Main advantages and applications of hybrid stepper motor

1. Basic introduction to hybrid stepper motor

A hybrid stepper motor is a type of electric motor that combines the features of both permanent magnet and variable reluctance stepper motors, offering higher torque and precision than either type alone. It achieves this by having a rotor with permanent magnets and a stator with electromagnets, which interact to create precise rotational movement in discrete steps when energized by electrical pulses. 

2. Working principle of hybrid stepper motor

Hybrid stepper motors operate by precisely controlling the energization of stator windings to rotate the rotor in discrete steps. This is achieved by creating a magnetic field that interacts with the permanent magnets embedded in the rotor, causing it to move in alignment with the field's direction. The step angle, or the amount of rotation per step, is determined by the motor's design, including the number of rotor teeth and stator poles. 

3.Advantages of hybrid stepper motor

1. High Positional Accuracy and Precision:One of the most significant advantages of hybrid stepper motors is their exceptional positional accuracy and precision. These motors can move in very small increments, typically 1.8 degrees per step. With precise control of each step, hybrid stepper motors provide highly accurate positioning, making them ideal for applications requiring precise movements, such as 3D printers, CNC machines, and medical equipment.

2. High Torque at Low Speeds:Another advantage of hybrid stepper motors is their ability to provide high torque even at low speeds. This characteristic is particularly useful in applications where the motor needs to start and move heavy loads, such as in industrial automation and robotics.

3. Open-loop Control:Hybrid stepper motors operate in open-loop control systems, which means they do not require feedback sensors to determine the rotor position accurately. This feature simplifies the control process and reduces system complexity. Open-loop control also eliminates the need for additional sensors, making the overall system more cost-effective.

4. Compact Size and High Power Density:Hybrid stepper motors are known for their compact size and high power density. The compact design makes them suitable for applications with limited space, such as small-scale automation systems and portable devices. Despite their small size, hybrid stepper motors can deliver mechanical power comparable to larger motors, thanks to their high power density.

5. Cost-effective Solution:Hybrid stepper motors offer a cost-effective solution compared to other motor types, such as servo motors. They have a relatively lower price point, making them more accessible for many applications. Additionally, the absence of feedback sensors further reduces the overall cost of the system.

4.Main applications of hybrid stepper motor

1.Robotics and Automation:Hybrid stepper motors are commonly used in robotics and automation due to their ability to provide precise and reliable motion control. These motors are essential for controlling the movement of robotic arms, grippers, and other automated systems. With their high torque output and accurate positioning capabilities, hybrid stepper motors play a crucial role in ensuring the smooth and efficient operation of robotic applications. 

2.3D Printing and Additive Manufacturing:The use of hybrid stepper motors in 3D printing and additive manufacturing has revolutionized the way objects are produced. These motors are used to precisely control the movement of the print head and build platform, enabling highly accurate and intricate 3D printed designs. Hybrid stepper motors are favored in 3D printing for their ability to provide high-resolution and smooth motion, resulting in superior print quality. 

3.CNC Machining and Milling:In CNC (Computer Numerical Control) machining and milling, hybrid stepper motors are widely used to drive the movement of cutting tools and workpieces with exceptional precision. These motors are capable of providing the high torque required for heavy-duty machining operations, while also delivering the accuracy needed for intricate and complex part production. 

4.Medical Devices and Imaging Systems:Hybrid stepper motors play a critical role in medical devices and imaging systems, where precision and reliability are paramount. These motors are commonly employed in applications such as MRI machines, CT scanners, robotic surgery systems, and laboratory automation equipment. With their ability to deliver consistent and controlled motion, hybrid stepper motors contribute to the advancement of medical technology by enabling more accurate diagnostics, minimally invasive procedures, and improved patient care.

5.Automotive Systems and Electric Vehicles:In the automotive industry, hybrid stepper motors are utilized in a wide range of applications, including fuel injection systems, HVAC (heating, ventilation, and air conditioning) actuators, power seats, and electric power steering. With the shift towards electric and hybrid vehicles, the demand for hybrid stepper motors continues to rise as they are essential for controlling various vehicle components with precision and efficiency.

Structural advantages and common applications of permanent magnet stepper motors

1. Basic introduction to permanent magnet stepper motors

Permanent magnet stepper motors are devices that convert electrical energy into mechanical energy. Their core feature is that the rotor uses permanent magnets, which can generate a magnetic field with alternating polarity in the air gap. When the stator winding is energized, the rotor will align with the direction of the magnetic field determined by the phase winding. When the winding is switched, the rotor will rotate a specific angle to achieve stepping motion.

2. Working principle of permanent magnet stepper motors

The working principle of permanent magnet stepper motors is based on the principle of electromagnetism. Its internal structure includes a fixed part (stator) and a movable part (rotor). The stator has a gear-like protrusion with a coil wound on it, and the rotor is a permanent magnet. When the stator phase is energized, the current passing through the coil generates a magnetic field, and the rotor will align with the magnetic field. By applying voltage to different phases in turn, the rotor will rotate a specific angle and eventually reach the required position.

3. Structural advantages of permanent magnet stepper motors

‌1. High efficiency‌: One of the biggest advantages of permanent magnet stepper motors is their high efficiency. Because it uses high-performance permanent magnetic materials, it does not require an external power supply to provide a magnetic field, which reduces energy loss, so the efficiency can reach more than 90%, which is significantly higher than traditional motors.

2. Excellent power density: Permanent magnet stepper motors have higher output power at the same volume and weight. This feature makes it particularly outstanding in application environments with limited space, such as electric vehicles, robots, and portable devices. High power density not only improves the performance of the equipment, but also helps to reduce the weight of the equipment, which is conducive to the portability and flexibility of the product.

3. Wide operating range: Permanent magnet stepper motors have a wide operating range and can work stably under various working conditions. Because its starting and running torque is relatively constant, it can still maintain good performance even at low speeds and high loads. This is particularly important in application scenarios that require frequent starting and stopping, such as elevators, lifts, etc.

4. Low maintenance cost: Compared with traditional motors, permanent magnet stepper motors have less mechanical wear. Its brushless design eliminates the wear and replacement of carbon brushes, greatly reducing maintenance costs. This low maintenance requirement enables permanent magnet stepper motors to maintain high reliability in long-term operation and reduce downtime.

‌5. High precision and repeatability: Permanent magnet linear stepper motors can achieve high-precision linear motion through precise linear motion control technology and efficient drive algorithms. Feedback systems such as grating scales or encoders provide real-time position information to the motor, and the drive algorithm adjusts the current and voltage based on this information to ensure the accuracy of the stepping action.

4. Common applications of permanent magnet stepper motors

1. Industrial automation and control: In CNC machine tools (CNC), permanent magnet stepper motors are used to drive the X, Y, and Z axes of lathes, milling machines, and engraving machines for precise linear or rotational motion, and control tool position and feed speed. In addition, they are also used in 3D printers to accurately control the movement of the print head and platform to achieve layer-by-layer material stacking.

‌2. Medical and laboratory equipment‌: In the medical field, permanent magnet stepper motors are used to control the rotation and positioning of the scanning head of CT/X-ray machines, adjust the precise position of certain components in nuclear magnetic resonance, and control the propulsion speed and distance of the piston in the infusion pump/syringe pump to achieve trace and uniform delivery of liquid medicine‌. In laboratory equipment, they are also used in DNA sequencers and automated sample processors to accurately move the position of sample trays and detection probes‌.

‌3. Office automation equipment‌: In printers, scanners, copiers and fax machines, permanent magnet stepper motors are used to control the precise movement of print heads, scanning heads and paper‌

1. In addition, they are also used in plotters to accurately control the movement of drawing pens or knives and draw fine graphics‌.

4‌. Consumer electronics and household appliances‌: In cameras, smart door locks and air conditioners, permanent magnet stepper motors are used to control the translation, pitch and rotation of cameras, the electronic unlocking of smart door locks, and the swing of air guide plates of air conditioners‌.

5. Other applications: Permanent magnet stepper motors are also used in stage lighting to control the angle and zoom of spotlights, as well as in instrumentation and control to rotate car dashboard pointers and adjust valve openings.

Source:https://plaza.rakuten.co.jp/yixing/diary/202506250000/

Main control methods and maintenance tips for servo motors

1. Basic definition of servo motors

A servo motor is an actuator motor used to precisely control the movement of mechanical components in a servo system. It can convert electrical signals into angular displacement or angular velocity, and has the characteristics of high precision, fast response and high stability. It achieves precise adjustment of position, speed and torque through a closed-loop control system, and is widely used in automation equipment, robots, CNC machine tools and other fields. ‌‌

2. Working steps of servo motors

1. Control signal reception: The controller (such as PLC, motion controller or microprocessor) generates a control signal according to a preset control algorithm, representing the desired motor position, speed or torque.

‌2. Precision control: After receiving the control signal, the servo drive adjusts the power supply to the motor to ensure that the actual motion state of the motor is consistent with the requirements of the control signal, involving complex current, voltage regulation and pulse width modulation (PWM) technology.

‌3. Feedback mechanism: The built-in or external encoder monitors the actual position, speed and/or torque of the motor in real time, and feeds this information back to the drive and even the controller.

‌4. Closed-loop control‌: The driver compares the actual feedback value with the target value of the control signal, calculates the deviation and adjusts the motor's drive current accordingly to achieve closed-loop control, ensuring that the servo motor can respond to the control command quickly and accurately, and achieve high-precision positioning and dynamic performance‌.

3. Main control methods of servo motors

1. Amplitude control ‌: By changing the amplitude of the control voltage, keeping the frequency and phase unchanged, the speed and torque of the motor are adjusted. In essence, the output is controlled by adjusting the voltage amplitude to affect the magnetic field strength.

2. Phase control ‌: Keep the control voltage amplitude and frequency unchanged, only change the phase difference, and affect the rotation direction of the magnetic field or the size of the synthetic magnetic field through phase changes, thereby adjusting the motor's operating state‌.

3. Amplitude-phase control ‌: Simultaneously adjust the amplitude and phase of the control voltage, comprehensively adjust the magnetic field characteristics, and achieve precise control of the motor‌.

4. Speed ​​control , position control and torque control ‌: These are the three most common control methods for servo motors. Speed ​​control is used to adjust the speed of the motor; position control is used to accurately control the position of the motor; torque control is used to adjust the output torque of the motor.

5. Fuzzy control: The motor parameters are self-learned through fuzzy logic algorithms to improve the stability and response accuracy of the motor under different loads and operating conditions. This method obtains the correlation information between the motor structure and load changes by jointly sampling and eliminating interference from multi-source operating data in the industrial site.

6. PID control: In complex environments, the three-loop superposition PID control logic of the current loop, speed loop and position loop is used to optimize the pointing stability and communication performance of the motor. This method can effectively overcome the limitations of the single-loop PID control of stepper motors and ensure the stable pointing and communication performance of the motor in various complex environments.

4. Servo motor maintenance tips

1. Regular inspection and maintenance: Regularly check the various components of the servo motor, including encoders, bearings, gears, etc., to ensure that they are firmly connected and well lubricated. Clean the dust and dirt on the surface of the motor to keep the motor clean.

‌2. Avoid overload operation‌: Match the rated load and speed of the motor reasonably to avoid overload operation. Check the maximum radial load force of the motor, improve the mechanical design, and ensure that the motor runs under a reasonable load‌.

‌3. Pay attention to heat dissipation issues‌: Ensure that there is enough ventilation space around the motor to avoid overheating of the motor. Clean the air duct and take cooling measures to ensure that the motor runs at a suitable temperature‌.

‌4. Reasonably control the operating environment‌: Ensure that the temperature, humidity, dust and other factors of the motor operating environment are within a reasonable range. In high temperature, high humidity or dusty environments, the heat dissipation and cleaning of the motor should be strengthened‌.

‌5. Check the connection wire regularly‌: Check whether the motor connection wire is loose or damaged to ensure a firm connection. Check whether the motor grounding wire is reliably grounded to ensure the safe operation of the motor‌.

‌6. Check the lubrication condition regularly‌: Regularly check the lubrication condition of the bearings and gears of the servo motor, and add or replace the lubricating oil in time to ensure the smooth operation of the motor‌.

‌7. Follow the operating procedures‌: When operating the servo motor, the operating procedures and safety specifications of the equipment should be followed to avoid improper operations such as frequent starting, stopping or overspeeding to reduce impact and wear on the motor‌.

Source:https://plaza.rakuten.co.jp/yixing/diary/202506040000/

What are the selection principles for right-angle planetary gearboxes?

1. Working principle of right-angle planetary gearboxes

The working principle of right-angle planetary gearboxes is based on the special design of planetary gears. Planetary gears can not only rotate around their own rotation axis (autorotation) like fixed-axis gears, but also rotate around the axis of other gears (revolution) with the planetary carrier. This design enables the gearbox to achieve efficient transmission when the input shaft and output shaft are at right angles.

2. Basic structure of planetary gearbox

1. Planet carrier: The planetary carrier is a disc-shaped structure with three shafts evenly fixed on it. These shafts are distributed at an angle of 120 degrees and remain parallel to each other. The rotating shaft of the planetary carrier is installed inside the bearing, and the other end is connected to the low-speed shaft flange, which is connected to the main shaft of the wind wheel.

2. Planetary gears: The three planetary gears are installed on the three shafts of the planetary carrier and can rotate freely around their respective axes, ensuring the flexibility and efficiency of the gearbox.

3. Ring gear: The ring gear is an internal gear whose internal teeth mesh with the planetary gears. When the planet carrier rotates, the planetary gear rolls along the inner teeth of the ring gear.

‌4. Sun gear: The sun gear is the high-speed output shaft, and its tooth design meshes with all planetary gears to ensure efficient transmission.

3. Advantages of right-angle planetary gearboxes

1. High-precision transmission: The continuous advancement of manufacturing technology has made the transmission accuracy of right-angle planetary gearboxes higher and higher. The use of advanced processing technology and precision assembly technology can control the tooth profile error of the gear within a very small range, thereby ensuring that the rotation accuracy of the output shaft reaches the micron level.

‌2. Diversified customization capabilities: Many manufacturers provide customized services for right-angle planetary gearboxes, and can adjust the reduction ratio, output torque, external dimensions and other parameters according to the special requirements of customers to meet different application requirements.

‌3. High efficiency and energy saving: The right-angle planetary gearbox adopts an efficient lubrication system and optimized internal structure design. The lubricating oil can form a good oil film between each friction pair to reduce energy loss; the reasonable structural layout reduces unnecessary mechanical resistance and improves the overall transmission efficiency.

‌4. Compactness and flexibility‌: Right-angle planetary gearboxes are simple in design, reliable in performance and extremely cost-effective. They can be integrated into applications through a variety of connection methods, providing a variety of installation options, increasing design flexibility‌. In addition, right-angle planetary gearboxes can be installed and used in any mounting position, which provides users with greater design flexibility‌.

‌5. High load capacity and long life‌: The planetary gear system of the right-angle planetary gearbox has a high load capacity and can work stably under heavy loads and challenging environments. Its design allows for lifetime lubrication, which further extends its service life‌.

‌6. Multiple installation methods‌: Right-angle planetary gearboxes usually provide a variety of installation methods, such as flange mounting, shaft mounting, etc., to meet different application requirements.

4. Selection principles of right-angle planetary gearboxes

1. Reduction ratio selection‌: First, you need to determine the required reduction ratio. The reduction ratio is the ratio of the input speed to the output speed. Selecting a suitable reduction ratio can achieve the required output speed. The selection of the reduction ratio should ensure that the value of the servo motor's rated torque multiplied by the reduction ratio is less than the rated output torque of the similar reducer provided in the product sample, and the required maximum working torque is less than 2 times the rated output torque.

‌2. Accuracy requirements: Select the appropriate accuracy level according to the application scenario's requirements for transmission accuracy. Accuracy levels are usually divided into general accuracy, high accuracy and ultra-precision levels. Users should select the appropriate accuracy level according to actual needs.

‌3. Power requirements: Select the rated power of the planetary gear reducer according to the power of the drive motor and the required output power in the application scenario. The rated power of the reducer should be greater than or equal to the required output power to ensure the normal operation of the equipment.

‌4. Reliability requirements: Select a planetary gear reducer with high reliability and long life. Reliability includes the quality of the reducer, the manufacturing process, the durability of the parts, etc.

‌5. Installation requirements: Consider the installation space and layout requirements of the planetary gear reducer and select the appropriate size and form. Right-angle planetary gearboxes usually have different installation forms, such as flange type, bearing type, flange bearing type, etc. Select the appropriate installation form according to the actual situation.

‌6. Maintenance requirements‌: Consider the maintenance requirements of the planetary gear reducer and choose a model that is easy to maintain and repair. Maintenance requirements include sealing performance, parts replacement, etc.‌

Source:https://plaza.rakuten.co.jp/yixing/diary/202505130000/

What methods can be used to judge the quality of hybrid stepper motors

 ‌‌‌1. A brief introduction to hybrid stepper motors

Hybrid stepper motors are a type of motor that combines the advantages of permanent magnet stepper motors and reactive stepper motors. It has high output torque and high step accuracy, and is widely used in industrial automation and precision control, especially as a drive device in economical CNC machine tools. Its high precision, high reliability and good speed regulation performance make it perform well in these fields.

2. The main structure of hybrid stepper motors

The main structure of hybrid stepper motors includes three parts: stator, rotor and armature. The stator is usually composed of a combination of a reluctance winding and a wound winding of a traditional stepper motor. The stator is equipped with a multi-way winding structure and a permanent magnet on the periphery; the rotor is composed of a magnet and a small reluctance magnetic needle of a traditional stepper motor; the armature is composed of a regulating reluctance and a power supply, which is used to control the rotation direction and step of the motor.

3. Design requirements for hybrid stepper motors

1. Performance requirements: Hybrid stepper motors need to meet specific performance indicators, including step angle accuracy, torque fluctuation, etc. The motor should work normally under the specified power supply and load conditions to ensure reliability and stability in practical applications.

2. Structural requirements: The rotor of the hybrid stepper motor itself is magnetic, which makes the torque generated under the same stator current greater than that of the reactive stepper motor. However, its structure is relatively complex, the rotor inertia is large, and the rapidity is low.

3. Material selection: Hybrid stepper motors are usually made of high-temperature resistant permanent magnets and high-quality cold-rolled steel sheets to ensure the reliability and stability of the motor. In addition, the selection of high-quality bearings and appropriate surface treatment can also improve the performance of the motor.

4. Environmental adaptability: Hybrid stepper motors should have good environmental adaptability and be able to operate stably in different working environments. This includes characteristics such as high temperature resistance and moisture resistance.

5. Test methods: The national standard specifies the test methods for hybrid stepper motors, including performance tests, environmental adaptability tests, and durability tests. These test methods ensure that the motor meets national standards and provide a basis for quality control and selection.

4. Quality judgment method of hybrid stepper motor

‌1. Appearance inspection: First observe whether the overall structure of the motor is complete, whether the cable connection is normal, and whether there is no damage or breakage. At the same time, check the nameplate or label on the motor to understand its model, voltage and other information to ensure that it meets the equipment requirements.

‌2. Resistance measurement: Use a multimeter to adjust the motor to the resistance range (such as 10K ohms), disconnect the power connection and signal line connection, and measure the resistance value of the motor coil. If the displayed resistance value is close to infinity, it means that the motor coil is basically normal; if the displayed value is very small, the motor may be short-circuited or open-circuited. In addition, the resistance values ​​measured at both ends of the motor should be almost equal, otherwise it may be caused by motor bearing wear, stator and rotor misalignment, etc.

‌3. Power-on test: Connect the motor to the power supply and observe its working status. Under normal circumstances, the motor should be able to work normally, rotate flexibly and without abnormal sounds. If the motor does not turn or turns with difficulty, it may be a motor failure.

‌4. Speed ​​and torque detection‌: Use a tachometer or other measuring tools to measure whether the speed and torque of the motor meet the requirements of the specification. If the speed or torque is significantly lower than the nominal value, it means that the motor performance is poor.

‌5. Noise detection‌: During the operation of the motor, use a noise meter or other measuring tools to record its noise level. If the noise is significantly greater than the nominal value, it means that the motor performance is poor.

‌6. Life test‌: In actual applications, the motor is tested for a long time to observe its service life. If the motor fails or its performance deteriorates in a short time, it means that its quality is poor.

‌7. Professional equipment detection‌: For some complex parameters, such as phase, phase angle, etc., professional motor testing equipment can be used for detection. These devices have high precision and can more accurately judge the quality of the motor.

Source:https://steppermotor.pixnet.net/blog/post/182020282

How to improve the stability and service life of right-angle planetary gearboxes

1. Introduction to right-angle planetary gearboxes

Right-angle planetary gearboxes‌ are gearboxes used for deceleration or acceleration transmission, with the characteristics of high transmission efficiency, small size, low noise and long service life. Its core structure includes sun gear, planetary gear and inner ring gear. This structure can achieve high-efficiency transmission, and at the same time has high load-bearing capacity and long service life. ‌

2. Working principle of right-angle planetary gearboxes

The working principle of right-angle planetary gearboxes‌ is based on the special structure of planetary gears, and its core lies in the rotation and revolution of planetary gears. The axis of rotation of the planetary gears is not fixed, but is installed on a rotatable bracket, which is called a "planet carrier". The planetary gears can not only rotate around their own axis (rotation), but also rotate around the axis of other gears with the planet carrier (revolution). This movement is similar to the movement of planets in the solar system. ‌

3. Methods for improving the stability of right-angle planetary gearboxes

1. High-quality materials‌: The right-angle planetary gearbox is made of high-quality materials, with precise gear engagement, low noise, and no obvious wear after long-term use, thereby improving the stability of the equipment. ‌

‌2. Precision manufacturing process: Through high-precision CNC machining technology, such as gear grinding and gear hobbing, the gear tooth profile accuracy is ensured to reach IT5-IT6 level, so that the gear is evenly stressed during the meshing process, vibration and noise are reduced, and a stable transmission ratio is maintained.

‌3. Compact structural design: The output shaft of the right-angle planetary reducer is at a 90-degree angle to the input shaft. This design enables the reducer to achieve efficient power transmission in a limited space, which is particularly suitable for occasions with limited space.

‌4. High transmission efficiency: The multi-stage transmission design of the right-angle planetary reducer enables it to have a higher transmission efficiency, usually up to more than 90%, reducing energy loss and improving the stability and reliability of the equipment.

‌5. High load-bearing capacity: The multi-point contact planetary gear system design enables the right-angle planetary reducer to have a higher load-bearing capacity, which is suitable for heavy-load occasions and further improves the stability of the equipment.

4. Methods to extend the life of the right-angle planetary gearbox

‌1. Regular cleaning and maintenance: Keeping the inside of the gearbox clean is the basic condition for extending its service life. Any impurities or dirt entering the gearbox will affect and damage its rotating system, thereby reducing its service life. Regularly clean the oil and dust on the equipment to ensure that the inside of the gearbox is clean.

2. Control the working temperature: Maintaining the normal working temperature of the gearbox can prevent the deformation of parts due to excessive temperature difference, ensure the normal operation of the gears, prevent excessive noise, and thus extend the service life. For gearboxes working in high temperature environments, heat dissipation devices such as radiators or cooling fans can be installed to avoid excessive temperatures that accelerate the failure of lubricants and wear of parts.

3. Reasonable use of lubricants: The use of lubricants is essential to the operation of gearboxes. Delayed use of lubricants or use of inferior oils will cause immeasurable damage to the gearbox. Regularly injecting an appropriate amount of lubricants and ensuring their quality can effectively reduce friction and wear.

4. Avoid overload and impact: Strictly use the rated torque and power of the gearbox to avoid overload operation. In the mechanical system design stage, the workload should be accurately calculated and a gearbox of appropriate specifications should be selected. Reduce the impact load during starting and stopping, adopt a slow and smooth operation method, and protect internal components.

‌5. Check and replace worn parts: Regularly check the relevant parts of the gearbox, such as oil seals and gaskets, and replace damaged or loose parts in time to ensure the normal operation of the gearbox.

‌6. Follow the instruction manual: Use the gearbox correctly in accordance with the instruction manual and avoid arbitrary and improper use, which can minimize the damage to the parts in the machine.

Linear guide rail usage precautions and design principles

1.A brief introduction to linear guide rail

Linear guide rail is a mechanical guide rail used to support and guide moving parts to reciprocate linear motion in a given direction. It usually consists of two parts: a track (slide rail) and a slider. The slider is equipped with internal circulation balls or rollers, which can achieve smooth, high-precision linear motion on the track and can withstand a certain load. ‌

2.Components of linear guide rail

1.Guide rail: The guide rail is the main part of the linear guide, providing a track or path for linear motion. It is usually made of wear-resistant and high-strength carbon steel or alloy steel. ‌2. Slider: The slider is installed on the moving part and cooperates with the guide rail. The rolling body slides on the guide rail to achieve linear motion. ‌

‌3.Rolling body: The rolling body is usually a steel ball or steel column, which rolls between the slider and the guide rail to reduce friction and improve motion efficiency. The rolling element of the ball type guide rail is a steel ball, which belongs to point surface contact, with a small load capacity but small friction resistance; the rolling element of the roller type guide rail is a steel column, which belongs to line surface contact, with a stronger load capacity but a higher price.

‌4.Retainer: The retainer is used to keep the rolling element in the correct position in the slider to prevent the rolling element from falling off.

‌5.Housing: The housing surrounds and protects the internal rolling element and retainer, while providing necessary support and protection.

3.Design principles of Linear guide rail

‌1.Automatic fitting principle: In order to make the guide rail high in precision, the guide rail pair must have the characteristics of automatic fitting. Horizontal guide rails can fit by relying on the weight of the moving component, while other guide rails require additional spring force or roller pressure to fit.

‌2.Full contact principle: Within the length of the fixed guide rail, the moving guide rail should be in full contact with the fixed guide rail at the two extreme positions of the maximum stroke to ensure that the guide rail pair can complete full contact during the contact process, thereby achieving a perfect state.

‌3.Principle of compensation for force deformation and thermal deformation: The guide rail and its supporting parts will deform when subjected to force or temperature changes. This deformation should be considered during design so that it can be deformed into a corresponding shape. For example, the crossbeam guide rail of a gantry machine tool is made into a convex shape to compensate for the bending deformation caused by weight.

‌4.Principle of proximity of dynamic and static friction coefficients: The dynamic and static friction coefficients of the guide rail contact surface should be as close as possible during design to improve repeated positioning accuracy and low-speed stability. This is easier to achieve with rolling guides and sliding guides with plastic plates.

‌5.Principle of non-interference in precision: The various precisions of the linear guide rail should not affect each other during manufacturing and use to ensure a higher precision coefficient.

‌4.Precautions for use of linear guide rails

1.Ambient temperature control: The ambient temperature should not exceed 80°C, and the instantaneous temperature should not exceed 100°C.

‌2.Installation and removal of the slider: When removing or replacing the slider, a dummy rail should be used to assist in installation, and the guide rail should be avoided from being removed unless necessary.

‌3.Use in special environments‌: Special attention should be paid when using in special environments such as frequent vibration, high dust, high and low temperatures.

‌4.Lubrication and maintenance‌: Wipe the anti-rust oil first and then seal the lubricating oil for use to avoid mixing lubricating oils of different properties. When using lubricating oil for lubrication, adjust according to different installation methods. After filling the lubricant, push the slider back and forth for at least 3 slider lengths, repeat more than 2 times, and confirm that the oil film on the surface of the guide rail is uniform.

‌5.Storage and protection measures‌: When storing linear guides, make sure to apply anti-rust oil and seal them in the designated envelope, place them horizontally, and avoid high and low temperatures and humid environments.

‌6.Handling and protection‌: When carrying heavy linear guides, more than 2 people or use handling tools to avoid personal injury or damage to the workpiece.

‌7.Safety and protection precautions‌: The slider and guide rail may fall due to weight after tilting, so be careful. Avoid disassembling the slider by yourself to prevent foreign matter from entering or adversely affecting the assembly accuracy.

Source:https://steppermotor.pixnet.net/blog/post/178004299