HPPS, driven by linear motors, can move at a combined high velocity on order of 3-5 m/s, high accelerations of 5-7 g, at micron or sub micron positioning accuracy with settling times on order of milliseconds and servo bandwidth of 30-50 Hz. Ball screw actuators, on the other hand, have typical bandwidth of 10-20 Hz and belt driven actuators at about 5-10 Hz. The bandwidth value of HPPS is about 1/3 of the lowest natural frequency in the range of 90-150 Hz. Settling time to +/- 1% Constant Velocity, or + / - 1 um jitter, after high acceleration or high deceleration respectively, takes an estimated 3 bandwidth periods. For example, a 50 Hz servo bandwidth, having a 1 / 50 · 1000 = 20 msec period, will settle to 1 um position accuracy within an estimated 3 · 20 = 60 msec. The lowest natural frequency equals the square root of system stiffness divided by moving inertia. A typical linear recirculating bearing rail, of a high performance positioning stage, has a stiffness on order of 100-300 N/um. Such a performance is required in semiconductor process equipment, electronics assembly lines, numerically controlled machine tools, coordinate-measuring machines, 3D Printing, pick-and-place machines, drug discovery assaying and many more. At their highest performance HPPS may use granite base for thermal stability and flat surfaces, air bearings for jitter free motion, brushless linear motors for non contact, frictionless actuation, high force and low inertia, and laser interferometer for sub micron position feedback. On the other hand, a typical 6 degrees of freedom articulated robot, with 1 m' reach, has a structural stiffness on the order of 1 N/um. That is why articulated robots are best being employed as automation equipment in processes which require position repeatability on the order of 100's microns, such as robot welding, paint robots, palletizers and many more.
The original HPPS were developed at Anorad Corporation (now Rockwell Automation) in the 1980s, after the invention of brushless linear motors by Anorad's Founder and CEO, Anwar Chitayat. Initially HPPS were used for high precision manufacturing processes in semiconductor applications such as Applied Materials, PCB Inspection Orbotech and High Velocity Machine Tool Ford.1 In parallel linear motor technology and their integration in HPPS, was expanded around the world. As a result, in 1996 Siemens integrated its CNC with Anorad linear motors to drive a 20 m' long Maskant machine at Boeing for chemical milling of aircraft wings. 2 In 1997 FANUC licensed Anorad's linear motor technology and integrated it as a complete solution with their CNC products line. 3 And in 1998, Rockwell Automation acquired Anorad to compete with Siemens and Fanuc in providing a complete linear motor solutions to drive high velocity machine tools in Automotive transfer lines.4 Today linear motors are being used in hundreds of thousands high performance positioning systems, which drive manufacturing processes around the world. Their market is expected to grow, according to some studies, at 4.4% a year and reach $1.5B in 2025. 5
System specification (technical standard) is an official interface between the application requirements (problem), as described by the user (customer) and the design (solution) as optimized by the developer (supplier).
HPPS configuration is typically optimized for maximum structural stiffness with maximum damping and minimum inertia, smallest Abbe error at the point of interest (POI), with minimum components and maximum maintainability.
System analysis is a process of understanding the relationships between design parameters, operating conditions, environmental variables and system performance based on system modeling and analysis tools
Component sizing is the process of selecting standard parts from component suppliers, or designing a custom part for manufacturing
System testing is an iterative process of system development, intended to validate system analysis modeling, proof of concepts, safety factor of performance specifications and acceptant testing.
BROWN, STUART (November 25, 1996). "The Fast New World of FLATMOTORS" (PDF). FORTUNE (Cover Page). Archived from the original (PDF) on June 5, 2020. Retrieved December 9, 2020. https://web.archive.org/web/20200605152837/http://www.stuartfbrown.com/articles/Brown_flat_motors.pdf ↩
Czajkowski, Stephen (September 1996). "Linear motors: The future of high-performance machine tools". Siemens and Anorad Corp. decided information was needed to support the major role high-performance linear motors will play as the prime machine-tool actuator. https://www.researchgate.net/publication/293701055 ↩
Eidelberg, Boaz (October 2020). "In memory of a great technology leader". LinkedIn. https://www.linkedin.com/posts/beidelberg_in-memory-of-a-great-technology-leader-activity-6720096774582747136-U0X- ↩
"Rockwell Automation buys Anorad, sees linear motor expansion". Control Engineering. October 1, 1998. https://www.controleng.com/articles/rockwell-automation-buys-anorad-sees-linear-motor-expansion/ ↩
"Linear Motors Market Size 2025". FRACTOVIA MARKET TRENDING NEWS. December 23, 2020. CAGR of 4.4%% ...USD 1508.1 million by 2025[permanent dead link] https://www.fractovia.org/news/linear-motors-market-size/20494 ↩
"Speed and precision meet in ASML's advanced lithography machines". ASML. Magnetically levitating wafer tables that accelerate faster than a fighter jet?.. with an accuracy of 60 picometers... It's all part of the extreme mechanics in ASML machines. https://www.asml.com/en/technology/lithography-principles/mechanics-and-mechatronics ↩
"Fuzion Platform Technologies for Performance, Flexibility & Yield". Universal Instruments. Archived from the original on 2020-11-30. Retrieved 2020-12-25. VRM Linear Motor Positioning System, High-accuracy (1μm resolution)... High acceleration – up to 2.5G https://web.archive.org/web/20201130175222/http://www.uic.com/solutions/surface-mount/fuzion-platform/ ↩
"Accurate and Reproducible Results Leica LMT260 XY Scanning Stage". Leica Microsystems. ... XY Scanning Stage uses ... two linear motors to produce such accurate and reproducible results with stereo microscopes https://www.leica-microsystems.com/products/microscope-accessories/p/leica-lmt260-xy-scanning-stage ↩
"Wire EDM Ultra-precise machining and surface finish for small/fine wire operations". Makino. ... achieving sub-micron level accuracy... using the machines Pneumatic Static Pressure Guideways and Linear Motor motion technology https://www.makino.com/machine-technology/machines/wire-edm/upn-01 ↩
"High-end measuring machine for maximum precision". ZEISS. ... linear drives on all axes. The benefits: high speeds, very fast acceleration, high positioning accuracy and shear force-free drives https://www.zeiss.com/metrology/products/systems/coordinate-measuring-machines/bridge-type-cmms/xenos.html ↩
"New video illustrates breakthrough in lab automation design". HEIDENHAIN. February 5, 2019. Achieving the high throughput and extraordinary accuracy necessary for lab automation https://www.heidenhain.us/resources-and-news/new-video-illustrates-breakthrough-lab-automation-design/ ↩
"Download MIL-STD-810H". IEST. 31 Jan 2019. https://www.iest.org/Standards-RPs/MIL-STD-810H ↩
"Designing machines for cleanrooms". Cleanroom Technology. October 6, 2004.[permanent dead link] https://cleanroomtechnology.com/technical/article_page/Designing_machines_for_cleanrooms/52706 ↩
"Linear Slides and Linear Stages Suppliers". GlobalSpec Engineering 360. 484 Linear Slides and Linear Stages suppliers https://www.globalspec.com/suppliers/47/linear_positioning_stages ↩
"Motion Control Online". mcma motion control & motor association. Companies that manufacture motion control, motors, software or related products and equipment https://www.motioncontrolonline.org/manufacturers.cfm ↩
"Programmable Logic Controllers (PLC) Suppliers". GlobalSpec Engineering 360. Find 656 Programmable Logic Controllers (PLC) suppliers with Engineering360 https://www.globalspec.com/suppliers/714/programmable_logic_controllers_(plc) ↩
"XL-80 laser system". The Renishaw XL-80 laser interferometer offers the ultimate in high performance measurement and calibration for motion systems, including CMMs and machine tools https://www.renishaw.com/en/xl-80-laser-system--8268 ↩
"Frequency Response Function Analyzer". ACS Motion Control. Increase Throughput with Electromechanical Frequency Analysis and Optimization https://acsmotioncontrol.com/capabilities/frequency-response-function-analyzer/#:~:text=Frequency%20Response%20Function%20Analyzer%20-%20ACS%20Increase%20Throughput,to%20optimize%20the%20performance%20of%20motion%20control%20systems. ↩
Kensler, Jennifer (March 21, 2014). "Reliability Test Planning for Mean Time Between Failures Best Practice" (PDF). STAT T&E COE-Report-09-2013. The goal...is to assist in developing rigorous, defensible test strategies to more effectively quantify and characterize system performance and provide information that reduces risk https://www.afit.edu/stat/statcoe_files/Reliability_Test_Planning_for_Mean_Time_Between_Failures2.pdf ↩