Hardware and software optimization for linear axis applications
Linear axes paired with industrial robots unlock flexible, space‑saving manufacturing of large components. Serial‑kinematic robots on modular, configurable linear tracks create compact, scalable cells with higher throughput. At Fraunhofer IFAM in Stade, the capabilities of these systems are evaluated and enhanced by conducting applied research addressing demanding tasks in machining, assembly, joining, application and metrology, particularly for large-scale components. To meet tight accuracy targets, robust mechanics are combined with advanced calibration. 3D metrology captures translational and rotational errors and spline‑based models compensate non‑linear deviations beyond simple 3D‑vector models. The methods also raise the precision of linear drives in machine tools and large special machines.
Performance is boosted by two preloaded rack‑and‑pinion drives that cancel reversal effects and raise stiffness, output‑side sensors measuring load‑side position for higher absolute accuracy and a rigid axis design that limits gravity‑induced torques from long lever arms.
The result: reliable, precise manufacturing, e.g., for aerospace, rail, shipbuilding, commercial vehicles and wind energy.
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