PBC Linear Blog

Manufacturing Positions

Thu, 25 Oct 2018 09:13:24 -05:00

Manufacturing Positions

Open Interviews Week of October 29, 2018

PBC Linear’s North Carolina plant is permanently shut down due to Hurricane Florence and is being relocated to our Roscoe facility. PBC Linear has immediate openings for both 1^st and 2^nd shifts for Machine Tool Operators (Grinders, Lathes, Saws, Mills, Induction Heat Treat); Maintenance (Building & Grounds, Machine Repair); and General Laborers.

If you are interested, please stop by with your resume during one of the times below. No appointment is necessary.

Tuesday, Oct. 30^th from 4:00 pm to 6:00 pm

Wednesday, Oct. 31^st from 7:00 am to 10:00 am

Thursday, Nov. 1^st from 4:00 pm to 6:00 pm

Saturday, Nov. 3^rd from 8:00 am to 10:00 am

PBC Linear offers competitive pay with great benefits.

Address:

6402 E. Rockton Road

Roscoe, IL 61073

Redi-Rail Mounting

Wed, 17 Oct 2018 15:47:16 -05:00

Redi-Rail Mounting

Redi Rail is a versatile product and can be mounted to utilize either the radial load capacity or the axial load capacity. Referencing the coordinate axis below, a load applied in the Y direction makes use of the radial load capacity. A load in the Z direction applies force in the axial loading condition.

Radial load orientation:

A standard 3-roller slider has a center bearing that is mounted offset from the centerline. This roller will contact one side of the rail.

The rollers at each end are mounted to contact the opposite side of the rail and will carry the majority of the load.

To identify which direction to mount the slider so that the two rollers designed to carry the load are oriented correctly, locate the arrows on the face of the slider (see below).
- Be sure to install the slider with the arrows pointing in the direction of the force or load being applied to achieve its rated radial load capacity.

Axial load orientation:

Mounting the rails so that the carriage sees the load in the axial (Z) direction is a valid mounting orientation; however, keep in mind that the load capacity is much lower than radial loading.

Make sure to consult the Cam Roller Technology catalog, http://www.pbclinear.com/Download/Catalog/Cam-Roller-Technology-Catalog.pdf, for load ratings.

Rail Fasteners

The rails have a shallow counter bore and very little clearance between the web of the rail and the rollers, and in the case of the metric series, the wipers. Therefore, the correct style of fastener is a button head cap screw (BHCS).

- Length of fastener will depend upon how the user is fastening to their supporting structure

Roller Bearings in Linear Motion

Fri, 07 Sep 2018 11:08:25 -05:00

Roller Bearings in Linear Motion

Linear motion applications are often found to have not only radial loads but also axial load requirements. For these applications, single or double row angular contact bearings are often used. Single row bearings offer the advantage of a slimmer profile and double row bearings offer the advantage of longer life and higher radial, axial and moment loads capability.

Some companies choose to use single row ball bearings; however, which limits the number of balls inside and also reduces radial, axial and moment load which the bearing can support. Double row bearings have a thick outer ring which is often machined to match the raceway. For these reasons, PBC limits the use of single row bearings only to custom products where load is not the limiting factor, where a slimmer profile is critical, single row bearings are not used in any IVT products to provide greater load capacity.

Figure 1 - Schematic of double row angular contact construction

Figure 1 above illustrates a typical double ball roller construction. For example, a 90-degree V profile matches a 90-degree raceway, or a Gothic Arch profile matches round shafting which have a double-row angular contact construction inside, and also have either V profile or Gothic Arch profile for the outer ring. Illustrated below shows the contact area between the outer race of the cam roller and the track upon which it rides. In the case of the Gothic Arch design, the track is typically a linear shaft and in the case of the V roller, the track is a V profile.

As you can see from figures 2 and 3, Gothic Arch rollers have two contact points and the V profile has a line segment contact. This means that load will be transferred from the roller to the rail either via a point or a line segment. A line segment can be defined as a perfectly straight curve between two points which contains an infinite number of points. This essentially means that the load will be transferred between the roller and the race either via a very small point contact or via a much larger (in comparison) line segment contact.

Figure 2 - Schematic of V profile outer ring contact (line contact)

Figure 3 - Schematic of Gothic Arch profile outer ring contact (2 point contact)

PBC Road Show

Mon, 16 Jul 2018 10:35:40 -05:00

The PBC Road Show Is On The Move!

PBC Linear’s Roadshow delivers hands-on solutions!

It’s one thing to see a linear motion product in a catalog or online video, but quite another to actually pick up and hold a real sample, examine its movement, and fully realize that mechanism’s potential. The PBC Linear Roadshow offers customers that hands-on experience, all within clients’ friendly confines. During this event, attendees may interact with their choice of a wide range of components and mechatronic samples, while engaging in a meaningful dialogue with PBC representatives.

Roadshow events can include training and educational visits, open houses and joint promotions, as well as regional meetings and trade shows. In tandem with 3DP Platform, the Roadshow Van has traversed an impressive 100,000+ miles across the United States, and has engaged enthusiastic crowds in over 290 demo events. PBC Linear is proud to offer professionals this highly valuable opportunity to get up-close and hands-on with linear motion technology.

What to expect from “The Roadshow”

Roadshow events offer flexibility in their location, and can be held indoors or outside, usually near the bay door or the back of a shop. Upon arrival of the Roadshow van, organizers and participants can expect a roll-out of 4 large tool chests, with each one containing a wide range of linear motion samples. These samples include Linear Bearings & Guides, Plain Bearings, Roller Bearings, Integral-V Linear Guides, and varying sizes of Mechatronics hardware. After a quick 30-minute set-up and a brief introduction, attendees of this informal setting are encouraged to familiarize themselves with the variety of samples or pose specific questions. The average duration of an event is anywhere from 2 to 2-1/2 hours, not including set-up and break-down times. At the end of the session, attendees will come away with informative literature and data, and a more thorough understanding of their linear motion options. Additionally, they can explore any possible custom solutions that may be beneficial to their specific application.

Reserve your Roadshow date!

The PBC Linear Roadshow is currently booking dates and planning routes for the remainder of 2018 U.S. Roadshow tour. Any companies interested in a requesting information or reserving a visit from the Roadshow Van should contact a PBC Linear representative at (800) 962-8979. Don’t miss out on this unique opportunity!

PBC Linear Celebrates Ground Breaking For New Facility

Wed, 13 Jun 2018 08:45:15 -05:00

On Wednesday, June 6, PBC Linear was joined by Winnebago County Chairman Frank Haney, South Beloit Mayor Ted Rehl, Senate aide to Dick Durbin Awis Quartey, and representatives from Alpine Bank and The LandMark Group Companies to celebrate PBC’s groundbreaking ceremony for its new manufacturing facility.

Chairman Frank Haney immediately thanked the Schroeder family for their investment and loyalty to families within the community saying, “If we’re going to be where we want to be in the future, we need to retain talented folks. To do that we need our employers in a position to be growing and attracting this talent back to our community.”

South Beloit Mayor Ted Rehl added his genuine comments proclaiming, “I am really giddy, because this is a big deal.” He reminded the crowd that, “The quality of community is not just the number of factories, but it’s the quality you have within those entities.”

PBC Linear President and CEO Robert Schroeder, stated that when he founded the company in 1983, Rockford had the highest unemployment in the nation. He added, “Regardless of what happens in the economy and throughout the world, if you have dedicated people, you can make things happen, and that’s what we do here.”

PBC Linear’s investment in the future will allow for the expansion of its assembly capabilities, as well as added warehousing and shipping capacity. Its aim is to not only increase profits and remain a global competitor, but also retain and nurture skilled workers. “It’s helping us secure our company’s future by helping retain our more than 220 employees,” spoke Vice president and Chief Operating Officer Tom Schroeder. “We’re also using a lot of local contractors so there will be jobs provided with the construction.”

It’s all about timing

PBC Linear President and CEO Robert Schroeder praised the recent corporate tax rates and rules that were part of the Tax Cuts and Jobs Act recently approved by Congress. Vice president and chief operating officer Tom Schroeder added, “We are taking advantage of the Trump administration’s tax incentives and investing $10 million over the next two years in building and equipment to ensure that PBC Linear will be a staple in the greater Rockford community.” Jonathon Schroeder added, “In getting the support, it just shows that the government at all levels is really tied to manufacturing in America. That’s really important for businesses like us.”

Building on a strong foundation

The new, state-of-the-art building will include over 66 thousand square feet of space, and will be divided between an optimized manufacturing floor, supporting offices and mezzanine, and a cafeteria. The expenditures for the new construction will reach $6.25 million, with the project scheduled to be completed during the 4th quarter of 2018. Within both the current and new facilities there will be additional investments in machines and equipment, spanning the next two years and totaling $3.75 million. The increased efficiency and productivity through these investments will help PBC Linear to further meet growing industry demands and remain a strong manufacturing presence for years to come.

Related links and Content

http://www.rrstar.com/news/20180606/pbc-linear-to-invest-10m-in-south-beloit

http://www.wrex.com/story/38366872/2018/06/Wednesday/pbc-linear-manufacturing-breaks-ground-on-multi-million-dollar-expansion

https://rockfordil.com/2018/06/06/pbc-celebrates-groundbreaking-for-new-10-million-facility-expansion/

http://www.mystateline.com/news/pacific-bearing-to-invest-10-million-in-roscoe-expansion/1222974006

http://www.wifr.com/content/news/Roscoe-company-breaks-ground-on-new-facility-484781891.html

http://www.beloitdailynews.com/news/20180607/10_millionexpansionproject_set

Machining Simplicity® Bearings

Mon, 14 May 2018 15:37:12 -05:00

Simplicity bearings can be machined and modified in the field.

If machining the I.D., be sure that more running clearance is actually needed! This is NOT a solution for binding!

To solve binding problems, first check:

1. Shaft alignment

2. Cantilever limitations (http://www.pbclinear.com/Download/Catalog/Round-Shaft-Technology-Catalog.pdf, pages 122-123)

3. Shaft deflection (see previous link, pages 124-125)

NOTE: The liner that is removed is also potential wear life

that is removed!

When using insertable tools, polycrystalline diamond tip inserts with a high positive rake are best.

Carbide tools will only work with an extremely high positive rake. Tolerance and finish will be more difficult to hold.

-Recommended insert: ISCAR CNMS or DNMS 432-12

-Machine the bearings at a minimum of 500 sfm (150 m/min.)

It is always best to cut from the inside out. When pushing in on the liner, it is possible to delaminate the material from the shell.

CAUTION: The bearing liner is relatively thin on each side of the bearing wall. At the time of manufacture, tight tolerances on size, roundness, and concentricity are maintained. Any after sale modifications may compromise this quality. PBC Linear will not be held responsible for any damaged or destroyed product that is machined or altered.

-To hone or ID grind the liner, a 60-80 grit grinding wheel is recommended.

Combating Environmental Issues With PBC Linear Guidance Solutions

Tue, 17 Apr 2018 15:47:44 -05:00

Its time to hang up the gloves and combat enviromental issues with a PBC linear motion guidance solution

Enviromental forces:

Indoor – cleanroom / food / lab / gen factory / steel fab / foundry

With correct product selection PBC linear products excel in these industries

Cleanroom / food – rst simplicity brg frelon j with alum hsg and 316 stn stl shaft products (rst simplicity brg frelon j with s = 316 stn stl bearing shell a good option)

Lab - all PBC linear products applicable, but dependent upon application

Gen factory – all PBC linear products applicable, but dependent upon application
Steel fab – rst simpicity brg & gst frelon gold products excel in this dirty enviroment (ceramic coated aluminum shaft near welding)
Foundry – rst simplicity brg & gst frelon gold products excel in this dirty hi-temp enviroment

Outdoor – exposure to weather elements

Sand
Saltwater

With correct product selection PBC linear products excel in outdoor enviroments

Rain – gst or crt products - redi-rail or v-guide with 400 series stn stl optionplus. Rst simplicity brg frelon j with 300 series stn stl shafting products
Snow - crt products - redi-rail or v-guide with 400 series stn stl option
Ice – crt products - redi-rail or v-guide with 400 series stn stl option
Desert sand – rst simplicity brgs & gst products excel in this dusty enviroment
Salt water – non-submerged - redi-rail or v-guide with 400 series stn stl option plus. Rst frelon j with 300 series stn stl shafting products
Salt water – submerged – rst simplicity brg frelon j with alum hsg and 316 stn stl shafting products

operating temperatures

Rst simplicity plain bearings & gst plain bearing technologies tolerate frigid cold to extreme hot temperatures
PBC linear rst ball brg, crt & ivt products rated 0 deg c to 80 deg c (32 deg f to 176 deg f)
PBC linear actuators rated 0 deg c to 80 deg c (32 deg f to 176 deg f)
PBC integrated stepper motors rated -20 deg c to 40 deg c (-4 deg f to 104 deg f)

Humidity levels

Consider selecting PBC linear corrosion resistant products when relative humidity levels exceed 70%.

Gst products or crt products - redi-rail or v-guide with 400 series stn stl option
Rst simplicity brg frelon gold with alum hsg and 400 series stn stl shafting products
Rst simplicity brg frelon j with alum hsg and 316 stn stl shafting products

PBC linear product access links: (ctrl click links below to access product catalogs.)

RST (ROUND SHAFT TECHNOLOGY)

http://www.pbclinear.com/Download/Catalog/Round-Shaft-Technology-Catalog.pdf

http://www.pbclinear.com/Download/Brochures/Roller-Pillow-Block-.pdf

CRT (CAM ROLLER TECHNOLGY)

http://www.pbclinear.com/Download/Catalog/Cam-Roller-Technology-Catalog.pdf

IVT (INTEGRATED VEE TECHNOLOGY)

http://www.pbclinear.com/Download/Catalog/IVT-Linear-Guide-System.pdf

GST (GLIDING SURFACE TECHNOLOGY)

http://www.pbclinear.com/Download/Catalog/GST-Catalog---Gliding-Surface-Technology.pdf

SIMO LINEAR ACTUATORS (GST & CRT VERSIONS)

http://www.pbclinear.com/Download/Catalog/SIMO-Series-Linear-Motion-Platform-Catalog.pdf

http://www.pbclinear.com/Download/Catalog/Simo-Series-Motor-Mounts.pdf

LAT (LINEAR ACTUATOR TECHNOLOGY) – (GST, CRT & PRT VERSIONS)

http://www.pbclinear.com/Download/DataSheet/Mechatronics-Enabled-Product-Overview.pdf

Feather Shaft • Feather Rail

Thu, 15 Mar 2018 09:51:23 -05:00

Feather Shaft and Feather Rail

PBC Linear offers a lighter weight alternative to hardened steel or stainless steel linear shafting and support rail assemblies. Feather Shaft and Feather Rail are aluminum alloy base materials with a hard coat to which weld splatter, paints, and other contaminants will not stick. They are also a great solution for applications requiring non-magnetic materials. Specifications can be found in the PBC Linear Round Shaft Technology catalog (http://www.pbclinear.com/Download/Catalog/Round-Shaft-Technology-Catalog.pdf), or the Simplicity 60 Plus data sheet (http://www.pbclinear.com/Download/DataSheet/Simplicity-60-Plus-Shafting.pdf).

Feather Shafting is designed to be used with Simplicity Frelon GOLD lined bearings and pillow blocks. It is NOT intended for use with linear ball bearings – the aluminum substrate will not hold up to ball bearings. Ideal for use in contaminated applications, the inch ceramic coated aluminum shafting offers excellent corrosion resistance and offers a weight savings for those applications where weight is an issue.

The availability of solid round or pre-drilled versions in metric and inch sizing offers the designer flexibility. Custom end machining is also an option, as aluminum is easily machined. For ease of selecting machined features, PBC Linear is pleased to provide an online configurator, http://www.pbclinear.com/Linear-Shafting---Inch-Ceramic-Coated---CC-CCPDL?tab=CADModel.

The pre-drilled inch ceramic coated shafting can be mated to aluminum predrilled support rail for fully supported applications to handle heavy loads. Another alternative to the combination of pre-drilled shafting on support rails is the one-piece integrated shaft and support rail design is the Feather Rail (CCR). The CCR is available in inch sizes only.

The integrity of the hard coat is demonstrated on a piece of equipment used in a trenching application – dirty, dusty, wet, vibration, etc. Extensive life testing was accomplished using a variety of contaminants, such as fly ash, grease, silicone spray lube, hydraulic oil, etc., and the Feather Rail tested passed with flying colors.

During the operational testing of the machine, the operator inadvertently ran it into a post anchored in solid rock, bending the Feather Rail. However, upon inspection of the Feather Rail, the design engineer of the equipment was pleased to see that none of the ceramic coating flaked off the round raceway section, even in spots where the coating was damaged during installation. This testimonial serves to underscore the versatility and toughness of Feather Shaft and Feather Rail.

What is Leadscrew Efficiency?

Tue, 06 Feb 2018 10:23:50 -06:00

What is Leadscrew Efficiency?

The efficiency of a leadscrew refers to how well a screw converts rotary energy (torque) into linear motion. Leadscrew efficiency is a pure calculated value, empirical testing is the best method to determine performance.

Efficiency % =

The efficiency of a leadscrew is primarily influenced by these factors:

Lead distance – i.e. 1mm ~ 25mm (available leads)
The efficiency is highly dependent upon the lead angle of the screw thread.
Lead angle – the angle between the helix of the thread and a line parallel to the axis of rotation of the screw
Friction – created by the contact area between the screw and the nut
Torque – Translating Rotary to Linear Motion
Driving the Screw to Translate the Nut
Driving the Nut to Translate the Screw

PBC Linear Leadscrew Efficiencies

What is Back Driving?

Back driving - Back drive is the result of the load (thrust force) pushing axially on the nut to create rotary motion. Which means the screw can be driven backwards by the load.

This can be a disadvantage in applications and may require a form of brake be utilized to support the load typically in a vertical orientation. In some cases, back drivability may be desired to allow an object to be moved if needed

As a Rule of thumb:

Leadscrews: Leadscrews typically provide efficiency between 20% - 80%

Leadscrews that have an efficiency of 50% or greater will back drive.
When the screw lead is less than 1/3 of the leadscrew diameter back driving will not occur

Example:

10mm dimeter screw with 2mm lead = 41% Efficiency (< 50% will not back drive)
10mm diameter screw with 25mm lead = 83% Efficiency (> 50% will back drive)

Ballscrews: Typical Efficiency = 90%

With a 90% efficiency will back drive
This creates the need to provide a form of braking to prevent back driving

How to improve Leadscrew Efficiency?

Efficiency increases as the screw lead increases

Leadscrew efficiency can be improved by increasing the helix angle of the thread

Example:

10mm dimeter screw with 2mm lead = 41% Efficiency
10mm diameter screw with 25mm lead = 83% Efficiency

Lubrication – but not conventional oil or grease

Conventional lubricants are typically not recommended as a form of lubricant with PTFE leadscrews & nuts

Leadscrews can be provided both with & without PTFE coating

Leadscrews with PTFE coating provides self-lubrication

Provides extend life of both leadscrew & nut when compared to un-coated screws
Provides dry lubrication that will not attract dust & debris
Using conventual lubrication can reduce screw coating & nut life
Reduces the need for preventative maintenance vs. un-coated or ball screws

PBC Linear Leadscrew Configurator: http://theconfig.com/external/default.aspx?c=1&n=B&r=CustomScrew

PBC Motor Leadscrew Catalog: http://www.pbclinear.com/Download/Catalog/LeadScrew-Catalog.pdf

PBC Actuator Configurators Now Available!

Tue, 24 Oct 2017 14:48:08 -05:00

PBC is proud to offer online configurators for our most popular lines of mechatronics products. Now you can visualize all possible options and variations, including the impact on pricing! You, the customer, can now review the list pricing to ensure that the selected product meets the budget requirement of your application. This tool also allows you to request a quote and quantity or prototype of anything you design. Our configurator will be able to instantly create a part number that directly matches your requirements. You can download a CAD model of the customized product as well as a PDF summary with a CAD preview imbedded to review with customers or peers.

Compact Series: http://theconfig.com/external/default.aspx?c=1&n=B&r=CompactSeries

SIMO Series: http://theconfig.com/external/default.aspx?c=1&n=B&r=SIMO

MUK Series: http://theconfig.com/external/default.aspx?c=1&n=B&r=MUK

ML Series: http://theconfig.com/external/default.aspx?c=1&n=B&r=ML

MT Series: http://theconfig.com/external/default.aspx?c=1&n=B&r=MT

PL Series: http://theconfig.com/external/default.aspx?c=1&n=B&r=PL

Integrated Motor & Lead Screw: http://theconfig.com/external/default.aspx?c=1&n=B&r=CustomScrew

With these powerful tools you will be able to design a custom product that fits YOUR needs.

PBC Launches New Product Configurator - A Better Buying Experience

Fri, 22 Sep 2017 10:19:14 -05:00

Can you imagine a world where you create a more precise product, save time and potentially save money with fewer returns and lower shipping costs? A world where the customer is ensured to get the product they wanted? Our new configurator is PBC’s step forward to helping our customers do just that.

Complex products have intricate configurations and multifaceted pricing, resulting in greater possibility for human error. Our new configurator allows you to be more naturally inquisitive and tinker around. It makes the buying process a little more self-serving and exploratory and less of being sold to. Having rich media like this gives you, the buyer/end user, a unique and better all-around experience.

Our new configurator can drastically reduce these possible human errors by pre-defining rules that create only valid configurations and more accurate pricing. This is not a case of out with the old and in with the new, but rather building upon the practices that we know to make a better, more precise buying experience for our customers. Our new configurator is here to not only help you reach your goals but exceed them.

Digital Scanning

Wed, 26 Jul 2017 13:49:32 -05:00

Digital scanning involves various horizontal linear movements, and thus requires high velocity smoothness. The key motion requirements for digital scanning include consistent velocity to ensure valid data acquisition, minimum torque ripple, and precise lead accuracy. To achieve this accuracy, the anti-backlash nut and consistent preload is vital for the application, and will increase the ability to scan across the entire travel length of large format prints.

Features:

Control – Enhanced motor commutation, high resolution feedback
Smart Motor – Low torque ripple, special magnetics mitigate cogging
Nut and Screw- Superior lead accuracy, anti-backlash nut, consistent preload

Check out our video to learn more: http://www.pbclinear.com/Videos/All/New-Quality-Linear-Motion-in-Scanning-Applications-Video-from-PBC-Linear

Managing Linear System Misalignment

Thu, 06 Jul 2017 09:27:19 -05:00

Linear misalignment is a fact of life:

Misalignment represents one of the leading causes of premature linear guidance failure
Misalignment can greatly reduce a products capability and expected life
Design needs to understand the process requirements of the application to select the appropriate product
Which linear product will provide acceptable process guidance

Mounting preparation must be taken into consideration to assure performance

Consideration for the rail mounting surface must always be addressed

Uneven mounting surfaces like welded frames, structural materials, etc. need extra clearance or ability to float to overcome alignment issues.
Higher accuracy requires less allowable deviation between rails and precision mounting surfaces are needed

Built in Systematic Alignment

PBC Linear offers products that can simplify system alignment, offering integrated products that incorporate built in alignment.

Built in Alignment:

Can simplify engineering design considerations
Reduce material costs
Reduce assembly times & costs
Overall reduction of system costs

Products with built in alignment:

Gliding Surface Technology – GST Products

Cam Roller Technology – CRT Products

Integral “V” Technology – IVT Products

Signs of Bad Alignment

Plain Bearing - Uneven Bearing Liner Wear

Ball Bearing – Shaft Spalling

Alignment Issues can lead to:

Systematic failures
Premature wear of bearings and rail
False sense of inappropriate product selection, when in fact it is an alignment issue
Production down times costs
Replacement of componentry due to component failure
Shortened component “life” due to premature failure
Replacement of componentry thinking a more expensive “precise” solution is needed

An Integrated Approach to Motor and Lead Screw Technology | WEBINAR

Mon, 10 Jul 2017 15:08:43 -05:00

PBC Linear presents: Integrated Approach to Motor and Lead Screw Technology. The webinar will discuss an overview of an integrated approach to motor and lead screw technologies, while also touching on how to optimize application solutions to increase performance and reduce costs and size. It will also cover the foundational elements of a lead screw motor as well as the applications that typically use this integrated solution.

Speakers for the webinar include Jayme Stockton of PBC Linear, as well as guest speakers Andy Sklierenko of Moons’ Industries (America) Inc., and Mike Maroney of Applied Motion Products.

To view this video, please click the following link: http://www.pbclinear.com/Videos/All/Advancements-in-Integrated-Motor-Screw-Technology-Webinar

Top Design Considerations for Cantilevered and Telescoping Applications

Mon, 12 Jun 2017 09:32:07 -05:00

Telescoping systems are essential for many industries, allowing for further reach and length in various applications. PBC Linear offers a wide range of products that are able to adapt to telescoping applications. For example, product lines like Cam Roller Technology (CRT) can be utilized in a cantilevered configuration to obtain the desired telescoping effect. This idea is illustrated by the image below (from top to bottom):

Hevi-Rail
Redi-Rail
Integral-V Technology
Comparable telescoping drawer slide

These examples show how a partial telescoping function is often adequate for a given application, though full telescoping is still obtainable by using extra rails (video). Essential information that must be provided when vetting a newly designed application include:

Typical application load
Length of extension required
Limits on rail length
Required bearing spacing
Application environment (vibration, washdown, etc)
A visual representation of the application (sketch) including length, width, spacing, and center of gravity

PBC Linear®, a Pacific Bearing Company, is the world leading manufacturer of the Simplicity self-lubricating bearings based in Roscoe, Illinois. With over 30 years’ experience in linear motion and bearing technologies, PBC has a wide range of solutions designed to solve difficult linear motion applications.

The 3 Why’s of StepSERVO Motors

Thu, 11 May 2017 14:57:17 -05:00

The primary goal of every manufacturing facility is to maximize efficiency. Improvements and upgrades are vital for increasing overall performance, helping to gain an edge on competitive industry leaders. Combining speed, quality, and reliability, StepSERVO motors can provide that edge.

Speed & Performance

StepSERVO Motors offer a closed-loop design that provides a peak torque range, helping to maintain accuracy. The closed-loop design also increases the available torque of the motor by 85 percent at speeds under 750 rpm, making it more economically efficient by consuming less power.

Quality & Positional Precision

Traditional stepper motors can lose position if the maximum torque output is exceeded. The StepSERVO motorfeatures a 20,000-count encoder and closed loop system that helps the motor know its position at all times, providing better accuracy with higher repeatability.

Reliability

All electronics for the StepSERVO Motor are on board with the motor, eliminating the need for cables and wires. The simplified design pulls the electronics out of the motor so it can run 50 percent cooler with 67 percent less energy. This makes the motor a more reliable solution for velocity and torque control applications, such as:

Labeling
Material handling
3D printing
Automated assembly
Pressing
Capping and screwing
CNC machining
Medical devices
Food and beverage
Semiconductor machinery

Watch the traditional stepper vs StepSERVO comparison video.

StepSERVO closed loop technology is found in PBC Linear’s SIMO Series and Compact Series actuators, providing a complete mechatronics solution at an excellent value.

4 Materials Best Suited for Washdown Design

Thu, 02 Mar 2017 16:43:00 -06:00

In a “washdown environment,” equipment needs to be cleaned either by hand or by automatic means with water, chemicals, or a mixture of these. Manufacturers that handle food, beverages, or pharmaceuticals are required to follow and maintain regulations, standards, and inspections, allowing them to produce goods and properly maintain equipment.

To ensure the successful performance of machine components in sanitary, washdown, or chemically cleaned environments, engineers must carefully choose materials for bearing, shafting or rail, and seal components. Here are 4 of them:

Stainless steel’s corrosion resistance and durability is typically preferred for general use in direct food contact areas. There are variations in stainless steel grades, mostly in the levels of chromium and nickel, that include a 300 and 400 series stainless steel.

300 Series Stainless Steel
Featuring relatively soft and non-magnetic properties, 300 Series Stainless Steel cannot be hardened. It is widely accepted for food and medical applications, and features various types that have slightly different formulations with varying strengths and weaknesses. These types include 303, 304, and 316.

303 is also referred to as “A1” under ISO standards. It is a free machining version of 304 due to added Sulphur and phosphorous. While its corrosion resistance is good in mild environments, it is subject to pitting and crevice corrosion in chloride containing environments over 60°C.304 is known as “A2” or “18/8” due to its 18-percent chromium and 8-percent nickel make-up. It is the most common grade of stainless steel with excellent forming and welding characteristics. 304 is typically used in food processing equipment (beer brewing, milk processing, and wine making) due to its corrosion resistance and excellent ambient and low temperature toughness properties.316, or “A4” (18/10), is the most commonly used alloy for food and pharmaceutical grade applications. The addition of up to a maximum of 3 percent molybdenum helps prevent corrosion from industrial chemicals and solvents, making it more resistant than 304.

400 Series Stainless Steel
There are several types of 400 series stainless available, but the most widely available and most used is the 440 stainless. It can be heat treated and hardened for use in cutlery, linear shafting, and in applications requiring higher wear resistance. Due to its carbon makeup, it will oxidize under washdown conditions.

Aluminum & Coatings
If weight is a concern, engineers can use aluminum in some washdown environments, but it must be coated for protection against pitting and cracking. Anodizing, ceramic coating, or other types of coatings with PTFE or other fillers are used, but they don’t provide the resistance or life that stainless steel offers. Stainless steel is preferred in more caustic chemical washdown environments.

Electroless Nickel Coatings
These coatings have become popular because of their corrosion and wear resistance combined with a smooth polished appearance. Some forms include a PTFE infusion to aid in non-stick properties. Most forms of this coating are FDA compliant as well.

Plastics, Polymers & Fillers
Due to cost, weight, manufacturability, etc., these non-metal materials are increasingly being used, “under the hood,” inside of mechanical drive components, guides, bearings, fasteners, and more. Many solid plastics, such as injection molded bearing inserts, present drawbacks in washdown applications in that most will absorb liquid, causing the component to swell and increasing the potential for binding and catastrophic failure.

3 Reasons to Use Mechatronics

Tue, 31 Jan 2017 16:12:20 -06:00

Mechatronics combines “mechanical engineering, electronics, computer engineering, telecommunications engineering, systems engineering, and control engineering” to improve and optimize product design and manufacturing processes.

As product development cycles continue to increase and rapid advances in technology continue to develop, the need for this integrated approach is even more critical, especially in linear motion applications.

You may quickly see many benefits to use mechatronics. Here’s our top three:

1. Simplified & Flexible Mechanical Design

Combining the mechanical, electrical, and control elements of engineering creates a simplified design that is flexible and more user friendly. A one-unit, compact design reduces the number of components as well as space needed for installation. Less components means less labor invested, reduced time spent in setup and maintenance, and maximized operational uptime.

2.Enhanced Features & Functionality for Optimized Performance, Productivity & Reliability

In a variety of situations, mechatronics has proven to be a more reliable solution due to its enhanced features and functionality. For example, in IoT, mechatronics provides the following benefits:

Reduced Troubleshooting – With fewer components and less wire connections, the job of tracing down problems that may arise is greatly reduced.
Streamlined Commissioning – Pre-programmed homing routines and distributed control reduces installation times and allows report progress via Internet connectivity. It also allows an operator to make in-process adjustments at an individual axis without affecting the PLC or entire production line.
Automated Adjustments – Automated adjustments increase manufacturing flexibility and speed. In addition, adaptive control is possible with conditions monitored and adjustments made locally, in real time, and right at the actuator level, without having to route instructions through the PLC.

3. Increase Efficiency, Decreased Costs

Combining various engineering subfields into the same design not only makes it safer, more efficient, and cost effective. Examples of efficiency and cost effectiveness of mechatronics in an IoT environment include:

Maximized Uptime – Real time monitoring of temperatures, friction, motor torque, and other performance related data can be routed to a mobile device allowing the human decision maker to proactively handle issues related to maximizing machine uptime.

Preventative Maintenance – Established timeframes for periodic maintenance based on cycles, number of pieces run, or other dynamic conditions can be monitored and reported to any IoT connected device such as a work station, tablet, or mobile phone, allowing teams to proactively keep machine running at peak efficiency.

Increased Output – Mechatronics solutions drive greater flexibility, less down time, increased performance, and greater bottom-line output for manufacturers, assembly lines, packaging equipment, and production equipment.

Top 4 Design Tips for Washdown Environments

Mon, 17 Oct 2016 15:41:26 -05:00

Design engineers in the food packaging, bottling, pharmaceuticals or similar industries are continually faced with challenges to minimize unwanted bacteria in linear motion components. These challenges are found in processing, packaging, handling, and automation equipment in washdown environments. Here are the top four design tips you should know for minimizing bacteria buildup, keeping your operation running clean:

Linear Bearing & Linear Guide Design

Two-piece, open-ended bearings with grooves or inserts should be avoided in washdown environments. Microscopic bacteria have the tendency to hide in the crevices, grooves, and plastic bearing inserts, increasing the chances of spreading disease. The same principle is true for recirculating ball bearing type products that require grease lubrication to be used due to the metal-to-metal contact. The lubrication picks up material from food items being processed, becoming trapped inside the multiple crevices and cavities around the balls in the raceways of the bearing, creating a breeding ground for unwanted bacteria.

One-piece bonded bearings are recommended for these types of washdown applications because there are no grooves, crevices, or space between the liner and bearing shell where residue can become lodged allowing bacteria to grow. They are also PTFE based, self-lubricating, with bonded linear material, and require no external lubrication that can potentially collect contaminated materials or bacteria.

When it comes to multiple component sub-assemblies, bacteria can build up around the connectors and joints. Newer technology that incorporates dual rail load capacities and functionality into a single rail design can eliminate potential areas of contamination collection.
Rail Design & Rail Selection

It’s best to minimize component assembly as much as possible in washdown environments. Traditional methods for linear assemblies include various connection points that create crevices, joints, or cracks where liquid can penetrate or bacteria can begin to accumulate.

Two-piece slide systems are ideal for washdown environments because they reduce the amount of connections points that come with multiple component assemblies, and they are designed with smooth, curved edges that do not have recesses where buildup can occur.
Standoffs

Washdown applications should get special attention when mounting linear rails. In these settings, it’s a good practice to use standoffs as a way to keep operation running clean around your linear motion system, especially where contamination and bacteria buildup are a concern.

Below is an exaggerated example of good practice when mounting with standoffs.
Location

Dirty Washdown Design

Clean Washdown Design
The location of fasteners and linear components is important to consider for washdown environments. Fasteners can protrude creating another area for contamination to accumulate, especially when mounted on the washdown side.

Bringing the fastener up through the bottom of the rail to be mounted can help eliminate these areas. For fastener that enter the washdown area, use a dome nut (or similar) for easier cleaning.

For components that are not FDA compliant or that don’t meet other regulations for food contact, it is recommended to cover those components with stainless steel shields or covers that have been radius on all corners.

For more information on PBC Linear solutions for washdown environments read: Linear Motion Design for Washdown Environments

A “Master” Washdown Application—The Tour Spin Club Washer

Thu, 07 Apr 2016 08:15:35 -05:00

(Above) TourSpin Club Washer—Image courtesy of Riveer Company.

Golf is a game of perfection—both for the player and for golf course management. When a player uses well-maintained equipment, quality of play is often significantly improved. Conversely, ill-maintained equipment can have adverse effects for a player, as well as the golf course with the introduction of invasive species from dirty or contaminated equipment. These risks inspired the development of the TourSpin Club Washer, by Riveer Company. The TourSpin, designed to clean an entire set of clubs, golf balls, and shoes in less than one minute, required a linear actuator capable of handling a repetitive washdown environment including contaminants such as grass, dirt, and sand. The application needed to achieve high speeds and quick change of direction over a travel of 50 inches while being able to withstand both indoor and outdoor environmental conditions. SIMO® Series linear actuators from PBC Linear® were an ideal solution due to the design flexibility for bearing and drive type that allowed application engineers to specify a system to meet all requirements.

(Above) The TourSpin Club Washer utilizes the SIMO Series linear actuators in a seamless washdown application. Image courtesy of Riveer Company.

The SIMO Series is a key design element for the machine; utilizing a cam roller carriage, stainless steel raceways, and stainless steel v-rollers. Stainless steel was selected for longevity within a washdown environment, while v-shaped rollers aid in pushing contaminants off of the raceway. A system cover was integrated to help protect the actuator from large or unnecessary contaminant buildup.

Recently featured at the 2016 PGA Merchandise Show, the TourSpin Club Washer has presented an extra revenue stream for golf courses, and has improved the overall golf course experience for customers and management alike. To learn how SIMO Series actuators can be a problem-solver for your next application, click here. To learn more about the TourSpin Club Washer, visit the TourSpin website or watch the product overview video here.

(Above) TourSpin Club Washer Product Overview Video

Case Study: Mechatronics Solution for Large Format 3D Printer

Tue, 16 Feb 2016 15:14:15 -06:00

PBC Linear^®’s Mechatronics Enabled^™ (ME) initiative provides a range of mechatronics solutions for small, medium, large and extra-large applications. For 3D Platform™, manufacturer of the large-format 3D printer, the 3DP1000, the world-class motion control for the XYZ gantry is provided by ME’s industrial strength SIMO® Series linear actuators.

PBC Linear’s SIMO Series actuators have been a core component for the 3DP1000 3D printer from the start; providing high rigidity, accuracy, and reliability. The actuators are equipped with Constant Force Technology (CFT) anti-backlash lead screws and nuts, providing the additional traction control and precision required for high quality 3D printing. Driving the SIMO Series actuators are StepSERVO™ motors from Applied Motion Products^®, a product that is available on all PBC Linear ME systems, offering faster print times and increased accuracy due to greater torque, as well as decreased energy usage. All of these components are contributing factors for the complete mechatronics solution provided by PBC Linear, enabling higher quality prints.

SIMO Series linear actuators are designed to be versatile, flexible, and affordable making it an ideal solution for an engineer who wants to test multiple interchangeable configurations while adapting to changing requirements. With multiple choices for design, such as bearing, drive, and motor options, the actuators can be built to specific application needs for large systems.

3D Platform has recently released a new video exploring these advancements in machine design titled, 3D Printing Utilizing Advanced Mechatronics—the video features the SIMO Series actuators, CFT anti-backlash nuts, and StepSERVO motors, boasting their contribution to the machine’s success in the additive manufacturing industry. Click here to watch the video.

PBC Linear^®, a Pacific Bearing Company, is the world leading manufacturer of the Simplicity^® self-lubricating bearings based in Roscoe, Illinois. With over 30 years’ experience in linear motion and bearing technologies, PBC has a wide range of solutions designed to solve difficult linear motion applications.

PBC Linear®, SIMO® are registered trademarks of PBC Linear and/or PBC Lineartechnik GmbH.

Applied Motion Products® is a registered trademark, and StepSERVO™ is a trademark of Applied Motion Products.

3D Platform™ is a trademark of 3D Platform.

How to Finish Hevi-Rail Linear Guides

Fri, 05 Feb 2016 13:10:53 -06:00

PBC Linear^®’s Hevi-Rail^®, a product in the Cam Roller Technology (CRT) family, is a common solution for industrial strength-handing applications with high load capacities. The natural state of the rail may—prior to any surface treatment—exhibit mill scale build-up and surface rust. If this natural state falls outside of the application requirements, there are treatments which can prevent this:

Order rails pre-sandblasted and/or pre-oiled to prevent surface rust and mill scale build-up
Purchase rails ready to finish, making it easier to apply a clear zinc plating or paint to the raceways

Note:

When finishing, it is important to tape off the raceways beforehand to avoid changes in performance
For Hevi-Rail with surface rust or mill scale build-up that already exists, sandblasting is the best way to prepare the rails for finishing

To learn more about how to finish Hevi-Rail linear guides, contact an application engineer at appeng@pbclinear.com or watch the video, Top 5 Design Tips for Hevi-Rail, here.

PBC Linear^®, Hevi-Rail^® are registered trademarks of PBC Linear and/or PBC Lineartechnik GmbH.

NEW Video: The Benefits of StepSERVO Closed Loop Stepper Technology

Fri, 22 Jan 2016 12:22:19 -06:00

StepSERVO™ Integrated Motor
from Applied Motion Products®

Traditional step motor systems offer many benefits for an automation engineer looking to accurately and repeatedly position a load. This class of motor is traditionally considered to be a go-to motor for engineers because they are easy to set up, maintain, and troubleshoot. Their simplicity comes with trade-offs though, and some of those trade-offs require special attention. For example, step motors are traditionally run open loop, which means that if the torque demand from the machine is greater than the motor can produce, the motor either loses position or stalls. Unless there’s a feedback device—like an encoder—attached to the rear shaft of the motor, the drive/controller isn’t aware that the motor has lost position or stalled, which can cause numerous problems for machine performance. Additionally, open loop step motors typically run hotter than other types of motors because they always run at full current, regardless of load conditions—this also causes the system to have significantly higher energy consumption.

A newly released motor technology from Applied Motion Products®, and provided by PBC Linear®, referred to as StepSERVO™ wraps a step motor and encoder inside a servo control loop improving the overall performance of open loop systems substantially. First, closing the loop around the step motor and encoder provides a peak torque range for the step motor that is well beyond the maximum torque range of the open loop motor and helps maintain accuracy. This increases the available torque of the step motor by as much as 85% at speeds under 750 rpm. The new system also reduces heat in the motor by regulating the current in relation to the torque demand of the load, which in turn lowers energy consumption by up to 67%. All of the benefits of closed loop stepper control are a part of the StepSERVO closed loop stepper system initiative. For more information on how StepSERVO closed loop stepper systems can improve your next machine design, download the white paper, watch the webinar, or watch the video.

StepSERVO closed loop stepper technology is available with PBC Linear’s SIMO Series and Compact Series actuators, providing a complete mechatronics solution.

NEW Video from PBC Linear
Traditional Stepper Motor vs StepSERVO™ Technology

PBC Linear^®, a Pacific Bearing Company, is the world leading manufacturer of the Simplicity self-lubricating bearings based in Roscoe, Illinois. With over 30 years’ experience in linear motion and bearing technologies, PBC has a wide range of solutions designed to solve difficult linear motion applications.

PBC Linear®, SIMO® are registered trademarks of PBC Linear and/or PBC Lineartechnik GmbH.

Applied Motion Products® is a registered trademark, and StepSERVO™ is a trademark of Applied Motion Products, Inc.

Eric Rice
Applied Motion Products
National Marketing Director
erice@applied-motion.com

PBC Linear featured in Design World: Top 10 Benefits of IoT Enabled Mechatronics

Mon, 11 Jan 2016 08:38:39 -06:00

PBC Linear was recently featured in the December 2015 issue of Design World magazine in a cover article, Top 10 Benefits of IoT Enabled Mechatronics. The article dives into the latest trend in machine design, the Internet of Things (IoT), and the key advantages of integrating the “smart” technology solution, including:

Cutting more than 50% of costs
Streamlined commissioning
Maximized uptime
Increased output
…and more

Click here to read the article, Top 10 Benefits of IoT Enabled Mechatronics, in Design World’s online publication.

NEW Video: The Internet of Things in Linear Motion

Wed, 13 Jan 2016 16:02:00 -06:00

PBC Linear has recently released a new video, “The Internet of Things in Linear Motion,” to show some of the key advantages of internet connected machines, such as:

Simplified design and build process
Enhanced functionality
Streamlined commissioning, troubleshooting, and maintenance
...and more!

The video shows the benefits of the Internet of Things, or IoT, of linear motion using a packaging line as an example, where the objective is to quickly and efficiently adjust cameras, sensors, and line guides for a recipe-driven configuration. Click here to watch the video.

NEW Video: The Internet of Things in Linear Motion | Internet connected machines and mechatronics simplify the design and... watch now!