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Drive technology wiki
All questions and answers about drive technology
Your central knowledge platform for linear axes, electric motors and control technology. Whether for design, automation or maintenance, in our wiki, we answer the most frequently asked questions and explain complex issues simply, practically and independently of the manufacturer.
Find out everything about the basics of our products, as well as specific questions directly from practice. All contents are continuously expanded and are based on current requirements from industry, mechanical engineering and automation technology.
Knowledge about electric motors
igus offers a wide portfolio of electric motors for automation and drive technology, which are specially matched to the use with linear axes and mechatronic systems. The product range includes direct current motors (DC motors), brushless direct current motors (BLDC motors), stepper motors and special solutions such as lead screw motors and linear actuators.
The motors are available in different sizes, power levels and designs and can be combined with suitable control systems and regulators depending on the application. This makes them ideal for simple positioning tasks as well as for dynamic, precise or continuous movements in industrial, mechanical and automation applications. All electric motors can be found in the shop:
To the electric motor online shopThere are three different types of stepper motors, the permanent magnet stepper motor, the reluctance stepper motor and the combination of both motors, the hybrid stepper motor. igus only supplies hybrid stepper motors. This combines the advantages of both motors.
To the stepper motor online shopThe stepper motor can apply a high and full torque at standstill and has an accurate step angle. Furthermore, the stepper motor has a holding torque. The disadvantage of a stepper motor is the high energy requirement, as it always operates at maximum current. This can be counteracted by means of a motor control system. Due to a rotary encoder and the close loop, both of which are adapted to the application, only the required current is consumed. The hybrid stepper motor is mainly used in industry for positioning tasks that require precise motion control.
DC motors are simple electric motors that operate with DC voltages. This means that they can also be operated with simple batteries. DC motors have two connections, one for plus and one for minus. Thus, for a different direction of rotation of the DC motor's shaft, only the connections of the supply line have to be interchanged.
DC motors are cost-effective due to their simple design. The disadvantage of DC motors without a motor control system is that they do not switch off automatically when the torque is increased, but draw more and more current until they come to a standstill. If a blockage lasts longer, the motor could be thermally damaged.
To the DC motor online shopBrushless DC motors, also called BLDC motors, are motors that have no carbon brushes. BLDC motors operate in principle like three-phase synchronous motors. This is achieved by an electrical circuit that controls the coils one after the other.
The advantage of brushless DC motors is that the lack of carbon brushes significantly extends their service life and makes them maintenance-free. In general, EC motors are used for dynamic and higher speeds. The disadvantage of these motors is their higher cost compared to stepper and DC motors.
A closed-loop stepper motor, also referred to as a hybrid servo motor, is a version of the conventional stepper motor that has an encoder. This system uses feedback, which allows the motor to detect and correct missed steps. This improves accuracy and efficiency while maintaining the stepper motor design. This option closes the performance gap but increases the cost and complexity compared to a traditional open-loop stepper motor.
Articles on electric motors
Knowledge about motor control systems
The choice of motor control system depends on the motor used, the required functions and the desired communication. Important criteria include motor type (stepper motor, DC motor or EC/BLDC motor), supply voltage, power requirements and interfaces such as Ethernet, CANopen or digital inputs and outputs. We would be happy to help you make your selection, or visit our online shop.
To the motor control system online shopYes. Several motor control systems can be combined and synchronised in one system. This allows more complex movements with several linear axes or drives to be realised.
Commissioning usually takes place via the relevant software or an integrated web interface. Here, motor parameters, travel profiles, speeds and positions can be set. Afterwards, the function is checked and optimised through test runs.
Our sample programmes will help you commission our igus motor control systems.
To the sample programsArticles on motor control systems
Knowledge about linear axes
The most important types for linear drives include:
- Toothed belt drive: It uses a tensioned belt for linear movement
- Lead screw drive: It uses a lead screw or a ball screw
- Rack and pinion drive: It uses a gear mechanism for linear motion
If a less high speed but a high accuracy is required, linear axes with trapezoidal thread are usually used. The linear axis with lead screw drive is also a good choice for high axial thrust forces. Due to the bending critical limit speeds of lead screws, the travel (max. 1,500mm), the speed and thus the speed of the lead screw are very limited. The recommended speed limit depends on the lead screw diameter. The applications at a glance:
- For use in format adjustment
- In extreme environments (heat, cold)
- When corrosion resistance is required
- When a quiet operation is required
- For shorter travels up to 1.5 metres
- For low to medium speeds
- For high accuracy
Linear axes with toothed belt drive are particularly suitable for fast positioning and handling tasks. Long travels up to 3,000mm and high speeds are the range for this linear drive. The applications at a glance:
- When high speeds are required
- For travels up to 3 m
- If the structure should be very flat
- If positioning accuracy can be >0.1mm
A rack and pinion drive is ideal for applications with long travels, high load capacity and robust performance in harsh environments. Linear drives with rack and pinion drive offer several decisive advantages:
- Long service life: Robust design for durable performance
- High load capacity: Effective handling of high loads
- Resistance in various environments: Reliable function under a wide variety of environmental conditions
- Use in heavy-duty applications: Ideal for demanding industrial applications
- High temperature resistance: Usable even at extreme temperatures
Disassembly, bearing replacement and reassembly according to the installation instructions make bearing replacement normally very time-consuming. Our pillow block offers a quick alternative: the bearings are changed in seconds without disassembly. The lateral fixation is released and the bearing is pushed out with a small installation tool or screwdriver. The new bearing is clipped on and pushed into the housing. All four bearings of a ZLW toothed belt axis, for example, can be completely renewed within two minutes. See what this looks like in the video at the link below.
Fast plain bearing replacement in linear modulesElectric linear drives convert electrical energy into precise, linear movements.
Typical applications:
- Robotics and automation
- Medical equipment
- Industrial automation systems
Benefits:
- High precision: Excellent accuracy and repeatability
- Easy integration: Effortless connection to digital control systems
- Quiet operation: Low noise levels
- Clean operation: No liquids or compressed air required
Linear axes with toothed belt drive are usually best for high-speed applications. Their design allows for fast linear movements with minimal mechanical resistance, making them ideal for applications requiring fast positioning.
They are particularly powerful in situations where speed is prioritised over a high load capacity, such as pick & place applications, rapid positioning systems and automated assembly lines.
Consider the following key factors when selecting a linear drive:
- Force requirements: How much weight or resistance needs to be moved?
- Speed requirements: How fast does the movement need to be?
- Precision requirements: How accurate does it need to be?
- Stroke: How far does the drive have to travel?
- Environmental conditions: Temperature, humidity, contamination
- Budget specifications: Acquisition costs and operating costs
