In this webinar, Jean-Paul Beyak from Nexen and I will explain how to build gantry and robot-positioning and transfer systems to meet the design objectives of long-stroke applications. We'll also cover the use of drives that use belts, rack-and-pinion sets, linear motors, and ballscrews for this purpose … and go over each setup's benefits, drawbacks, and limitations.

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How to Build Robotic Positioning
Systems for Long-Stroke
Applications

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q This webinar will be available afterwards at
www.designworldonline.com & email
q Q&A at the end of the presentation
q Hashtag for this webinar: #DWwebinar
Before We Start

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Lisa Eitel
Motion Editor — Power Transmission and
Motion Control
Design World Magazine
Jean-Paul Beyak
Regional Manager, Midwest/Eastern USA & Canada
Director of Sales, Latin America
Nexen Group Inc.
How to Build Robotic Positioning Systems for Long-Stroke Applications

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Gantry and robot-positioning systems perform myriad functions:

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RTUs —
Sold as pre-engineered assemblies, as custom-engineered systems from integrators, or built from motion components
TranTek
ABB
Milwaukee MachineTool

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Gantry and robot-positioning systems need components that deliver:
High speed •
High positional accuracy •
Low backlash •

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Otherwise, alternative designs also called robot-transfer
units (RTUs) use adaptive control to prioritize flexibility …

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RTUs for gantry and precision robot-positioning systems necessitate:
• Low maintenance
• Long life
• Safety

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The long-stroke applications can use drives with:
Belts
Rack-and-pinion sets
Linear motors
Ballscrews
... and all drive types have
benefits and limitations.
Gantry and robot-positioning RTUs use an array of drive setups

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Check out this example — an RTU that lets one robot automate a whole machine-tool operation:
Gantry and robot-positioning systems abound

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Robot gantries traversing mid-range linear
distances use motor+ belt designs
— belt drives are quite common on H robots and other gantry setups…
... especially those with shorter strokes

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… so are more common on shorter axes
… but there are exceptions to the scalability caveat.
Belt drives in long-stroke applications can be subject to limitations

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— these use framing and linear tracks in various orientations to get more precision from belt drives …
Belt-driven gantry and robot-positioning RTUs exist —
Stroke — 30 ft
Payload — 3,000 lb
Repeatability — ±0.001 in.

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... So what are some benefits and caveats?
Long-stroke applications can also use drives with ballscrew axes …
Peak Analysis & Automation — robot track
with ballscrew or linear motor option
Thomson linear ballscrew-driven axes
exceed 10-meter strokes

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Long-stroke applications with ballscrew-driven axes must address the
challenge with more supports, appropriate diameter, and speed limits …
On longer axes, the main problem is whip—

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Long-stroke applications with screw variations …
… just another option:
There are other iterations of screws in seventh-axis setups—

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Consider this option
— using linear
actuators driven by
servomotors instead
of hydraulics for
vertical platform lifts.
One manufacturer
decided it was the
only option.
Long-stroke vertical arrangements are also seeing alternative designs

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Motor-driven actuators on the lifts
ensured a clean environment for the
composite aircraft-hull manufacture.
Electric actuators may come to displace hydraulics for aerospace

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Pneumatic robot transfer units (RTUs)
— low-cost solution for A and B
Not to say that fluid power is completely out …

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Accurate though expensive • More
common is average-sized gantry setups
Linear motors … always an option

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Eight meters long … reproducible accuracy of ±0.01 mm
Linear motors … here, for a specialty application

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• Higher accuracy; more controllability
Rack-and-pinion sets excel on seventh-axis designs (RTUs)

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Stroke — 30 meters with repeatability to ±0.2 mm!

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• Standard for the longest setups
• Length exceeds 50 feet
Rack-and-pinion sets — for the longest RTUs

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• Racks assemble together
• Rack-pinion sets maintain accuracy
More rack-and-pinion sets (though note difference in
guides + bearings that keep tracks aligned and supported)

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Quick note on software considerations — Programming

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Another quick note on software considerations — Calibration

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Now we’ll hear from Jean-Paul Beyak, regional
manager for our sponsor on this topic.
Beyak will explain some of Nexen’s product
offerings, including:
• A zero-backlash roller-pinion system in linear-rack
and rotary-gear forms
• A high-speed PRD Precision Ring Drive indexer
• A compact HG Harmonic Gearhead
Jean-Paul Beyak
Regional Manager, Midwest/Eastern USA & Canada
Director of Sales, Latin America
Nexen Group Inc.

29. Precision Motion Control Solutions
for Gantry and Robot Positioning
Systems
Jean-Paul Beyak Eng. BIE, MBA
Regional Manager
jbeyak@nexengroup.com

30. Gantry and Robot Positioning
Systems
Gantry and Robot Positioning/Transfer Systems require
components that provide some or all of the following attributes:
high speed, positional accuracy, low backlash, low
maintenance, long life and safety.
Nexen offers numerous innovative Precision Motion Control
products that provide these benefits and integrate well into
these types of systems.

31. Precision Motion Control Products

32. RPS Roller Pinion System
The Precision Roller Pinion System
converts rotary motion to linear motion.
Its revolutionary design makes it an
excellent choice for applications that
require a linear drive system.

33. Linear Drive Technologies
• RPS Roller Pinion System
• Linear Motors
• Ball Screws
• Rack and Pinion
• Lead Screws
• Chain Drives
• Belt Drives

34. Roller Pinion System (RPS)
• High Positional Accuracy (up to 30 µm)
• Unlimited Travel Distances (modular)
• Extremely High Speeds (up to 11 m/s)
• Near Zero Backlash (≤3.2 µm)
• Low Maintenance/No Maintenance
• Long Life (60,000,000 pinion revs)
• Efficient (>99%)
• Quiet (≤75 db)
• No Magnetic Field

35. RPS Pinion Bearing & Roller

36. Typical Applications

37. Robot Transfer Unit-RTU

38. Flow Waterjet and RPS
The ability that it provides for our new modular
waterjet system (an industry first) to be expanded
by customers as their business needs change, has
single-handedly won us three orders totaling over
one million dollars. Besides these three orders,
other post-sales interviews were quick to iden5fy
the Nexen RPS system as THE KEY DRIVER of their
decision to "go Flow". Ongoing accuracy tests have
conBnued to be fantasBc and these machines are
turning out the most accurate waterjet parts the
world has ever seen. We conBnue to be
impressed, as we increasingly see the benefits of a
high-precision, backlash free, highly efficient,
modular moBon system is able to do.
TIM FABIAN
Manager, Global Product MarkeBng
Flow Waterjet Americas

39. Rotary RPS Systems
• Accurate Positioning
• Near Zero Backlash
• High Speed
• Arc Segments, Rings &
Fully Programmable Ring
Drives

40. HG Harmonic Gearhead
Industry’s Shortest and Most
Compact Automation Gearhead
• Compact-Replace Larger,
High-Ratio Planetary Gearheads
• Zero Backlash, Extremely Accurate
Save up to 70% or
more in Gearhead
length

41. Aerospace Gantry Riveting System

42. Thank you
www.nexengroup.com

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How to Build Robotic Positioning Systems for Long-Stroke Applications
Questions?
Lisa Eitel
Design World
@DW_LisaEitel
Jean-Paul Beyak
Nexen Group Inc.
@NexenGroup

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Thank You
q This webinar will be available at
designworldonline.com & email
q Tweet with hashtag #DWwebinar
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