Linear Modules

Linear modules are a precision electromechanical integrated devic that can convert rotational motion into linear motion. Linear modules are an integrated linear motion system that integrates transmission, guidance, and drive components into modular units through standardized design, enabling precise linear displacement control. Linear modules are widely used in the field of automation and are an efficient solution to replace traditional decentralized linear motion mechanisms. Its core feature is to simplify the equipment design process, improve motion accuracy and stability, while reducing installation and maintenance costs.

Since THK Corporation first achieved commercialization in Japan in the 1980s,the development of Linear modules has gone through three stages:

1). Mechanical transmission stage (1980-2000): centered around ball screws and sliding guides

2). Mechatronics stage (2000-2015): Integrated design of drive motor and module body

3). Intelligent IoT stage (2015- present): Intelligent module integrating sensors and communication interfaces

By 2023, the global market size will reach 6.2 billion US dollars (according to QYResearch data), with China becoming the largest production and application market, accounting for 38%.

1. Core structure and working principle of Linear Modules

a. Transmission system:

Ball screw: diameter 6-50mm, lead 1-20mm, accuracy level C3-C7

Synchronous belt: polyurethane material, width 10-100mm, maximum speed 5m/s

Linear motor: The thrust of the coreless type can reach 3000N, while the coreless type can reach 20kN

b. Guidance system:

Ball guide rail: four row ball structure, rated dynamic load 1-50kN

Roller guide rail: rigidity increased by 3 times, suitable for heavy-duty applications

Cross roller guide rail: bi-directional equally rigid, used for precision measuring equipment

2. Drive control of Linear Modules:

Servo motor: 23-130 flange specification, paired with 17/23 bit absolute encoder

Stepper motor: 1.8 ° step angle, subdivision up to 25600 pulses/rev

Closed loop control: positioning repeatability ± 0.005mm, speed fluctuation<1%

3.Comparison of key technical parameters of Linear Modules.

4. Innovative technological breakthroughs in Linear Modules

a. Hybrid drive technology:

The composite module of "screw+linear motor" developed by TM combines high precision (± 1 μ m) and high speed (2m/s)

TM's magnetic levitation module reduces friction resistance by 90%

b. Intelligent monitoring system:

THK's iLM series integrated vibration sensor can predict the wear status of lead screws

HIWIN's smart module is equipped with temperature compensation, reducing thermal deformation error by 60%

c. Application of new materials in Linear Modules:

Carbon fiber guide rail (weight reduced by 40%)

Ceramic ball bearings (life increased by 3 times)

5. In depth analysis of industry applications of Linear Modules

a. Semiconductor manufacturing:

Lithography machine workbench: using air bearings and linear motor modules, with a positioning accuracy of ± 1nm

Wafer handling: Cleanliness Class 1 module, particle release<5/ft ³

b. New energy batteries:

Polar cutting: Linear module combined with visual system, cutting speed 120m/min

Cell stacking: Six axis module linkage, stacking accuracy ± 0.1mm

c. Medical equipment:

Surgical robot: Nano level module achieves 0.1 ° joint control

Gene sequencing: 96 channel pipetting module, flux increased by 50 times

d. New Display:

OLED evaporation: multi-mode group synchronous control, positioning error<3 μ m

Glass cutting: gantry module system with acceleration of 2g

6.Methodology of Selection Engineering of Linear Modules

a. Load analysis:Static load ≤ 50% rated load,

Dynamic loads require calculation of inertia matching (inertia ratio<30:1)

b. Accuracy verification: Consider back clearance (<0.05mm) and walking parallelism (<0.02mm/300mm)

Thermal deformation compensation (0.5 μ m/℃)

c. Life calculation: Formula for the lifespan of ball screw: L10=(C/P) ^ 3 × 10 ^ 6 revolutions per minute

Guide rail lifespan: L=50 × (C/P) ^ (10/3) × 10 ^ 3km

7.Future Development Trends of Linear Modules

a. Miniaturization: Nano level module (stroke 50mm, accuracy 10nm)

b. Intelligence: Self regulating module integrating AI algorithms

c. Greening: Energy recovery drive system (saving 30% energy)

d. Standardization: ISO 18758-2 international standard accelerates popularization

According to Boston Consulting Group's prediction, the global linear module market is expected to exceed $10 billion by 2028, with annual growth rates in the medical and semiconductor sectors remaining above 18%. With the implementation of China's "14th Five Year Plan" for the development of intelligent manufacturing, domestic modules are moving towards the 0.5 μ m precision tier, and the speed of replacing imports is accelerating.

You are welcome to watch more projects or visit our video gallery by Youtube: https://www.youtube.com/@tallmanrobotics

Ball Screw Linear Modules for General Environment from Tallman Robot have following series:

Lead Screw Linear Module for Clean Environment from Tallman Robot have following series TM-S-CR

Long Stroke Screw Linear Module for General Environment TM-SL-CM

Organ Cover Water proof Lead Screw Linear Module TM-SF

Timing Belt Linear Module for General Environment TM-B-CM

Timing Belt Linear Module for Dust-proof Environment TM-B-CR

Organ Cover water proof Timing Belt Linear Module TM-BF

European dustproof Timing Belt Module TM-EB

What are the classifications of linear modules?

Linear modules can be classified based on dimensions such as transmission mode, drive type, and structural form. Different types have significant differences in performance and applicable scenarios. The specific classifications are as follows:

1. Classified by core transmission method (most commonly used classification method)

1). Linear module for screw drive

Using a screw as the core transmission component, rotational motion is converted into linear motion through the meshing of the screw and nut.

Subdivision type:

Ball screw module: The ball serves as an intermediate medium, with a transmission efficiency of 85% -95% and high accuracy (positioning error ≤± 0.01mm), suitable for precision scenarios such as semiconductor equipment and testing instruments.

Trapezoidal screw module: sliding friction transmission, efficiency of 20% -40%, low cost and self-locking (power-off anti fall), suitable for low-speed heavy load (such as lifting platforms and civilian equipment).

Features: Strong load capacity (up to several tons), moderate speed (usually ≤ 1m/s), and controllable accuracy.

2). Synchronous belt drive linear module

Composed of a synchronous belt, pulley, and guide rail, the motor drives the pulley to rotate, and the synchronous belt drives the slider to move in a straight line.

Features: Fast speed (up to 2-5m/s), long travel (can be spliced up to 10m or more), lower cost than screw modules, but lower accuracy (positioning error ± 0.1-0.5mm), suitable for high-speed conveying (such as sorting machines, laser cutting equipment).

3). Linear motor drive linear module

Without mechanical transmission components, linear motion is directly driven by the electromagnetic force of the stator and rotor.

Features: High precision (positioning error ≤± 0.001mm), large acceleration (up to 50m/s ²), no wear and tear, long service life, but high cost (3-5 times that of screw modules), requiring a supporting cooling system, suitable for high-end scenarios such as semiconductors and precision measurement.

4). Linear module for rack and pinion transmission

The motor drives the gear to rotate, and the gear meshes with the rack to achieve linear motion.

Features: Almost infinite travel (rack can be spliced), strong load capacity (suitable for ton level loads), but low accuracy (± 0.1-1mm), suitable for heavy equipment (such as machine tool translation axis, large storage machinery).

2.Classified by type of driving power

1). Electric linear modules

Using motors (servo motors, stepper motors, DC motors) as power and controlling speed and position through electrical signals is the mainstream choice for industrial automation.

Advantages: Strong controllability, capable of achieving closed-loop precise positioning, and wide adaptability.

2). Pneumatic linear modules

Powered by compressed air and driven by a cylinder to move the slider, it has a simple structure and low cost.

Disadvantages: Low accuracy (dependent on gas source pressure, positioning error ± 1-5mm), uncontrollable speed, suitable for low-end scenarios (such as simple push and switch actions).

3). Hydraulic linear modules

Powered by hydraulic oil, it outputs high thrust (up to tens of tons) through hydraulic cylinders, suitable for ultra heavy load scenarios such as metallurgical equipment and heavy machinery.

Disadvantages: The system is complex (requiring hydraulic pumps and pipelines), prone to leakage, and has high maintenance costs.

3.Classified by structural form

1). Single axis linear modules

Single directional linear motion unit, compact structure, can be used alone or combined into a multi axis system (such as XY cross slide table, XYZ gantry structure).

Application: Single axis feed for 3D printers and dispensing machines.

2). Multi axis combination modules

Multiple axis linear modules are combined through connectors to achieve planar (XY) or spatial (XYZ) motion, such as a Cartesian coordinate robot.

Application: Multi directional material handling for automated assembly lines and trajectory control for welding robots.

3). Integrated linear modules

The transmission, guidance, and driving components are highly integrated, and the housing is enclosed (with a protection level of IP54 or above), suitable for harsh environments (such as dust and humid scenes).

Features: Easy to install, low maintenance, commonly used in food processing and outdoor equipment.

4. Classified by accuracy level

Precision level: Positioning accuracy ≤ ± 0.01mm, repeated positioning accuracy ≤ ± 0.005mm, such as linear motor modules and ball screw modules (C3 level), used in semiconductor and optical equipment.

Industrial grade: Positioning accuracy ± 0.01-0.1mm, such as ordinary ball screw modules (C5 grade) and synchronous belt modules, used for automated production lines and machine tools.

Civilian grade: Positioning accuracy ≥ ± 0.1mm, such as trapezoidal screw modules and pneumatic modules, used in low precision scenarios such as furniture, doors and windows.

The core of different classification methods is to match scene requirements: high-precision linear motor or ball screw modules is selected, high-speed long-distance synchronous belt module is selected, heavy-duty gear or hydraulic module is selected, and low-cost pneumatic or trapezoidal screw module is selected. In practical applications, multiple classification dimensions of linear modules are often combined for selection (such as "industrial grade electric ball screw single axis module".