60 75 90 105 120 135 150 lbs
67 133 200 267 334 400 467 534 601 667 N 51 2
Thrust FRMS FPEAK
0
0 100 200 300 400 500 600 700 lbs
445 890 1335 1779 2224 2669 3114 N
Thrust

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 Linear
Engineering Motion
Terminology
Actuator Precision
Parameter Definition Dominating Factors
The maximum error between expected
Absolute Accuracy and actual position.
• Accuracy of the motor/drive system
• Leadscrew pitch error (lead accuracy)
• System backlash (drive train,
leadscrew and nut assembly)
Repeatability The ability of a positioning system to • Angular repeatability of the motor/
return to a location during operation when drive system
approaching from the same direction, • System friction
at the same speed and deceleration rate.
• Changes in load, speed, and
deceleration
Resolution The smallest positioning increment • Angular resolution of the motor/drive
achievable. In digital control systems, system
resolution is the smallest specifiable • Drive Train Reduction
position increment.
• Leadscrew Pitch
Backlash The amount of play (lost motion) between • Leadscrew wear (acme)
a set of moveable parts. • Drive train wear
• Spaces between moving parts

Accuracy and Repeatability Ideal System

Assume three linear positioning
Start Expected Position
systems each attempt five moves Position A
from an absolute zero position to
absolute position “A”. The No
Motion Error
individual end positions of each
move are charted on a linear scale
below to demonstrate their accuracy
and repeatability by displaying their
proximities to the expected
position.
Engineering

Degree of Degree of
Start Position Expected Position Accuracy Repeatability Comment
System 1 High High System 1 is both accurate and repeatable,
Move 1
Move 2 the end positions are tightly grouped
Move 3
Move 4 together and are close to the expected
Move 5 position
System 2 Low High System 2 is inaccurate but repeatable,
Move 1
Move 2 the end positions are tightly grouped
Move 3
Move 4
around a point but are not close to the
Move 5 expected position.
System 3 Low Low System 3 is neither accurate nor
Move 1
Move 2 repeatable, the end positions are not
Move 3
Move 4
tightly grouped and are not close to the
Move 5 expected position.

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 Linear
Motion Engineering
Actuator Precision Terminology

Backlash Primary Sources of Backlash

The clearance between elements in a drive train or
leadscrew assembly which produces a mechanical 1. Drive Nut/Leadscrew Assembly
“dead band” or “dead space” when changing directions,
is known as the backlash in a system.
Backlash
In most mechanical systems, some degree of backlash is
necessary to reduce friction and wear. In an IDC
Actuator System, system backlash will typically be
0.010 – 0.015 inches. Usually 0.006 – 0.008" is
attributed to the leadscrew/nut assembly. For
ballscrews this will remain constant throughout the life
of a cylinder, while for acme screws it will increase
with wear. Ballnut

Reducing the Effects of Backlash

1. Approach a stop position from the same direction. 2. Drive Train (Gears, Timing Belt/Pulley)
2. Apply a constant linear force on the cylinder thrust
tube or carriage. This is done automatically for
cylinders used in vertical orientations with a
backdriving load.
3. For programmable positioning devices it is possible Backlash
to program out backlash by specifying a small
incremental move (enough to take out the backlash)
prior to making your normal moves in a particular
direction.
4. Use a preloaded nut on a leadscrew to counteract
the backlash. Contact IDC about the precision
ground screw option which reduces backlash in
the drive nut.
5. An inline actuator with the motor directly coupled
to the leadscrew has less backlash than parallel or 3. Timing Belt/Pulley
reverse parallel units which utilize a gear train or
drive belt/pulley.

Engineering
6. Use an IDC LM or LD Linear Motor Module.
Backlash

4. Coupling

Backlash

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 Engineering
Linear
Motion
Critical Speed
Terminology and Column Loading
Critical Speed
All leadscrew systems have a
rotational speed limit where
harmonic vibrations occur. In
Industrial Devices cylinders, this
limit is a function of unsupported
leadscrew length. Operation beyond
this critical speed will cause the L
leadscrew to vibrate (whip violently)
eventually bending or warping the
screw.
Thrust
Load

Column Strength
All leadscrews have a maximum
column loading limit which causes
the screw to compress as load
increases. In IDC cylinders this limit Compression (column) Load
is a function of unsupported
leadscrew length. Exceeding this Column
limit will cause the leadscrew to mm/s in/s R3B23-105B Load Limit
305 12
buckle and become permanently 254 10
damaged. 203 8
Speed

152 6

102 4 Critical Speed

Limit
Determining the Limits 51 2

Critical Speed and Column Loading 0

0 100 200 300 400 500 600 700 lbs
information for each screw type (i.e. Useable Speed
445 890 1335 1779 2224 2669 3114 N
and Thrust Thrust
2B, 5A, 8A, 5B …) can be found at
the bottom of each “Performance” Rodless Actuator

page in the particular actuator’s R3 Performance

100 lbs Payload
Brushless Servo
R3B

section. Acme Screw Models

mm/s in/s R3B23-105A

305 12
230VAC R3B23-105A-P: 1:1 Timing Belt, 5 rev/inch Acme Screw
254 10 R3B23-105A-I: 1:1 Inline Coupling, 5 rev/inch Acme Screw
Engineering

Min. Backdrive Load 400 lbs 1779 N

Speed

203 8
Max. No-Load Accel. 360 in/s2 9.1 m/s2
152 6
Backlash 0.015 in 0.38 mm
Example

Rodless Actuators
102 4
60% 115VAC Repeatability ±0.001 in ±0.025 mm
51 2 Lead Accuracy ±0.005 in/ft ±0.13 mm
0

Find the Column Load and Critical 50

222
100
445
150
667
Thrust
200
890
250
1112
300 lbs
1335 N

R3B23-155A
Speed limits for an R3B23-105B, 42 mm/s in/s
203 8
178 7
230VAC
R3B23-155A: 1.5:1 Timing Belt, 5 rev/inch Acme Screw
Min. Backdrive Load 400 lbs 1779 N
152 6

inch stroke actuator. The actuator Max. No-Load Accel. 420 in/s2 10.7 m/s2
Speed

127 5
Backlash 0.015 in 0.38 mm
102 4
115VAC Repeatability ±0.001 in ±0.025 mm
76 3

data can be found in the R3B 51 2

25 1
60% Lead Accuracy ±0.005 in/ft ±0.13 mm

Section. Reading off the chart at the 50 100 150 200 250 300 350 400 450 lbs
222 445 667 890 1112 1335 1557 1779 2002N
Thrust

bottom of page, the limits are 400 lb mm/s in/s

152 6
127 5
R3B23-205A
230VAC
R3B23-205A: 2:1 Timing Belt, 5 rev/inch Acme Screw
Min. Backdrive Load 400 lbs 1779 N

and 3.6 in/sec. The usable speed/ Max. No-Load Accel. 430 in/s2 10.9 m/s2
Speed

102 4
76 3 Backlash 0.015 in 0.38 mm
Repeatability ±0.001 in ±0.025 mm
thrust is restricted to less than these 51 2
25 1
60% 115VAC Lead Accuracy ±0.005 in/ft ±0.13 mm

0
values as seen in the modified speed 100
445
200
890
300
1335
Thrust
400
1779
500
2224
600 lbs
2669N

vs. thrust curve. mm/s in/s

64 2.5

51 2.0
R3B23-505A
230VAC
R3B23-505A: 5:1 Helical Gears, 5 rev/inch Acme Screw
Min. Backdrive Load 400 lbs 1779 N
Max. No-Load Accel. 130 in/s2 3.3 m/s2
Speed

38 1.5
Backlash 0.015 in 0.38 mm
25 1.0 Repeatability ±0.001 in ±0.025 mm
60% 115VAC
Lead Accuracy ±0.005 in/ft ±0.13 mm
13 0.5

0
100 200 300 400 500 600 700 800 lbs
445 890 1335 1779 2224 2669 3114 3559 N
Thrust

60% duty region Intermittent duty max region

(230 VAC/115VAC) (max 2 second duration)
(max rms torque, over
5B any 10 minute interval)

To configure your system see page B-90.

15.0 9.4 6.5 4.7 3.6 2.8 1.9 1.3 Critical Speed (in/sec)
• Consider leadscrew critical speed and column load limits when specifying longer lengths.

6 thru 18 24 30 36 42 48 60 72 Stroke (inches) 5B

15.0 9.4 6.5 4.7 3.6 2.8 1.9 1.3 Critical Speed (in/sec)
5A
15.0 11.3 7.1 4.9 3.6 2.7 2.1 1.4 1.0 Critical Speed (in/sec)
6 thru 18 24 30 36 42 48 60 72 Stroke (inches) 6 thru 12 18 24 30 36 42 48 60 72 Stroke (inches)

n/a n/a 780 540 400 300 190 130 Column Load Limit (lbs) n/a n/a 780 540 400 300 190 130 Column Load Limit (lbs) n/a 700 390 250 175 125 95 60 40 Column Load Limit (lbs)

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 Linear Actuator
Environmental Engineering
Environment Considerations

Environmental conditions are an important design Primary Environmental Factors

consideration when selecting an IDC actuator. Industrial
• Temperature
Devices’ units are self-contained systems which are
protected from “direct contact” with harsh • Liquid contaminants
environments by an aluminum housing with a durable • Particle contaminants
anodized and epoxy coated surface finish. However,
extreme conditions can have an adverse effect on
cylinder operation and life. Factors such as extreme
temperature, liquids or abrasive contaminants (gaining
internal access) can impede performance and cause
premature wear of mechanical parts. Review the
information below when sizing your application to
choose appropriate options or protective measures.

Rod Type Rodless

Temperature
• NV actuators are rated for use between 0 and 60°C • R-series rodless actuators are rated for use between
(32 to 140°F). -28°C and 60°C (-20°F to 140°F).
• EC actuators are rated for use between -30 and 70°C
(-22 to 158°F)
Particle and Liquid Contaminants
• NV series actuators are protected against dust but are • Rodless actuators are protected by a flexible stainless-
not protected against direct water (or any liquid) steel-backed flouro-silicon seal. They are IP44 rated,
contact. Liquid or moisture can gain access into the which protects the actuator where minimal liquid
housing, eventually corroding internal components. splash may occur. Units require a customer supplied
• EC actuators are sealed and gasketed and are rated to bellows when placed in an environment containing
IP 54. They are protected against dust and light water liquid spray or washdown.
sprays and splashing.

Engineering
Protective Boot Option
The -PB option is available for EC actuators and
increases the actuator’s resistance to liquids. The
diagram to the right shows a typical installation of an
EC with the -PB option. This option protects the
actuator to IP65. Note that some IDC motors are not
protected to this level. The -PB option is not available
with NV or R-series Rodless actuators.
Custom Environmental Options
IDC has over 20 years experience designing custom
actuators. We have designed fully encapsulated
actuators for Corrosive, Food Processing, and
Washdown environments, and have experience EC Actuator Thrust Tube Protective Boot
designing Cleanroom compatible actuators. Call IDC
for more information regarding Custom environmental
options.

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 Engineering Motor
Introduction to
Technology
Motion Control Technology
Many different components are used in a variety of successful application depends on choosing the right
combinations to create a complete motion control or combination of actuator, motor, drive, and control
positioning system. IDC offers the broadest range of technology. More than one technology may meet the
products spanning the complete spectrum from requirements of your application. In this case, factors
mechanical actuators to microstepping and brushless such as performance, cost, flexibility, and simplicity may
servo drives to programmable motion controllers. A determine your selection.

PC
or Motion Drive Motor Feedback Mechanical
PLC Control Device System

Host Computer DC Motor Encoder Linear Actuator

Programmable Programmable Limit Switch Control Brushless Servo Linear Potentiometer Linear Positioning Table
Controller Motion
Microstepping Drive Step Motor Direct Drive Linear Motor
Controller
Brushless Servo Drive Linear Servo Motor Rotary Table
Gearhead
Smart Drive
Programmable Drive Control

Introduction to Motor Technologies Stator Magnets

DC Motor Systems
DC motors are used with IDC’s DC motor controls to Rotor
Windings
control velocity and position. With these simple
controls, limit switches attached to the actuator or the Brushes
customer’s load provide position feedback. DC motors
are also used with analog position controls and a linear
potentiometer for position feedback. The result is an
absolute positioning system. They can also be used in
closed loop servo systems with an incremental encoder
Commutator
Engineering

for position feedback.

DC motors have windings on the rotor of the motor. To
supply current to the rotor, a set of brushes ride on a
segmented commutator, which supplies current to the Common Applications
appropriate internal windings depending on the position • Air cylinder replacement
of the rotor. Brushes may need to be replaced
periodically, depending on the load, speed and duty • Clamping, pressing
cycle. The commutation method limits the top speed • Transfer mechanisms
that can be reached before arcing over the commutator Advantages
segments occurs. The heat generated in the windings • Lower cost than brushless
must travel across the air gap and the through stator to
• Simple controls
be dissipated. This long thermal path results in a motor
that is less thermally efficient and is therefore larger than Disadvantages
a brushless motor with an equivalent power rating. The • High maintenance (brushes).
windings also add inertia to the rotor, which results in • Larger motor
lower peak acceleration rates than a similar brushless
• Less responsive
motor.

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 Introduction to Motor Engineering
Motion Control Technology Technology

Step Motor Systems

Step motors have the inherent ability to divide a
revolution into discrete steps and to hold position at rest
without the need for a feedback device. Electromagnets
in the stator are energized and cause teeth in the rotor
to line up with teeth in the stator. Sequencing the
current in the windings causes motion. The rotor will
“follow” the stator as if attached by a spring, as long as
the available torque from the motor is not exceeded.
A typical “full-step” system will achieve 200 steps per
Stator Rotor
revolution with a 50-tooth hybrid step motor by
following a simple four-state sequence of positive and
negative winding currents. After each four steps an 1 2 3 4
adjacent rotor tooth will be lined up with a given stator
tooth. Fifty cycles through the sequence results in a
complete revolution, with the original rotor and stator
Phase A
teeth lined up. The direction you proceed through the
sequence determines the motor direction.
Full Stepping
Microstepping is a technique that increases resolution
by controlling both the direction and amplitude of
Phase B
current in each winding. Instead of a square wave with
four steps, we sequence through what looks like a sine
and cosine waveform. The cycle is divided into as many 1 cycle
4 full steps
as 1000 steps. The result is a positioning resolution of 1/50 rev.
50,000 steps or more per revolution. Microstepping
improves low speed smoothness and minimizes the low Phase A
speed resonance effects common in full step systems.
IDC microstepping drives employ unique anti-resonance Microstepping

circuitry which damps oscillations and improves

performance and throughput. Phase B

Step motors can operate open loop in most applications

and provide excellent repeatability (±5 arc sec, ±

Engineering
0.0005" with actuators, submicron with precision
tables). An encoder can be used if closed loop operation
is desired. This may be important when a jam or stall
condition must be detected. An encoder attached
Common Applications
directly to the load can improve the overall accuracy of
the system as well. • Short, rapid moves
• Accurate positioning systems
Advantages
• High acceleration, duty cycle
• Excellent repeatability
• No maintenance (brushless)
• High torque at rest, moderate speeds
• Mechanically stiff with no vibration at rest
• Lower cost than brushless servo
Disadvantages
• Inefficient at high speeds
• Excessive loads can stall motor

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 Engineering Motor
Introduction to
Technology
Motion Control Technology
Brushless Servo Systems
IDC brushless servo systems use a three-phase brushless Magnets
servo motor with an incremental encoder for position
feedback.
S
Brushless servo motors are constructed with the
windings in the stator or outer portion of the motor and N N
have permanent magnets attached to the rotor. The
location of the windings next to the finned surface of S
the motor provides a shorter path for heat generated in
the windings to escape. This improved thermal
efficiency when compared to a dc motor results in
higher power ratings for a similar sized motor. Less Windings
rotor inertia and no mechanical commutator limits result
in higher speed and acceleration capabilities. Common Applications
The servo controller and drive use the encoder feedback • Higher speeds and accelerations
signal to continuously adjust the motor torque so that • Changing loads
the desired position is maintained. This is referred to as
a closed loop servo system. The electronics required to • Clamping, pressing
operate a brushless motor and “close the loop” are Advantages
therefore more complex and expensive than • Closed loop control
microstepping or dc motor controls. • Highest torque at high speeds
Unlike DC motors, which use a mechanical commutator • No maintenance (brushless)
to deliver current to the appropriate torque producing • Efficient operation
windings, the brushless motor requires a feedback
device to sense the position of the permanent magnet Disadvantages
rotor in relation to the motor’s windings. The servo • Higher cost
drive must maintain the correct relationship between
the magnetic vector created by the windings and the
rotor position to produce torque.
IDC brushless servo drives employ proprietary vector
torque control and advanced servo algorithms to provide
unmatched closed loop servo performance (see page
Engineering

K-32 for a more thorough discussion).

Linear Brushless Servo Motors Common Applications

A special type of brushless servo motor, IDC direct drive • Highest linear speeds and accelerations
linear motors use an innovative design that houses the • Repeatable linear positioning
permanent magnets in a cylindrical thrust rod. The Advantages
motor’s windings reside in the thrust block which • Direct production of thrust
surrounds the rod. A linear incremental encoder is used
for closed loop position feedback along with hall sensors • High reliability
for commutation. • Efficient operation
All of the electromagnetic force is utilized to produce Disadvantages
thrust directly, eliminating the need for rotary to linear • Higher cost
conversion mechanisms. This eliminates backlash, lead
error and other mechanical system innacuracies.

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 Introduction to Motor Engineering
Motion Control Technology Technology

Introduction to Feedback Devices

Incremental encoder
Optical encoders generate an output signal as the
encoder disk rotates. The disk passes between a light Channel A
source and photo detectors. The number of lines on the
disk determines the number of on-off cycles of each
output during a revolution. The detectors are arranged
Channel B
such that the two output signals are in “quadrature”
(shifted in phase 90°). A once per revolution index
channel is usually provided for establishing a home or
zero position upon power up. Index

Electronic circuitry in the motion controller counts the

pulses from the encoder to determine the position of the
motor. The quadrature signal allows the controller to
count up when rotating in one direction and down in
the other, thus always remembering the absolute
position of the system as long as power is applied. There
are four unique transitions per cycle and controllers will
generally count each transition. The number of counts
per revolution is often referred to as the “post
quadrature” resolution. For example, an encoder with
1000 lines will generate 4000 counts per revolution
“post quadrature”.

Incremental encoder with commutation channels

The process of steering current through the appropriate Vab Vbc Vca

motor windings in order to produce output torque is

Motor
called commutation. In brush motors, commutation is Back EMF
performed electro-mechanically via brushes and the
commutator. In brushless motors, commutation is
performed by electronically steering the current to the
appropriate winding. To do this, the rotor position must

Engineering
be determined. A circuit board containing the Hall Hab
devices is aligned with a magnet on the rotor, so that the Hall
relationship shown between the Hall outputs and the Devices
motor back EMF can be established. Hbc

When a brushless motor is used in a servo application Hca

requiring position feedback, room must be made for 0 60 120 180 240 300 360 60
both the commutation circuit board as well as the Degrees
encoder. This generally adds both cost and complexity
to the motor package. Encoders are now available with
integrated commutation outputs equivalent to those
produced by Hall devices. The result is a more compact
system, reduced alignment time and superior switching
accuracy, due to the much lower hysteresis of the
encoder when compared to a Hall device. Adding
additional data tracks to the encoder disk provides the
commutation outputs.

Industrial Devices Corporation

707-789-1000 • [Link] • 24 hour info by fax 916-431-6548 K-25
 Engineering Motor
Increasing
Technology
Step Motor Performance
How Anti-Resonance Increases
Step Motor Performance and Throughputs
The goal in step motor/drive selection is to identify the torque to accelerate the load. This reduction in useable
most economical motor/drive package that will reliably torque can either severely limit the system’s
perform all the moves required in a given application. performance, leading to reduced throughput, or prevent
This can be a challenging task, since using conventional the stepper system from working at all. In Microstepping
step motor systems is not always a straightforward systems, Resonance is especially troublesome in the
procedure. Step motors can lose synchronization (stall), motor’s speed range of 10-15 rps where it is commonly
which causes a loss of positional accuracy resulting in called Mid Range Instability. IDC’s microstepping drives
an unsuccessful move. Step motor systems will stall eliminate the problem of Resonance via proprietary Anti-
when the torque demand for the move being executed, Resonance circuitry, and thereby give the user the
plus the torque lost in overcoming vibration, exceeds maximum amount of torque possible throughout the
the available torque from the motor. One of the major motor’s speed range. To illustrate the negative impact of
causes of step motor stalling is a phenomenon called resonance on conventional step motor performance, and
Resonance. to show how much better the same system will work
with an IDC microstepping drive, a look at the causes
In conventional step motor systems, the increased
and effects of resonance on underdamped
torque demand on the motor due to Resonance
microstepping systems is in order.
decreases the performance of the motor throughout the
motor’s speed range due to a reduction in useable

Step Motor Dynamics

7.2°
Motor torque is delivered to the step motor’s rotor 1.8°
when the rotor lags behind or leads the commanded +
position (see Figure 4). The maximum amount of New
Commanded
torque the motor will exert on the rotor occurs when Position
Tm
the rotor is displaced 1.8° from the commanded
position (Torque equals Tm). Any deflection past 1.8°
Torque

ƒS ƒS
from the commanded position will cause a reduction in
Shaft Position
applied motor torque from the max torque Tm (see s
Figure 4). When the rotor is deflected from the
commanded position, a restoring torque acts on the
rotor to move it back to the commanded position Previous
Commanded
Engineering

(equilibrium) much like a spring. The torque seen by - Position

the rotor at any time is a sinusoidal function of its
displacement from the commanded position. In Figure 4. Operating detent of a step motor.
Figure 4 a 1.8° full step (dashed line) is applied to a
rotor which is located at the previous commanded
position. The instantaneous torque seen by the rotor
when the full step is applied is Tm. Since the torque seen 100.0

by the rotor is a function of position, the 1.8° step

command has caused a step change in applied torque to 0.01
0.10
10.0
the rotor that will cause the motor to ring about the 0.20
0.40
Response

new commanded position (See Figure 6).

1.0
Resonance
Resonance is troublesome to step motor users due to
0.70
the increased torque demand caused by motor vibration. 0.1
This vibration causes the difference between the
commanded and actual position of the rotor to vary in 0
an undesirable manner. The difference between the 0.1 1 10
commanded and actual position is called the position Frequency (fn)
error. It is this position error that dictates the amount of
Figure 5. Frequency response of step motor system. Higher
torque that is applied to the load. Resonant behavior
Values of ζ lead to reduced shaft vibration.

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 Increasing Motor Engineering
Step Motor Performance Technology

in a poorly damped step motor system increases the 2.0

likelihood of the position error exceeding 1.8° (point of 0.02
maximum motor torque). Once the rotor has slipped
past 1.8° there is a decrease in torque applied to the 1.5
0.2
load which can quickly lead to a motor stall if the

Response
required move needs the motor torque that was lost. 0.4
1.0
This torque loss due to shaft vibration is why we look to 0.7

increase the amount of damping present in the system.

Minimizing shaft vibration leads to optimal torque 0.1
0.5
utilization.
The amount of damping in a system can be described by
the system’s damping ratio ζ (Zeta). The higher the
0
0 5 10 20 30
value of ζ the more the system is damped. A typical Time
value of ζ for a conventional underdamped step motor
Figure 6. Ringing transients following a unit step. Increasing
system is 0.02. A step motor system with the optimal
ζ results in more rapid settling.
amount of damping has a ζ value of approximately 0.7.
The effect of increasing the damping ratio is shown in
Figure 5. A typical underdamped step motor system
14.0
magnifies disturbances (vibration) around its natural
Commanded
frequency by a factor of 50. It is this vibration 12.0
Motor Response
magnification which often causes step motors to stall. 10.0
An optimally damped step motor system (like the Velocity (rps) 8.0
) with a damping ratio of 0.7 shows no such
™

vibration amplification. This well behaved system can 6.0

fully utilize a motor’s torque to do real work in your 4.0

application, hence higher acceleration rates are possible
2.0
and greater headroom is provided for varying loads.
0
To illustrate how increasing the damping of a step
0 10 20 30 40 50 60 70 80 90 100
motor system reduces ringing and improves settling Time (msec)
time, it is useful to look at the response of a step motor
to a unit step input for different values of ζ. This is Figure 7. Typical step motor system’s response to a
shown in Figure 6. A system with a damping ratio (ζ) of trapezoidal velocity profile. Lack of damping leads to vibration
at the top and bottom of the profile.
0.7 settles to the commanded position promptly, while a

Engineering
conventional step motor system with a damping ratio of
0.02 rings far off to the right of the graph. Reducing a
system’s settling time increases your system’s 14.0
Commanded
throughput, allowing a user to make more parts per 12.0 Motor Response
minute.
10.0
A step motor system that lacks adequate damping not
Velocity (rps)

only has ringing when a position step is applied, but 8.0

also has significant ringing when the motor is 6.0

commanded to follow a given velocity profile. A popular
velocity profile used in most applications is the 4.0
trapezoidal velocity profile (accel-slew-decel). A typical
2.0
step motor system’s response to a trapezoidal velocity
profile is shown in Figure 7. Notice the ringing in the 0
0 10 20 30 40 50 60 70 80 90 100
motor’s velocity both at the higher speed and after the Time (msec)
ramp. Compare this to the velocity tracking found in an
optimally damped system like the (Figure 8).
™
Figure 8. system response to a trapezoidal velocity
™

The superb velocity tracking and quick settling found in profile. Increasing the damping leads to better velocity tacking
the IDC microstepping drives allows a user to make very and smoother overall motion.
aggressive moves without having excessive ringing at
speed.

Industrial Devices Corporation

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 Engineering Rotary Sizing
Calculations
Rotary System Selection
This section provides useful information for calculating 3. Peak Torque and RMS Torque
your application’s mechanical requirements, and Requirements
selecting the proper motor and drive to meet your To find the peak and RMS torque required by the motor
needs. To insure the proper motor/drive system is to make the move successfully, the Reflected Torque,
selected, follow these steps: TRL, is added to the Torque required to accelerate (or
decelerate) the load. TRL includes all external forces,
1. Sketch the move profile and calculate acceleration,
such as gravity, friction, and applied forces. The
deceleration and maximum velocity required to make
the desired move. equations for peak torque and RMS torque required are:
2. Select mechanical drive mechanism to be used
and calculate inertia, friction and load torque using
formulas for the mechanical drive mechanism.
TPEAK = TRL + [ J eα ]
T

3. Determine peak and continuous (RMS) torque

requirements for the application. TRMS =
√ TA 2 tA + TRL2tR + TD2tD
tc
4. Select a system – choose the appropriate motor and
drive combination that meets all of the application
4. Selecting a System
requirements.
Once the above torques have been calculated, a safety
1. Move Profile factor needs to be added. The safety margin varies with
Refer to the Move Profile section on page K-10 to the motor type desired.
determine your peak velocity and acceleration. Rotary
Safety =
distance units should be radians. Time units are seconds.
NOTE: 1 rev = 2π radians.
Margin (
(Torque Avail)-(Torque Req.)
(Torque Req.) ) x 100
Example: We need to move a total distance of 10 Stepper Systems
revolutions in 1 second using a 1/3, 1/3, 1/3 trapezoidal When selecting a step motor system, you should allow a
move profile. What is the distance (dtot), peak velocity torque safety margin of 50% above your calculated peak
(ωmax) and acceleration (α) required to make the move. torque requirements at the peak speed required by your
application.
ω max
150
50% Safety
ωavg Margin
Torque

100 Peak Torque Required

Velocity
(in/sec)
50
Engineering

ta tv td
t max (time in sec)
Speed
Servo Systems
rad For servo systems, a torque safety margin of at least 20%
Total distance, dtot = 10 rev • 2π rev = 63 rad is recommended. The peak torque required by the
application must fall within the peak torque rating of the
1.5dtot 1.5•63 motor at the peak speed. You must also calculate the
Max velocity, ωmax = = 95 rad
ttot = 1 sec RMS torque based on your application’s duty cycle. The
RMS torque must fall within the continuous area of the
4.5dtot 4.5•63 rad speed torque curve at the peak speed of the application.
Acceleration, α = = = 284 sec2
(ttot)2 12
2. Mechanical Drive Mechanisms 20% Safety Margin
Peak Torque
Required
The system equations on the following page will help
Torque

Peak
you calculate the reflected inertia (J), reflected applied
loads (T), motor speed (ω), and acceleration (α), based
RMS Torque
on the move requirements that were determined in step Required
20% Safety
one. Margin Continuous

Speed

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 Rotary Sizing Engineering
Rotary System Selection Calculations

Inertia Solid Cylinder Inertia Hollow Cylinder Tangential

(Conveyor, Rack and Pinion, etc.)
Ft, V L , a
Tt
Tt WL
WB
R2 L
R
R1
L R2, JG2
Ft
ωL, αL, ρ, JL, WL Ft R3, JG3
ωL, αL, ρ, JL, WL
R1, JG1

ω ω = ωL ω = ωL ω=
VL
R1

α α = αL α = αL α=
a
R1

W L + WB
WL = Lρ R2 WL = Lρ [R22 - R12] JRL = • R12
g
JT JT = JL + JMotor
JL = 1 W L • R 2
JT = JL + JMotor
JL = 1 WL [R22 + R12]
JT = JMotor + JRL + JG1 + JG2 ( )
R1 2
R2
R1 2
2 g 2 g + JG3
( )
R3

Ft = FFriction + FApplied + FGravity Ft = FFriction + FApplied + FGravity Ft = FFriction + FApplied + FGravity

TRL
TRL = Ft • R + Tt TRL = Ft • R2 + Tt TRL = Ft • R1
e

Leadscrew Gear Box

FT, V L, a WL
N: 1, J

Tt
D
R
L
Js, TPL, p JL , V L , αL Ft

ω ω=2 pVL ω = VNL Gear Reducers

Follow these guidelines when selecting an
α α = 2 pa α
α= L
N
IDC precision gearhead:

Engineering
1. Be sure your application's peak torque is
JS 0.0012 LD4 less than the maximum momentary torque
(for steel) JL rating of the gearhead. Be sure to multiply the
JRL =
J WL 1 2 N2 motor's torque by the gearhead efficiency and
JRL =
g 2 p JT = JRL+ JReducer + JMotor gear ratio when determining output torque
JT = JRL+ JS+ JMotor from the reducer.
2. Be sure your application's RMS torque is
Ft = FFriction + FApplied + FGravity Ft = FFriction + FApplied + FGravity less than the rated continuous torque of the
T TRL =
Ft
+ TPL TRL =(Ft • R) + Tt gearhead.
2 •p•e N•e

Units
a = acceleration rate (rad/sec2) JRL = reflected load inertia TPL = preload torque of leadscrew
α = rotary acceleration (rad/sec2) (oz-in-sec2) (oz-in)
D = diameter L = length (in) tR = running time (sec)
e = efficiency of mechanism ρ = material density (oz/in3) TR = running torque (oz-in)
Ft = total load force including p = pitch of screw (rev/in) TRL = reflected load torque due to
friction, gravity, or other R = radius (in) friction, gravity, or other
external forces (oz) tA = acceleration time (sec) external forces (oz-in)
g = gravity = 386 in/sec2 TA = acceleration torque (oz-in) VL = linear velocity of load (in/sec)
J = rotary inertia (oz-in-sec2) tD = deceleration time (sec) ω = rotary velocity (rad/sec)
JT = total inertia seen by motor TD = deceleration torque (oz-in) W = weight (oz)
(oz-in-sec2)
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 Engineering Rotary Sizing
Calculations
Rotary System Selection
EXAMPLE 1–STEPPER: Calculate the motor torque required t A= tD = t R= t/3 = 0.33 sec.
to accelerate a solid cylinder of aluminum 5" in radius and
0.40" in length from rest to 10 rev/sec in 0.3 seconds. Assume
no friction is present and there are no applied forces or gravity 2
Select mechanical drive mechanism as a leadscrew.
forces opposing the motor's rotation.
3
1 Calculate inertia, friction and load torque. A B32 motor was
Calculate maximum velocity and acceleration rates. chosen to see if it will meet the requirements of the
rev rad rad application. The friction coefficient of plastic on steel is 0.2.
= 10 sec 2 rev = 63 sec
2 oz 2
W 1 500 lb 16 lb 1
=
final - initial
=
63 - 0 rad
= 210 sec 2 JRL= gL = = 0.131 oz-in sec2
t A 0.3 2 p 386 in/sec 2 2 2 rev
in
2
Mechanical drive mechanism selected as direct drive. JS = 0.0012 LS D4 = 0.0012 24 14 = 0.0288 oz-in sec2
3 JTotal = JMotor + JRL + JS = 0.016 + 0.131 + 0.029 = 0.176 oz-in sec2
Calculate inertia (assume no friction or load torque). oz
Ft = WL µS +FApplied= 500 lbs 16 lb 0.2 + 125 lbs x 16 oz
lb
Hint: The density of aluminum can be found on page K-47.
W = ρ L s R2 = 3.14 0.40 1.57 5.0 2 = 49.3 oz + 2000 = 3600 oz
Ft 3600
1 w 2 1 49.3 TRL = + TPL = + 0 = 318 oz-in
JL = R = 5 2 = 1.6 oz-in sec2 2 e 2 2 0.9
2 g 2 386
J Total Assume motor is S42, rotor
= J Load + J Motor inertia is 0.114 oz-in-sec 2 4
= 1.6 + 0.114 = 1.71 oz-in-sec 2 Determine peak and continuous torque requirements.
4
Determine peak and continuous torque requirements. JT 0.176 567
TA= TRL + e = 318 + = 429 oz-in
0.9
JT 1.71 210
TA= TRL + e = 0+ = 359.1 oz-in JT 0.176 567
1.0 TD= TRL - = 318 - = 207 oz-in
e 0.9
[N-m] oz-in S42 If the dwell time between moves is 1.0 second, the total cycle
[8.75] 1250 time becomes 2.0 seconds.
[7.00] 1000 100%
TRMS = TA2 tA + TR2 tR + TD2 tD
Torque

[5.25] 750 75%

tc
[3.50] 500 50%
359.1 oz-in • T
V = (429)2 • 0.33 + (318)2 • 0.33 + (207)2 • 0.33
[1.75] 250 25%
2.0
Engineering

0 0
0 10 20 30 40 50 RPS
= 233 oz-in
0 600 1200 1800 2400 3000 RPM
[N-m] oz-in B32
Plotting the required torque on the S42 speed torque curve 100%
[5.6] 800
shows sufficient torque is present with a safety margin of 80%.
Torque

230 VAC 75%

EXAMPLE 2–SERVO: Select a motor which will move a 500 lb [4.2] 600
115 VAC
load 10 inches in 1 second using a 2 pitch leadscrew 24 inches
in length, and 1 inch in diameter. The load is externally [2.8] 400 •FPEAK 50%

supported by plastic bushings sliding on steel supports. There

is a 125 lb applied force. There will be 1.0 second dwell [1.4] 200 FRMS • 25%

between moves. The orientation of the leadscrew is 0 0

horizontal. 0 10 20 30 40 50 60 70 RPS
0 600 1200 1800 2400 3000 3600 4200 RPM
1
Calculate distance the motor must rotate, acceleration,
deceleration and maximum velocity using a 1/3, 1/3, 1/3 The maximum torque required by the application is 429 oz-in.
trapezoidal move profile. This falls within the speed/torque curve of the B32 motor, but
it falls in the peak region. In order to have adequate torque
rev rad margin in this application the B8000 Series drive used with the
D = 2 p d=2
2 in rev 10 in = 126 rad
B32 motor would need to be run off of 230 VAC. Assuming
1.5D 1.5 126 rad the B8000 Series drive is run off of 230 VAC, the peak torque
= = = 189 sec
T 1.0 safety margin is 98.1%
4.5D 4.5 126 rad
= = = 567 sec 2
T 1.0 2

Industrial Devices Corporation

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 Interfacing Controls Engineering
with IDC Controls Technology

IDC controls are designed to provide the optimum Edge Guide Controls
combination of cost and performance for a variety of IDC edge guide controls are a special purpose type of
applications All of our controls are designed for use with limit switch control used to maintain the position of the
IDC actuators, providing the fastest implementation time edge of a moving web of material.
in the industry.
The control uses feedback from sensors that can detect
Drives the edge of the material and move an actuator when
IDC drives provide the power to the motor and control adjustment is required. Two different correction speeds
it’s torque, velocity or position output. They are can be defined based on the amount of error.
designed to accept industry standard signals from When to use: When you want to control a web edge
motion controllers. based on input from simple on-off sensors.
Microstepping systems control the position of a step
Analog Position Controls
motor and provide resolutions up to 50,400 steps per
revolution. These drives accept a digital step and Analog position controls combine our drive electronics
direction signal and move the motor one microstep for with an analog absolute position controller. They
each pulse received. Varying the frequency of incoming control the absolute position of an actuator in direct
pulses controls velocity. proportion to an analog input signal. An IDC actuator
equipped with a linear potentiometer provides position
Brushless servo drives are available to control torque, feedback to the controller.
velocity or position of a brushless servomotor. These
drives accept digital step and direction or analog Analog position commands often come from a PLC,
command signals. industrial computer, sensor, data acquisition system, or a
manually operated joystick. Typical applications include
When to use: Use drives when your application cannot controlling flow or mixing of materials, web edge
be solved with one of IDC’s packaged motion guiding, and remote manual positioning.
controllers.
When to use: Use analog position controls when you
Limit Switch Controls need to control absolute position relative to an analog
Limit switch controls combine the functionality of a DC command signal, when you cannot home the system or
variable speed drive with a very simple position control when you need to know the position at power up.
that uses limit switches to provide position feedback.
Programmable Motion Controls
Manually adjustable (actuator or load mounted) limit IDC’s Smart Drives combining one or more of our drive
switches sense the load position and signal the control products packaged together with a powerful
to reverse direction, change speed or stop the motor. programmable positioning control.
Inputs are also provided for jog or run modes.

Engineering
A single package combines a one or two axis motion
Limit switch controls often interface with PLCs or controller, drive(s), an AC input power supply, support
industrial PCs and are our most cost effective solution for OPTO22 modules, an optional detachable front panel
for applications requiring simple position control. and RS232 communications interface.
When to use: Use limit switch controls when your They use IDC’s powerful and intuitive IDeal
positioning requirements can be met with limit switches programming language. This language has been called
and when positions, loads and speeds don’t change “simply sophisticated” by some due to its combination
frequently. of advanced capabilities in an easy to understand format.
You’ll have your system up in running in a minimum
amount of time.
When to use: Use programmable Smart Drives when
you need a flexible, powerful and easy to use motion
control system.

Industrial Devices Corporation

707-789-1000 • [Link] • 24 hour info by fax 916-431-6548 K-31
 Engineering Controls
Interfacing
Technology
with IDC Controls
One of the most important considerations when Limit Switch Control – PLC,
selecting a linear motion system is how it will interface Using Discrete I/O
to your PLC, your machine, your operators and the rest Industrial Devices’ H3301B, H4301 and D2000 Series
of your plant. In many applications more than one type Controls allow simple positioning control using extend,
of interface is employed. For example, you could use retract, and stop inputs. Limit switches (reed or hall
RS-232C for programming, dedicated “program select” effect) can be mounted to the cylinder sides and wired
inputs for program execution, digital I/O for sensors, back to the control to signal a stop position, change in
and a keypad/display for entering run-time operation speed or direction, or to activate an output.
variables. The following examples show common
interface techniques using IDC controls.

Axis 1

H3301B
Stop Extend
Ground
PLC Stop Retract

Axis 2

H4301

Stop Extend
Ground
Stop Retract
Engineering

Analog Position Control,

Using an Analog Input
Industrial Devices’ H3501, H4501, B8501 Controls can the user to scale and offset the stroke and tune the move
accept analog position signals (4-20ma or 0-10V) from a profile to suit the application. We also offer drives with
variety of sources. IDC actuators are available with linear analog velocity or torque inputs for use with servo
potentiometer position feedback. The actuator position controllers.
is proportional to the input signal. Adjustments allow

• PC Analog output
• Potentiometer Joystick
• Sensor Output
• Others . . .
Command Input

Gnd
H3501 Linear
Disable
Potentiometer
STOP

Industrial Devices Corporation

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 Interfacing Controls Engineering
with IDC Controls Technology

Remote Program Control – PLC, Using Industrial Devices’ controls have the capability of
Binary or BCD Inputs remote program execution. A program is selected using
binary (or BCD) coded digital inputs with a PLC,
computer, or simple switches (thumbwheels or rotary).

PLC

Inputs
Program
Number 3 2 1
0 1 1 1
1 1 1 0
0 0 2 1 0 1
3 1 0 0
4 0 1 1
5 0 1 0
3 4 6 0 0 1
2 5
1 6 7 0 0 0
0 7

Stand-Alone Machine Control

An Industrial Devices’ keypad control can function with programmable function keys, an IDC keypad
as a basic control system for your machine. Our control can replace a small PLC in many cases. To
IDEAL™ motion programming language includes further increase the interfacing possibilities, 8 I/O ports
functions for I/O control, time delays, variable input, are OPTO 22 compatible. By selecting the appropriate
conditional branching, and interrupts. With 24 OPTO 22 modules the user can output or input AC,
optically isolated I/O, and a built in operator interface DC or analog signals.

Engineering
Saw Control Saw
Blade

Operator
Interface
Clamp Saw
Pipe Travel
Sensor

Feed

Rodless Cylinder

Industrial Devices Corporation

707-789-1000 • [Link] • 24 hour info by fax 916-431-6548 K-33
 Engineering Application
Examples
Applications
Application 1: Packaging

Customer’s Objectives IDC Solution Why IDC?

In a manufacturing line, the Control B8961 This customer had considered using
maximum throughput of the line is Actuator EC Series pneumatics or building the system
determined by the slowest from components and using another
component in the line. In this case, The EC series cylinder High thrust manufacturers control.
the customers throughput was and duty cycle capability coupled
with B8961’s high level Compared to the pneumatic
limited to 200 bottles per minute by
the packaging equipment. programming language proved to be solution, the IDC system offered
the perfect solution for this much simpler set up, (verses moving
To improve the throughput of the customers application. The the hard stops on the pneumatic
line, (which was capable of a conditional branching math and cylinder), which cuts production
maximum of 1000 bottles per counter functions allowed the downtime significantly. The cost
minute, without the packaging control to know when to shift lanes, savings realized from the additional
bottle neck), the customer wanted and the ability to skip a lane if a production, (as well as lower
to divert the line to 5 packaging bottle jam had been detected by maintenance costs) quickly
machines, each capable of 200 remote photo eyes. The Flexible overcame the initial saving of the
bottles per minute, thus increasing Opto 22 I/O allowed the customer pneumatic system.
his throughput to 1000 bottles per to control all of the inputs and Purchasing a complete system from
minute. outputs without needing any IDC reduced vendors, came with a 1
The customer needed to do several additional interface modules. year warranty, and was a lower total
product changeovers (bottle size, Inputs cost. In addition his I/O
quantity per case, etc.) per day, and 1-5 Jam Sensors requirements could not be met by
wanted to use just one control for all 6 Bottle Counter Input other control manufacturers without
of the machine functions including 7-8 Ends of travel additional components.
I/O and intelligent control. In 9 Start Button
addition he wanted to make the 10 Estop
machine easy to use, by making 11 Reset
product changeovers with just a turn 12-15 BCD Program Select from
of a rotary switch. thumbwheel switch
Outputs
B8961 Pushbuttons
1-5 “Pack” Signal to
machine Error Light
Start
Engineering

6 “Run” light Run Light

Estop
7 “Error” light
8 Fault Output to Encoder EOT SW
Motor Cable Reset
main system
Up
Lane Changer Requirements 3
EC
Series Down
Load 200 lbs 1000/Minute
Thumbwheel
Speed 10 in/sec
Duty Cycle 70%
Repeatability 0.010"
Programmability 8 different
cominations of
bottle size and Change
Lanes
package quantity
Interface Thumbwheel
Switch and RS232
Interface for
200/Min x 5 to
programmaing Linear Bearing Packaging Equipment

Industrial Devices Corporation

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 Application Engineering
Applications Examples

Application 2: Cable Manufacturing

Customer’s Objectives IDC Solution H3301B Inputs

A cable manufacture wanted to build 1. Analog speed, from PLC
a wire winding machine for less than Control H3301B
Actuator R3H105B-18-SC-MF3-Q 2. Extend, from PLC and switch
the cost of off-the-shelf general
Accessories RPS-1 Limit switches 3. Retract, from switch
purpose winders.
(for end positions) 4. Stop Extend, from switch
Most general-purpose machines use
complex and expensive master-slave The customer found a simple, cost 5. Stop Retract, from switch
position following controls. Since effective solution in our H3301B H3301B Outputs
this customer’s products were Limit Switch Control and a small PLC 1. In Motion, to PLC
established and their winding with analog input/output capability.
2. Fault/Current Limit, to PLC
requirements were predictable and The H3301B drives an R3H Series
Rodless actuator between limit Why IDC?
consistent, a less sophisticated
control solution would be sufficient. switches for the traverse motion. The unique features of the H3301B
control make it an ideal solution for
The wire would be fed at a constant The PLC calculates the diameter of
this application. Other controls and
speed from an extruder, and the the roll based on a speed signal from
actuators were considered, however
wire would be guided onto the a tachometer attached to the spool,
the unnecessary complexity and cost
spool by a linear positioning device. and adjusts the traverse velocity
made the H3301B an excellent
To get a uniform wind, the traverse (through the H3301B’s remote
choice.
speed of the guide needs to decrease speed input) as the spool speed
as the circumference of the wire changes.
wrapped on the spool increases, and
as the rotational speed of the spool
slows down.

H3301
Winding Control
Requirements
Load 50 lbs Analog
PLC Speed Input

Engineering
Speed 15 in/sec max Go Extend
Go Retract
Duty Cycle 100% In Motion
Extend Limit
Repeatability ±0.1 inches Retract Limit
Tach Signal
Programmability Automatic R3 Series

extend/retract Motor
sequencing
Interface Discrete I/O to
PLC Traverse
Wire Feed
From Extruder

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 Engineering Application
Examples
Applications
B8961
Application 3: Fence Making

Customer’s Objectives
A manufacturer of fence making
equipment received a special 120 VAC
Fault
request from their customer for a
machine which cuts fencing sections Estop
to length from 0 to 120 inches, with
as many as 150 product (length)
Engage Saw 240VAC
changes per day.
Motor/Encoder
Clamp
Although the company already has 120VAC
fence cutting equipment, the set up Sensor 12VDC
time to change lengths (changing
stops on a hydraulic cylinder) took Feed
more than five minutes. A five Fence
minute set up was unacceptable to
this customer. R4 Series

Feed to Length IDC Solution The B8961 display prompts the

Requirements operator to enter the length of the
Control B8961 Servo Control fence in inches, as well as the
Load 150 lbs moving,
Actuator R4 Series number of sections to cut. The
800 lbs holding
Accessories RP1 home sensor Home offset command allows the
Speed 3.0 inches/sec RP2 end-of-travel user to enter in the actual length of
Duty Cycle 40% fence.
The customer mounted the fence
Repeatability ±0.01 inches gripper to the carriage of our 120 B8961 Inputs
inch R4H Series rodless cylinder. To 1. Material present, from sensor
Programmability Prompt operator make a fully automated 0-120 inch (12 VDC)
for position in cut to length system. 2. Emergency stop, from push-
inches and
button (12 VDC)
quantity
B8961 Outputs
Interface Operator interface 1. Grip fencing, to air valve (120
Engineering

VAC)
2. Engage saw, to cutter (240 VAC)
3. Fault/Current limit, to yellow
light (120 VAC)
Why IDC?
The customer chose our RH Series
actuator because of its compact size
and excellent carriage moment load
capacity.
The B8961 control was chosen for
its high performance servo response,
integral operator interface, ease of
programming, and I/O capability,
which eliminated the need for a
PLC.

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 Application Engineering
Applications Examples

Application 4: Sawing

Customer’s Objectives IDC Solution Why IDC?

A manufacturer of large, custom size Control S6962 two axis micro- The high repeatability of the system
masonry flooring material wanted to stepping smart drive (±0.0005) provided the consistent
automate the cutting width of their Actuators EC Series high quality product the customer
saw. Several set-up changes Accessories RPS-1 home sensor desired. The programmability and
occurred per day, each one taking RPS-2 end-of-travel operator interface capability of the
10 to 15 minutes. The operator sensors S6962 provided the rapid set-up
would set the backstop to a new needed. The cylinder was provided
position, make a sample cut, The S6962-2 axis microstepping with the -PB option which protects
measure the results and then make smart drive has the ability to the cylinder from cutting fluid spray
further fine adjustments. The goal synchronize two actuators and and masonry particles.
was to reduce set up time to a few independently home them to ensure
Prior to being contacted by an
seconds and reduce scrap by 90%. orthogonality. The S6962 stepper
Industrial Devices distributor, the
drive provides the high current to
The eight foot long backstop has to customer had considered building
operate the two EC Series cylinders.
be held perpendicular to the saw their own. After reviewing the steps
The keypad/display prompts the
blade. Because of this, the customer required to build, and seeing what
operator to enter the width and
wanted actuators to position each IDC had to offer, the customer
provides a signal to begin cutting.
end of the backstop and at least 800 found the IDC solution to be more
lbs. of holding capacity during 6962 Inputs simple, and more cost-effective.
cutting. 1. Move (push-button)
2. Inhibit motion (while cutting)
3. Operator Interface (for position)
6962 Outputs
1. In position
2. Fault

Back-stop Adjustment
Requirements
Load 400 lbs moving,

Engineering
800 lbs holding S6962
Keypad
Speed 1 in/sec
Duty Cycle 10%
Repeatability ±0.0005 inches
Programmability Synchronize two
actuators EC Series Width Adjust EC Series
Interface RS-232C
programming

Backstop

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 Engineering Application
Examples
Applications
Customer’s Objectives H4501
A particle board manufacturer Position Signal
PLC
needed an inexpensive way to Inhibit Motion

Analog Feedback
automatically adjust the height of a In Position
scrubbing deck, based on the Fault
thickness of the material passing
underneath. The rotating wire
brushes on the scrub deck were
used to smooth the surface of the
wood. EC
Series
The company received several
quotes for expensive position
following servo controls which were Ultrasonic
capable of much greater accuracy Sensor
than they needed (0.025" inches).
They also wanted the solution to
take full advantage of the PLC being Partical Board Feed
used to control the machine.

Height Control IDC Solution Why IDC?

Requirements The H4501 control provides a
Control H4501-C
Load 1000 lbs, vertical simple, low cost alternative to the
Actuator EC Series
more expensive servo positioning
Speed 0.3 inches/sec
Brush height control was easily systems.
Duty Cycle 30%
realized using a H4501-C Control
Repeatability ±0.025 inches which accepts a 4-20 mA analog
(position) output from the PLC. The
Control Analog position
PLC takes the height measurement
command from PLC
from an ultrasonic sensor, and
Interface 4-20 mA signal provides a corresponding position
signal to the H4501-C Control.
Engineering

H4501 Inputs
1. 4-20 mA position input, from PLC
2. Inhibit, from PLC
H4501 Outputs
1. In position, to PLC
2. Fault/Stall to PLC

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 Application Engineering
Applications Examples

Application 6: Valve Positioning

Customer’s Objectives IDC Solution Why IDC?

A power company has had many High precision hydraulics were also
Control B8961 Servo Control
problems with a mechanical control considered. Because of the need to
system which manipulates a large Actuators EC Series
have an orderly shutdown in the
hydraulic valve. This valve regulates Accessories RP2 end-of-travel
sensors event of hydraulic system failure, a
the flow of water through a Hydro- separate power unit would have
Electric power generator. As part of The customer’s computer been needed. Furthermore, 0.001
their plant modernization program, commanded the B8961/EC actuator inch repeatability proved to be
the customer wished to replace the to the proper valve position using difficult and costly to achieve.
old valve control system with a more discrete outputs. Since there was a
reliable and more accurate system. The B8961’s easy-to-use, yet
large amount of electrical noise
powerful IDEALTM motion
present, a self-contained control
programming, extensive I/O
system was desired which did not
capability, and compact drive/
rely on RS-232C or analog
control/power supply package
communication from the master
Valve Control Requirements encouraged this customer to choose
computer. The EC’s cylinder’s high
this solution.
Load 1,200 lbs. speed and thrust ensure rapid
response to changes in signal.
Speed 1.8 in/sec
Furthermore, in the event of system
Duty Cycle 50% problems, an input was triggered,
Repeatability ±0.001 inches which runs and emergency
shutdown procedure (program #98)
Programmability Start-up Sequence
B8961 Inputs
Shutdown B8961 Program
1. Start, from computer Host Computer
Sequence Run Select Lines
Sequence Using program select lines from
Emergency computer:
Shutoff 1. Coarse Increment
Interface Stand-alone 2. Fine Increment In Position

programming, Fault
3. Coarse Decrement
4. Fine Decrement

Engineering
B8961 Outputs
1. In position
2. Fault

Flow

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 Engineering Motion Control
Terminology
Glossary
Absolute Move Binary Dwell Time
A move referenced from a fixed Numbering system in which the Time within a move cycle where no
absolute zero position. base is two, each number being motion occurs
Acceleration expressed in the powers of two, by EEPROM (Electrically Erasable
0 or 1. Programmable Read Only Memory)
The change in velocity as a function
of time, going from a lower speed to Bearing Non-volatile data storage chip.
a higher speed. A support device which allows a
smooth, low friction motion Efficiency
Accuracy Ratio of output power vs. input
between two surfaces loaded against
An absolute measurement defining each other. power.
the difference between expected
and actual position. Bushing EMI (Electromagnetic Interference)
A cylindrical metal sleeve inserted Electrical disturbances which
Acme Screw interfere with proper transmission of
into a machine part to reduce
A leadscrew which uses a threaded friction between moving parts. electrical signals, also known as
screw design with sliding surfaces ”Electrical noise”.
between the screw and nut. Closed Loop
Encoder
Actuator (Electric Cylinder) A positioning system which employs
feedback information to regulate the An electromechanical device which
A self contained leadscrew system output response. produces discrete electrical pulses
which converts rotary motion (from directly related to the angular
a motor) to linear motion. Cogging position of the input shaft, providing
ASCII (American Standard Code for Motor torque variations which occur high resolution feedback data on
Information Interchange) at low speeds due to a weak position, velocity, and direction.
A code which assigns a number to magnetic field. Force
each numeral and letter of the Critical Speed The action of one body on another
alphabet. This allows information to Rotational speed of a leadscrew at which tends to change the state of
be transmitted between machines as which vibrations (whipping) will motion of that body. Typically
a series of binary numbers. occur. described in terms of magnitude,
Backdrive Current direction, and point of application.
Tendency of a cylinder to creep out The flow of charge through a Friction
of its set position due to an applied conductor. The resistance to motion of two
load or force. surfaces that touch.
Cycle
Backlash Helical Gear
One complete extension and
The amount of play (lost motion)
Engineering

retraction of a cylinder. Gears with teeth that spiral around

between a set of moveable parts the gear.
when changing the direction of Deceleration
travel. Typically seen in drive trains, The change in velocity as a function Incremental Move
leadscrews, & bearings. of time, going from a higher speed A move referenced from the current
to a lower speed. set position.
Ball Screw
A leadscrew which uses a ball nut Drive Ratio Inertia
which houses one or more circuits The ratio of motor revolutions per Property of an object that resists a
of recirculating steel balls which roll leadscrew revolution. change in motion. It is dependent on
between the nut and screw. the mass and shape of the object.
Drive Train The greater an object’s mass, the
Baud Rate The arrangement by which the greater its inertia, and the more
The number of binary bits motor is coupled to the leadscrew. force is necessary to accelerate and
transmitted per second on a serial Typically provided by gears, timing decelerate.
communication link such as RS232C. belt/pulley or direct coupling.
Lead
BCD (Binary Coded Decimal) Duty Cycle The linear distance a nut on a
A binary numbering system in which The ratio of Motor on time and total leadscrew will travel with one
the decimal digits 0 to 9 are cycle time within a given cycle of revolution of the leadscrew.
represented by a 4 bit binary operation.
number.
Duty Motor ON Time
(%) = X 100%
Cycle Total Cycle Time

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 Motion Control Engineering
Glossary Terminology

Leadscrew Overshoot Resonance

Device which converts rotary The amount by which a parameter Oscillatory behavior in a mechanical
motion to linear motion. being controlled exceeds the desired body when operated or subjected to
Mass value. Typically referring to velocity a periodic force occurring at its
or position in servo systems. natural frequency.
The quantity of matter that an object
contains. PID (Proportional, Integral, and ROM (Read Only Memory)
Microprocessor Derivative) A memory chip that can be read but
Refers to a group of gain parameters not altered.
A device that incorporates many or used for tuning or optimizing the
all functions of a computer in a RS232C
response of a closed loop
single integrated circuit. Used to positioning system. A method of Serial Communication
perform calculations and logic where data is encoded and
required to do motion or process Pitch transmitted on a single line in a
control. The number of revolutions a sequential time format.
Moment (Load) leadscrew must turn for the nut to Servo Motor
Rotational forces applied to a linear travel one inch (single start only). A motor which is used in closed
axis, typically expressed as yaw, PLC (Programmable Logic loop systems where feedback is used
pitch, and roll. Controller) to control motor velocity, position,
Motion Profile A programmable device which or torque.
utilizes “ladder” logic to control a
A method of describing a move Spur Gear
bank of inputs and outputs which
operation in terms of time, position, Gears with teeth straight and parallel
are interfaced to external devices.
and velocity. Typically velocity is to the axis of rotation.
characterized as a function of time Power
or distance which results in a Stepper Motor
How much work is done in a
triangular or trapezoidal profile. specific amount of time. Motor which translates electrical
pulses into precise mechanical
Motor PWM (Pulse Width Modulation) movements. Through appropriate
A device which converts electrical A type of adjustable frequency drive drive circuitry, controlling the rate
energy into mechanical energy. output where the drive’s output and quantity of pulses will control
voltage is always a constant the motor’s velocity and position.
Non-Volatile Memory
amplitude and by “chopping” (pulse
Memory that does not lose width modulating) the average Thrust
information on loss of power. output power is controlled. The measurement of linear force.
Open Collector (NPN) RAM (Random Access Memory) Torque
An output signal which is provided A memory chip that can be read

Engineering
A measure of angular force which
by a transistor where the “open from and written to. Used as a produces rotational motion.
collector output” acts like a switch medium for temporary information
closure to ground when activated. TTL (Transistor-Transistor-Logic)
storage. Data is lost after power loss.
Refers to a family of integrated
Open Loop Repeatability circuit devices used for control.
A positioning system which does not The ability of a positioning system to Typically use voltage levels from 5-
employ feedback information. return to an exact location during 12 VDC.
Optically Coupled operation (from the same direction Velocity (Speed)
with the same load and speed). The change in position as a function
An interface circuit that transmits a
signal with no direct electrical Resistance of time.
connection except for the logic The opposition to the flow of charge Voltage
ground. through a conductor. Difference in electrical potential
Optical Isolation Resolution between two points.
An interface circuit that transmits a The smallest positioning increment Weight
signal with no direct electrical achievable. In digitally programmed Force of gravity acting on a body.
connection. systems it is the smallest specifiable Determined by multiplying the mass
positioning increment. of the object by the acceleration due
to gravity.

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 Engineering Conversion
Tables Conversion Tables
Torque
B
A dyne-cm gm-cm oz-in kg-cm lb-in N-m lb-ft kg-m

dyne-cm 1 1.019x10-2 1.416x10-5 1.0197x10-6 8.850x10-7 10-7 7.375x10-6 1.019x10-6

gm-cm 980.665 1 1.388x10-2 10-3 8.679x10-4 9.806x10-5 7.233x10-5 10-5
oz-in 7.061x104 72.007 1 7.200x10-2 6.25x10-2 7.061x10-3 5.208x10-3 7.200x10-4
kg-cm 9.806x105 1000 13.877 1 .8679 9.806x10-2 7.233x10-2 10-2
lb-in 1.129x106 1.152x103 16 1.152 1 .112 8.333x10-2 1.152x10-2
N-m 107 1.019x104 141.612 10.197 8.850 1 .737 .102
lb-ft 1.355x107 1.382x104 192 13.825 12 1.355 1 .138
7 5 3
kg-m 9.806x10 10 1.388x10 100 86.796 9.806 7.233 1

Inertia (Rotary)
B lb-ft-s2 or
A gm-cm2 oz-in2 gm-cm-s2 kg-cm2 lb-in2 oz-in-s2 lb-ft2 kg-cm-s2 lb-in-s2 slug-ft-s2

gm-cm2 1 5.46x10-2 1.01x10-3 10-3 3.417x10-4 1.41x10-5 2.37x10-6 1.01x10-4 8.85x10-7 7.37x10-4

oz-in2 182.9 1 .186 .182 .0625 2.59x10-3 4.34x10-4 1.86x10-4 1.61x10-4 1.34x10-5

gm-cm-s2 980.6 5.36 1 .9806 .335 1.38x10-2 2.32x10-3 10-3 8.67x10-4 7.23x10-5

kg-cm2 1000 5.46 1.019 1 .3417 1.41x10-2 2.37x10-3 1.019x10-3 8.85x10-4 7.37x10-5

lb-in2 2.92x103 16 2.984 2.925 1 4.14x10-2 6.94x10-3 2.96x10-3 2.59x10-3 2.15x10-4

oz-in-s2 7.06x104 386.08 72.0 70.615 24.13 1 .1675 7.20x10-2 6.25x10-2 5.20x10-3

lb-ft2 4.21x105 2304 429.71 421.40 144 5.967 1 .4297 .3729 3.10x10-2
Engineering

kg-cm-s2 9.8x105 5.36x103 1000 980.66 335.1 13.887 2.327 1 .8679 7.23x10-2

lb-in-s2 1.129x104 6.177x103 1.152x103 1.129x103 386.08 16 2.681 1.152 1 8.33x10-2

lb-ft-s2 or 1.355x107 7.41x104 1.38x104 1.35x104 4.63x103 192 32.17 13.825 12 1

2
slug-ft

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 Conversion Engineering
Conversion Tables Tables

Angular Velocity
B deg/s rad/s rpm rps
A
deg/s 1 1.75 x 10-2 .167 2.78 x 10-3
rad/s 57.3 1 9.55 .159
rpm 6 .105 1 1.67 x 10-2
rps 360 6.28 60 1

Linear Velocity
B in/min ft/min in/sec ft/sec mm/sec m/sec
A
in/min 1 .0833 .0167 1.39 x10-3 0.42 4.2 x10-4
ft/min 12 1 .2 .0167 5.08 5.08 x10-3
in/sec 60 5 1 .083 25.4 .0254
ft/sec 720 60 12 1 304.8 .3048
cm/sec 23.62 1.97 .3937 .0328 10 0.01
m 2362.2 196.9 39.37 3.281 1000 1

Abbreviated Terms Metric Prefixes

C = Celsius lb(f) = pound force Name Abbreviation Multiple
cm = centimeter lb(m) = pound mass Giga G 109 1,000,000,000
F = Fahrenheit min = minute Mega M 106 1,000,000
ft = foot mm = millimeter Kilo k 103 1,000
g = gravity m = meter Hecto h 102 100

Engineering
N = Newton deka da 101 10
gm = gram
— — 100 1
gm(f) = gram force oz(f) = ounce force
deci d 10-1 .1
HP = Horse Power oz(m) = ounce mass
centi c 10-2 .01
in = inch rad = radians
milli m 10-3 .001
kg = kilogram rpm = revs per minute
micro µ 10-6 .000001
kg(f) = kilogram force rps = revs per second nano n 10-9 .000000001
KW = Kilowatt s = seconds

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 Engineering Conversion
Tables Conversion Tables
(To convert from A to B, multiply by entry in table)
Length
B in ft micron (µm) mm cm m
A
4
in 1 0.0833 2.54x10 25.4 2.54 0.0254
5
ft 12 1 3.048x10 304.8 30.48 0.3048
-6
micron(µm) 3.937x10 -7
3.281x10 1 0.001 1.0x10 -4
1.0x10-6
mm 0.03937 0.00328 1000 1 0.1 0.001
4
cm 0.3937 0.03281 1.0x10 10 1 0.01
6
m 39.37 3.281 1.0x10 1000 100 1

Mass
B gm kg slug lb(m) oz(m)
A
-5 -3
gm 1 .001 6.852x10 2.205x10 .03527
-2
kg 1000 1 6.852x10 2.205 35.274
slug 14590 14.59 1 32.2 514.72
lb(m) 453.6 .45359 .0311 1 16
oz(m) 28.35 .02835 1.94x10-3 .0625 1

Force
B
A lb(f) N dyne oz(f) kg(f) gm(f)
lb(f) 1 4.4482 4.448 x 105 16 .45359 453.6
N .22481 1 100.000 3.5967 .10197 ——
-6 -5
dyne 2.248 x10 .00001 1 3.59x10 —— 980.6
Engineering

4
oz(f) .0625 .27801 2.78x10 1 .02835 28.35
kg(f) 2.205 9.80665 ——
35.274 1 1000
-3 -3
gm(f) 2.205x10 —— 1.02x10 .03527 .001 1
Note: lb(f) = 1slug x 1 ft/s2 N = 1kg x 1 m/s2 dyne = 1gm x 1 cm/s2

Power
B
A Watts KW HP(english) HP(metric) ft-lb/s in-lb/s
Watts 1 1 x 10-3 1.34 x 10-3 1.36 x 10-3 .74 8.88
KW 1000 1 1.34 1.36 738 8880
HP(english) 746 .746 1 1.01 550 6600
HP(metric) 736 .736 .986 1 543 6516
-3 -3 -3
ft-lb/s 1.35 1.36 x 10 1.82 x 10 1.84 x 10 1 12
-4 -4 -4 -2
in-lb/s .113 1.13 x 10 1.52 x 10 1.53 x 10 8.3 x 10 1

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 NEMA and Mechanical Engineering
Material Specifications Specifications

Material Densities Friction Coefficients

3 3 3
oz/in lb/in gm/cm (Sliding) µs
Aluminum 1.57 .098 2.72 Steel on Steel 0.58
Brass 4.96 .31 8.6 Steel on Steel (Greased) 0.15
Bronze 4.72 .295 8.17 Aluminum on Steel 0.45
Copper 5.15 .322 8.91 Copper on Steel 0.36
Plastic .64 .04 1.11 Brass on Steel 0.40
Steel 4.48 .28 7.75 Plastic on Steel 0.2
Hard Wood .46 .029 .8 Linear Bearings 0.001
Soft Wood .28 .018 .48
Temperature
Mechanism Efficiencies °F = (1.8 x °C) + 32
Acme Screw (Bronze Nut) 0.4 °C = .555 (°F - 32)
Acme Screw (Plastic Nut) 0.5
Ball Screw 0.9 Gravity
(Acceleration Constant)
Helical Gear 0.7
g = 386 in/s2 = 32.2 ft/s2 = 9.8 m/s2
Spur Gear 0.6
Timing Belt/Pulley 0.9

NEMA Standard Motor Dimensions

NEMA NEMA NEMA
Dimension (in) 23 34 42 ØA +0.0000 [0.0]
- 0.0005 [0.0]

“A” Motor Shaft Diameter 0.250 0.375 0.625

Engineering
“B” Motor Shaft Length* 0.810 1.250 1.380
ØC
“C” Pilot Diameter 1.500 2.875 2.186
“D” Pilot Length* 0.062 0.062 0.062
“E” Mounting Bolt Circle 2.625 3.875 4.950
ØF Hole (4x) D
“F” Bolt Hole Size 0.195 0.218 0.218 Equally Spaced
on a "E" Dia B.C.
B

* These dimensions can be less than value indicated.

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 Engineering Rotary & Linear
Selection Worksheet
Selection Worksheet
For selection assistance, fax, to your local IDC Distributor or directly to IDC

Prepared By Prepared For

Name Name

Company Company

Phone Phone

Fax Fax

Email E-mail

Address Address

User’s primary business

Type of machine IDC product to be used on

Current IDC user? Yes No

Project Time Frame Volume Requirements

Proposal Next 12 months:

Build prototype Year 2:

Engineering

In production Year 3:

Action Required

Demo Price quotation

Recommend product Call me to discuss

Please include drawings, comments or

additional information on separate pages.

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 Linear Actuator Linear Selection Engineering
Selection Data Worksheet

Electric Cylinder or Rodless Actuator

Loads
Fn
Payload Carriage Loads My
Orientation
(Rodless only)
Weight lbs Mp Vertical
Mp in-lbs Mr
Payload Externally Supported, Horizontal
by (rails, etc.) Mr in-lbs Fs

Inclined °
My in-lbs (angle from
Hold Position:
After move Power off Side Load lbs horizontal plane)

Motion

Travel Speed (WCM=Worst-Case Move) Precision

Stroke Length Required in WCM Distance in Repeatability in
(= usable travel distance + min. 2 inches
for limit switches) Time for WCM sec Accuracy in
Shortest Move in or
Max. Backlash in
Max. Avaliable Stroke Length (in) Max. Speed in /sec
Resolution in
Electric Cylinders: Min. Speed in /sec
Complete Move Profile Chart (see p. K-55) Straightness / Flatness in

Thrust Calculation (See Engineering Section in IDC catalog for assistance)

Thrust
Thrust = ForceACCELERATED MASS + ForceFRICTION + ForceGRAVITY + ForceEXTERNAL

Engineering
lbs = lbs + lbs + lbs + lbs

Duty Cycle/Life

Duty Cycle Required Life

Total Cycle Time sec. Extend/Retract Cycles per day Units: Inches Meters Cycles
Months Years
Sum of Move Times sec. Move Distance per cycle Minimum Life
Complete Move Profile Chart (see page K-55) Maintenance / Lube Interval

Environment

Operating Temperature Contaminants (Check all that apply)

Normal 32-140°F [0-60°C] Solid: Liquid:
High Temp. °F / °C non-abrasive coarse chips Dripping Non-corrosive
Low Temp. °F / °C abrasive fine dust Mist / Spray Corrosive
Splashing
Conditions
High Pressure
Washdown Outdoor Vacuum Cleanroom

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 Rotary
Engineering Selection
Worksheet Motor Selection Data
Direct Drive System Gearhead / Geartrain

R2 L Gear Ratio
R R1
L Gearhead Inertia
(reflected to pinion) oz-in-sec2
Radius (R): in Weight of Cylinder oz Efficiency %
Inner Radius (R1) in Length (L) in Radius of Pinion in Radius of Driven Gear in
Outer Radius (R2) in Weight of Pinion oz Weight of Driven Gear oz
Density of Material oz /in3 Radial load on output shaft lbf
Type of Material Distance of radial load from gearhead face in
Will a gearbox be used? Yes / No / Not Sure Axial load on output shaft lbf
Orientation
Move Requirements
Horiz Vertical Incline:
Distance from Cylinder CL to Motor Face in Move Distance inches revs of motor
Move Time secs
Tangential Drive System
Required Motor Peak Speed rev/s
W F Required Accel Time secs
Required Decel Time secs
Minimum Motor Speed rev/s
Accuracy arcminutes, degrees, or inches
R
Repeatability arcminutes, degrees, or inches
Radius (R) in Duty Cycle (%) Time in Motion
Efficiency of belt or chain Total Cycle Time
Weight of load Cycle Time secs
plus belt or chain (W) lbf Maximum Continuous Time in Motion secs
Weight of Pulleys lbf Friction (F) lbf
Will a gearbox be used? Yes / No / Not Sure Cabling Requirements
Belt Tension lbf Length of Motor / Encoder Cable Required ft
Will pulleys be supported by external bearings? Yes / No Will cable be moving in application? Yes / No
Engineering

Leadscrew System
Environment
W
Operating Temperature
D
L Normal 32-140°F [0-60°C]
High Temp. °F / °C
Orientation Low Temp. °F / °C
Horiz Vertical Incline:
Contaminants (Check all that apply)
Ball Screw Acme Screw Other Solid:
Efficiency of Screw non-abrasive coarse chips
Pitch of Screw revs /in abrasive fine dust
Length of Screw (L) in Liquid:
Diameter of Screw (D) in dripping non-corrosive splashing
mist / spray corrosive high pressure
Weight of Load (W) lbf
Running Friction Coefficient (Load/Surface) Conditions
Washdown Outdoor
Breakaway Force lbf
Vacuum Cleanroom
Will a gearbox be used? Yes / No / Not Sure

Industrial Devices Corporation

K-48 707-789-1000 • 800-747-0064 • E-mail: info@[Link]
 Rotary and Linear
Selection Engineering
Motion Control Data Worksheet

Motion Profile Motor Type Preferred

Graph your most demanding cycle, include accel/decel, velocity and Servo Stepper
dwell times. You may also want to indicate load variations and I/O
changes during the cycle. Label axes with proper scale and units. Other

Speed ( ) Axes of Motion

Single Multiple #
Synchronized

Interface
Host PLC Computer
Analog I/O RS232
Digital I/O Control
Other
( ) Operator
Time Keypad/LCD Display
or Pushbuttons
Distance
Potentiometer/Joystick
Thumbwheels

Supply Voltage
110 AC 220 AC
Other

Control Method Feedback Required

Programmable External Control Signal Encoder Linear Potentiometer
Manual Jog Digital (Step & Direction) Analog Velocity Other
Analog Torque Analog Position
Limit Switches
Input Functions
Description of Application

Engineering
Output Functions

Industrial Devices Corporation

707-789-1000 • [Link] • 24 hour info by fax 916-431-6548 K-49