Linear Motion

Which linear guide is right for my application?

Whether it’s dirt, clean rooms, high dynamics, or limited installation space: If you are clear about the loads, environment, and service life, you will usually find the right solution in the Rexroth standard portfolio.

Linear guides rarely get the spotlight, but they play a central role in mechanical engineering and factory automation. They guide linear movements precisely and reliably under defined environmental and load conditions – as efficiently, compactly, and with as little maintenance as possible. But which linear guide is suitable for dirt, vacuums, clean rooms, extreme temperatures, high dynamics, or limited installation space?

In this blog post you will learn which selection criteria are crucial for linear guides and which applications you can realize particularly economically with our proven standard solutions. If you have special, individual requirements, our experts with decades of application knowledge will be happy to assist you.

Tip: For an overview of the most important types of linear guides – from linear bushings to profiled rail systems and cam roller guides – please visit our linear guides product page.

Which linear guide for which application?

Rexroth linear guides can be found in virtually every industry – from machine tool manufacturing to medical technology, from the food and packaging industry to wood processing, from semiconductor and electronics manufacturing to battery production. The common denominator: the possibility to implement almost any application quickly and cost-effectively. The advantages of the broad standard portfolio of linear guides are a wide selection of proven, quickly configurable solutions with global availability as well as shorter project lead times and machine designs tailored to specific needs. Below are some examples of industry-specific applications and customized solutions:

1. Linear guides for special environmental conditions

Many environments expose linear guides to dirt and contaminants, such as in woodworking and stone processing. Profiled rail systems with special seals (either integrated or as attachments) and the fully sealed standard linear bushings from Bosch Rexroth have proven to be a cost-effective solution for these applications.

Picture collage showing how double-lipped seals protect linear guides from contamination by metal and wood chips.

Harsh environmental conditions: Double-lip seals protect the linear guides in woodworking and metalworking from dirt and contamination.

The all-metal ball rail systems for extreme conditions NRTVG (NRII Temperature Vacuum Graded) withstand extreme temperatures from -30 to 200°C. They impress not only in cold rooms or glass manufacturing, but also in vacuum environments – such as those encountered in wafer and electronics production. The same applies to the all-metal standard linear bushings.

A risk of corrosion exists in the case of contact with acids, alkalis, or electrolytes in electroplating or battery production, as well as during steam sterilization in the medical or pharmaceutical environment. Linear guides made of NRII (corrosion-resistant steel) and hard chrome plated and coated versions (e.g. zinc-iron) prevent these damaging effects. For use in dry rooms, the Rexroth standard portfolio also includes linear guides with resistant plastics such as POM as well as special lubricants.

Ball runner block for extreme conditions NRTVG

Runner block NRTVG for extreme environments.

Miniature ball rail systems and corrosion-resistant profiled rail systems, among others, meet the requirements of various clean room classes in semiconductor and electronics production.

Tip: Depending on the required clean room class, standard versions are often sufficient.

Linear guides are also indispensable in the food sector, especially in packaging and final inspection. The Rexroth ball rail systems in corrosion-resistant NRII or NRFG design (NRII Food Grade) are particularly well suited to these environments. Process-related guiding tasks without direct food contact (e.g. bottle fillers, film wrapping machines, or bag forming, filling, and sealing machines) also benefit from the easy-to-clean, all-metal linear bushings.

All-metal linear bushings

All-metal linear bushings.

2. Linear guides for precision, dynamics, and limited installation spaces

Ever-increasing automation is also pushing the boundaries of accuracy, dynamics, and installation space. When it comes to precision, the roller and ball rail systems RSHP/BSHP lead the way in the Rexroth standard portfolio. Why? A patented entry zone in the runner block ensures optimal smooth running – from workpiece machining, feeding, handling, and assembly to cover plate and laser cutting or 3D printing.

Functional principle of the precision ball rail system BSHP in cross-section: The graphic shows how elastic steel bearing plates enable the balls to enter the bearing zone harmoniously and without impact.

Ball rail system BSHP: Thanks to elastically deformable steel bearing plates (2), the entry zone adapts individually to the current operating load of the runner block (1). The balls (4-7) enter the bearing zone between the runner block and the ball rail (3) smoothly, i.e. without any impulse loads.

Tip: Linear axes and multi-axis systems equipped with BSHP linear guides also achieve maximum precision and dynamics.

Symbolic image for maximum speed: A sprinter in starting position next to two high-speed runner blocks on a blue stadium running track.

Short cycle times require high speeds: The high-speed runner block from the Rexroth standard portfolio reaches a record-breaking 10 m/s. Typical application areas include plastic injection molding, pressing and joining, laser cutting, and handling with long travel ranges. The Rexroth standard linear bushings and standard ball rail systems in small sizes also move quickly at speeds of up to 5 m/s.

Incidentally, the durable cam rollers from Bosch Rexroth are also ideally suited for fast movements up to 10 m/s.

Integrated additional functions save installation space and reduce costs. How? For example, through the temperature control function TCRS, which ensures thermal stability in high-precision workpiece machining, or through linear guides with integrated measuring systems.

Good to know: Both options can be retrofitted.

Roller rail system RSHP on a blue background, with a detailed view of the patented TCRS temperature control option and reference to the online configurator, visualized by a tablet.

Roller rail system RSHP with patented temperature control option TCRS for high-precision machine tools.

Do you want to implement demanding applications in the mid-range price-performance segment economically? Then the all-round guide system BSCL (Ball Rail System Compact Line) is the right choice. Why? Fast selection, configuration, and ordering, combined with the familiar Rexroth quality, many cost-reducing features, and rapid delivery (worldwide from stock).

Incidentally, the price-optimized BSCL line will be consistently expanded in the coming years to cover even more requirements and applications at an optimized price.

Ball rail system BSCL in a spot on a dark blue background

Cost-effective ball rail system BSCL for various applications.

Practical tip: With all Rexroth linear guides, you can interchange rails and runner blocks across all precision and preload classes, thereby saving resources.

For small workspaces and compact machine designs, the Rexroth portfolio also includes miniature ball rail systems that combine small sizes with high load-bearing capacity and positioning accuracy. These properties are in demand in the areas of packaging, medical technology, measurement and testing, as well as in the textile industry and electronics production.

Suitable linear guides for typical requirements

RequirementSuitable standard solutions from the Rexroth portfolio (examples)
Dirt and shavingsSealed linear bushings, profiled rail systems (BSHP, RSHP) with comprehensive sealing variants, wipers, and optional cover strips for easy closing of the mounting holes in the rail
Clean roomMiniature ball rail systems and ball rail systems NRTVG in all-metal design for extreme conditions
Extremely high dynamicsBall rail systems with high-speed runner blocks
High precisionPrecision rail guides RSHP/BSHP, optionally also with temperature control function TCRS
Compact design for limited installation spaceMiniature ball rail systems
Price-optimizedBall rail systems BSCL for the medium performance range
Vacuum / extreme temperaturesBall rail systems in all-metal design, e.g. NRTVG
Hygiene areasBall rail systems NRII or NRFG

With Bosch Rexroth as a broad-based solution partner, you can quickly find the right linear guide for your application. Whether for process automation, increased efficiency, or miniaturization; whether for special environmental conditions or for new requirements in dynamics, precision, or functional integration such as measurement or temperature control. With the Linear Motion Technology Selector, you can easily select, configure, and order any individual linear guide from the extensive standard portfolio that perfectly matches your application. A broad standard portfolio not only simplifies selection and engineering, but also often reduces the effort involved in purchasing, logistics, servicing, and spare parts inventory. Take advantage of Bosch Rexroth’s low-maintenance, best-in-class solutions now to reduce your costs over the entire life cycle – and ultimately benefit from greater competitiveness and sustainability in mechanical and plant engineering.

Linear Motion Technology Selector

With the Linear Motion Technology Selector, you can quickly find the right linear guide for your application – including technical data, CAD models, and suitable accessory components.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Handling small parts the easy way

Author: Jürgen Fischer Position: Product Manager Linear Motion Technology, Bosch Rexroth AG

Whether it be consumer goods, medical technology or 3D printing: Countless small parts need to be moved precisely and cost-effectively. This is now much easier.

When you hear “SMS”, you don’t immediately think of linear modules. But you should remember the term in this context as well. After all, these three letters refer to a cutting-edge, particularly cost-effective solution for handling the small parts found in a wide range of sectors. They include the consumer goods and packaging industry, semiconductor and battery production, 3D printing, the automotive sector, medical technology and mechanical engineering.

Small Modules SMS: Handling small parts the easy way

Exact positioning, compact and low maintenance requirements

Many of these applications require a high repeatability of up to ± 0.005 mm with low to medium dynamics. And if the design is compact, robust and requires little maintenance – all the better! The new SMS linear modules from Bosch Rexroth meet exactly these requirements and help to reduce system and life cycle costs. They also welcome an alternative to pneumatically driven axes and provide a good opportunity for electrification with all of the associated benefits.

Robust linear modules with ball screw assembly

The compact SMS modules with ball screw assembly (Small Modules Screw driven) are manufactured to the usual Rexroth quality standards and impress with their flat aluminum profile offering integrated, precise guidance. In addition, a magnetically fixed steel cover strip protects the components inside.

Small Modules SMS available for five different sizes.

Quick selection, available from stock

To ensure the shortest possible delivery times, the SMS linear modules can be ordered from stock. The five tailored sizes range from 30 to 120 mm and are suitable for travel ranges of up to 1,200 mm. They can be selected and ordered easily from the Rexroth online shop with the help of a product selector. Optional attachment sets for popular servo motors are available – either as a belt side drive or a flange coupling. Naturally, a choice of motors and drive controllers from Bosch Rexroth is available too.

Conclusion: Expanded portfolio saves time and money

The SMS linear modules expand the range of linear axes, adding an ultra-compact series with a particularly flat design offering excellent value for money. Simple positioning and delivery tasks can thus be carried out economically – and at short notice. This opens up an attractive electrification path for greater precision, flexibility and energy efficiency in production – two key qualities in the Factory of the Future.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

What is “smart mechatronics” and how can it support fastener manufacturing?

01/23/2023 

Brad Klippstein, Product Management – Mechatronics Bosch Rexroth

Assembly operations that use handling, joining, and pressing tools for a range of production applications — including fastener manufacturing — continually seek to improve the versatility, ease of use, production time, and quality of such operations.

In today’s digital world, this means adding smarter, Industry 4.0 capabilities to production platforms. For efficiency, this must entail data tracking of a machine’s production and performance with real-time sharing capabilities.

As manufacturers begin to incorporate the benefits of Industry 4.0 technology, a new concept called “smart mechatronics” has evolved, offering more intelligence and functionality in handling and joining. Mechatronic systems are devices that have fully integrated mechanical and electrical components, thanks to the combination of sensors, circuits, and motion-control applications.

In some ways, mechatronic systems could be considered a forerunner of Industry 4.0 technology. They combine disparate mechanical and electronic components into solutions for specific product assembly and transport tasks, such as Cartesian robots (capable of moving in multiple linear directions) and forming and crimping tools.

Meeting industry needs at one time, mechatronic solutions were integrated with components from multiple suppliers. That’s no longer the case. Mechatronics suppliers are replacing that time-consuming acquisition and integration step with complete solutions that are “plug and produce.” This includes the software necessary, which is preprogrammed and delivered as a single production tool. Manufacturers should know that all of the components for a complete mechatronic solution — a Cartesian robot or a pressing or joining tool — can now be specified.

Assembly operations are shifting away from individual products toward complete system kits for manufacturing equipment that produces fast solutions for handling, joining, and pressing tools — along with real-time data.

Users can enter parameters such as stroke, workpiece weight, and cycle time, which generates an output that can be verified in the CAD environment.

It’s clear end users require precise control and execution of motion sequences, but also automated tracking of production data and easy connectivity with machine-level and plantwide production management systems.

Additionally, there’s a demand for easier and faster changeovers. Many production lines or mid-sized shops seek tools that make it easier to produce a range of batch sizes — from the low end of only a few thousand parts up to hundreds of thousands — without extensive effort to reprogram tools for a new part.

The price point also matters. End users require cost-effective measures that meet budgets and readily support manufacturing orders. Kitted solutions that provide flexibility in a space-saving envelope with minimal integration time are highly desired.

Easier, faster commissioning is one significant advance provided by newer, smarter mechatronic systems and the technology that supports them. Equally valuable are the improved efficiency, flexibility, and productivity it provides end users looking for easy-to-automate solutions.

For those wanting to integrate mechatronics and update production lines, consider systems that:

  • Combine all the hardware and software into a single solution to support a broader range of applications, including pressing and joining, logistics, packaging, pick-and-place, palletizing, assembly operations, and more
  • Feature an easy-to-use graphical user interface that lets operators build production sequences simply and intuitively
  • Require no special motion-control or programming skills
  • Monitor systematic data such as position, velocity, and acceleration
  • Include kitted solutions that offer simple integration, flexibility, and tracking options, providing users with the ability to set conditions for automated quality control
  • Provide real-time updates and recordings as requested
  • Offer a multi-axis system that can interface with individual peripheral tools such as gripping devices, nozzles, and actuators

Times are changing, and so are industry requirements and processes. To keep up, fastener manufacturers are wise to digitalize their operations with Industry 4.0 technology.

Smart mechatronics solutions leverage easy to-use tools, such as drag and-drop functionality and simple programming. Bosch Rexroth’s Smart MechatroniX system for pressing and joining applications is one example that demonstrates this intuitive model.

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

240% MORE PRODUCTIVITY IN THE SAME SPACE WITH ACTIVEMOVER

Guest Contributor: Jeroen Brands, Bosch Rexroth

Many customers aim to increase productivity in short-cycle applications, but the space available for the planned systems is limited and often set in stone. That means that our challenge is to potentially double the quantities being produced, whilst using as little space as possible.

Sounds impossible? Actually, it isn’t.

In North America, we’ve already achieved the impossible for one of our customers. The decisive solution that made all the difference was our highly flexible ActiveMover transfer system. It has enabled the customer to consolidate two stations into one, reduce the footprint by 44% per line and produce almost two and a half times the quantity in the same amount of time over virtually the same surface area.

Increasing capacity in limited spaces.

The customer was faced with unexpectedly high demand for a complex product, which required a rapid increase in production. As the plant only had limited space for new systems the customer was forced to connect two machines with different cycle times via a classic conveyor belt with a limited buffer capacity.

The system occupied a space measuring around 80 m². Three multi-stations in the system covered longer processes in order to shorten lead times. The entire process involved a total of nine work steps.

The engineers knew that this current set-up was never going to manage more than 50 products a minute and any planned capacity increase would require the basic layout to be changed.

That’s where we stepped in.

Our team suggested using the ActiveMover transfer system as the central element to the operation. It is composed of straight sections and curved units, with vertically installed, low-wear linear motors, which form a closed oval shape. Workpiece pallets travel across the entire section to precisely specified positions independently of each other. They can even approach several positions within one station, one after the other, and change their direction of travel. The individual processing stations are installed on the ActiveMover’s oval shape from outside which make them easily accessible.

br_activemover_body1_dec19.jpg

240% more productive with the same surface area.

The engineers were able to integrate all the stations in the ActiveMover in two steps. This allowed them to decouple processing stations with different cycle times and save on a range of multi-stations. The result: as opposed to the original system’s footprint of 80 m², the customer now needs less than 45 m². That corresponds to a space saving of 44%. At the same time, the output per system has increased by 20%. The customer has more or less installed two machines with increased productivity in the original space available, thereby increasing productivity by 240%.

 

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.

Five trends that support intelligent linear motion technology in practice

Guest contributor; Dr. Steffen Haack, Bosch Rexroth AG

When it comes to progress in linear motion technology, one thing is immediately clear: linear guides and systems move increasingly larger loads more regularly and with increasingly higher positioning accuracy and repeatability. Anyone with an understanding of the interplay between the drive technologies will know the potential resulting from it.

Through a combination of electrics, sensors and software, linear motion technology makes a crucial contribution for integrated factory. Here are the five trends that support intelligent linear motion technology in practice:

Figure 1: Modularization and flexibilityBild1

Ready-to-install electromechanical cylinders combine mechanics with the flexibility of electric drives. A software command to the electric drive and the cylinder move them to any position and carry out complicated movement profiles. Without an additional position measuring system, they can achieve repeatability of up to ± 0.01 mm. Load measuring pins transmit the values analogously to the electric drive or the control and enable a decentralized process management.

Figure 2: Functional integration reduces complexityA006_C010_0101XP

If the precision requirements are high but the environment conditions are rough, conventional measuring systems soon reach their limits. Absolute measuring systems integrated into ball rail and roller rail systems detect the absolute position of the axis with a resolution of 0.025 μm. They immediately recognize the absolute position of the axis when the machine is switched on and report it to the controller without carrying out a reference run. In addition, modern systems do not require buffer batteries that need to be replaced regularly.

Figure 3: Predictive maintenance increases availabilityA008_C023_0101C0

Sensors measure temperature peaks and vibrations. This data forms the basis for future approaches to predictive maintenance. However, it is only significant if it is compared with life cycle models. In load tests, the newly developed runner blocks have demonstrated twice the service life through increased load capacities with the same size. Together with the detected operating conditions and predictive maintenance, they significantly increase the availability of machines and systems.

Figure 4: Digitally supported commissioningBild4

Previously, an experienced technician could easily have spent twenty minutes commissioning a linear axis. With the new mechatronic linear axes and actuators, the commissioning takes only three to five minutes. A digital assistant supports the application engineer with this. The technician only has to enter a few pieces of axis-specific data and can then immediately program or parameterize the drive. In the future, this functionality will automatically be available via the QR code.

Figure 5: Digital engineering for secure and quick dimensioningBild5

More and more engineering departments are changing to integrated digital workflows. With selection guides or sizing tools, design engineers find the correct linear motion technology components and mechatronic systems through intuitive user guidance, which can even be application-specifically configured. The electronically generated data are then integrated directly into the digital construction model and enables the virtual simulation of complex machine movements, for example.

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CMA/Flodyne/Hydradyne is an authorized  Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.