With the advancement of direct drive technology, the comparison between linear motors and traditional "rotary servo motor + ball screw" drive systems has become a topic of growing interest in the manufacturing industry. Many leading manufacturers of high-speed machining centers are now incorporating linear motors into their advanced equipment, driven by the need for higher performance and precision.
In terms of accuracy, linear motors offer significant advantages. Unlike the "rotary servo motor + ball screw" system, which relies on multiple mechanical components that can introduce interpolation hysteresis, linear motors eliminate this issue through direct motion control. Positioning, repeatability, and absolute accuracy are all enhanced due to the direct feedback from position sensors. Linear motors can achieve positioning accuracy as high as 0.1 micrometers, while the traditional system typically reaches 2 to 5 micrometers. To maintain such precision, the ball screw system requires a complex setup involving CNC-servo motors, gapless couplings, thrust bearings, cooling systems, high-precision linear guides, nut holders, and a closed-loop workbench. This makes it more complicated and less efficient compared to the linear motor’s simpler design. Additionally, achieving high stability with the ball screw system often requires dual-axis drives, whereas linear motors operate more efficiently on a single axis.
In terms of speed, linear motors clearly outperform traditional systems. They can reach speeds of up to 300 meters per minute with accelerations of 10g, while ball screw systems typically max out at around 120 meters per minute with only 1.5g of acceleration. As a result, linear motors are better suited for high-speed applications. Moreover, once the heat management issues are resolved, their speed potential can be further increased. In contrast, the ball screw system is inherently limited in speed and has little room for future improvements.
Regarding longevity, linear motors have a clear advantage. Since there is no physical contact between the moving and fixed parts, there is no wear caused by high-speed reciprocating motion. This ensures consistent positioning accuracy over time, making them ideal for high-precision applications. On the other hand, ball screws suffer from wear due to friction during high-speed operation, which gradually degrades their accuracy and limits their suitability for demanding precision tasks.
Overall, linear motors represent a major leap forward in machine tool technology, offering superior accuracy, speed, and durability. While they come with higher costs and require advanced cooling solutions, their long-term benefits make them an attractive choice for the next generation of high-performance machining systems.
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