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Optimising manufacturing: How sensors boost precision and reliability in linear drives

A picture of a CNC machine in operation using sensors to optimise performance

In today’s manufacturing landscape, precision and reliability are essential for efficient and high-quality production processes. Linear drives, which convert rotary motion into linear motion, are widely used in manufacturing processes like CNC machining, robotics and automated assembly lines. These systems provide the high precision and repeatability required for tasks such as cutting, positioning and material handling. 

Linear drive applications

Sensor-integrated linear drives are commonly used to enhance efficiency, accuracy and flexibility in manufacturing environments. Applications include:

  • CNC machines: to ensure accurate tool movement for milling, drilling or cutting.
  • Packaging: automating conveyor belt operations and sealing mechanisms for speed and accuracy.
  • Robotics: providing smooth, precise, repeatable movements in robotic arms for assembly or welding.
  • Inspection systems: positioning sensors or cameras for quality control and defect detection.

Sensing components used in linear drives

Linear drives rely on a range of sensors for real-time feedback and control, such as:

  1. Linear potentiometers for drive position feedback. These sensors are used in closed-loop control systems to provide feedback on the drive’s position relative to a desired setpoint. This allows the system to adjust inputs—such as motor power or direction—to correct any errors. In manufacturing, this ensures a linear drive maintains precise positioning for tasks like assembly or cutting, even under varying loads and conditions.
  2. Proximity switches to detect the presence or position of components without physical contact. They signal when the drive reaches the travel endpoints, protecting the system by ensuring it doesn’t overextend and cause mechanical damage.
  3. Thermal switches installed near the drive or critical components such as motor windings, bearings or housing, to monitor the drive’s temperature. When the temperature exceeds a predefined limit, the switch activates to either shut down the system or trigger cooling mechanisms. This ensures safe operation, prevents damage to sensitive components and extends the drive’s lifespan.
  4. Temperature probes for monitoring the drive’s temperature to detect overheating or irregular conditions. This real-time data helps prevent thermal overload and means the load on the drive can be adjusted based on its temperature readings. For example, if it is overheating due to excessive load, the system can reduce the workload, increase cooling or temporarily shut down to prevent damage.

In manufacturing, where precision and efficiency are paramount, linear drives provide the foundation for success. Businesses within Variohm Group design, manufacture and supply a wide variety of sensors tailored to enhance linear drive performance in manufacturing applications. With expertise in temperature, proximity and position sensors, they provide reliable, high-quality solutions to meet specific manufacturing needs.

Ready to optimise your system? Explore our range of advanced sensors and discover how we can help you enhance precision, efficiency, and safety in your applications. Please contact us today to learn more.

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