Flexible Modular System of Highly Dynamic AL8000 Linear Motors

PB-46-Beckhoff-AL8000LinearMotors-400.jpg

June 25, 2021

The new AL8000 linear motors supplement the Beckhoff drive technology portfolio by another innovative product series. In the three widths of 50, 80 and 130 mm, their modular design enables new solutions for linear motion applications in modern mechanical engineering.

Linear motors such as the AL8000 allow direct transmission of the motor power to the load to be moved and are therefore also called direct drives. No additional mechanical transmission elements are required, which would otherwise have to be taken into account in the design. This represents a decisive advantage over conventional mechanisms such as rack and pinion, spindle and toothed belt drives.

Linear drive technology – advantages and requirements

Due to the direct transmission of the linear motor power, a backlash-free construction between the motor and the load can be realized, which makes high-precision applications possible. The linear motor is therefore a wear-free drive and does not require regular maintenance. Since a linear motor eliminates the speed-limiting components through the direct operating principle, applications with the highest demands on speed and dynamics can be operated without any problems with maximum precision at the same time.

Even if the mechanical, backlash-prone transmission elements are eliminated by the use of a linear motor, other structural components, such as adequately dimensioned guide rails and bearings, are required. In addition, there is an individual machine carriage, which provides for the mounting of the coil part as well as other machine components. These structural components are indispensable for the completion of a linear axis based on a linear motor and often pose a challenge to the design.

Simplification through symmetry and modularity

In order to enable the designers to work as flexibly as possible despite machine-specific requirements, the development of the AL8000 linear motors focused on a symmetrical design and thus the realization of the simplest and most uniform machine design possible. The main approach is the modular coil concept of the AL8000. It aims to facilitate the design of the individual machine carriage with regard to the attachment of the coil part and to create a common basis for different machine types or different coil parts.

In line with the modular concept, the entire coil part is assembled from individual identical segments during final production at Beckhoff in Germany. These segments represent the smallest modular unit of the coil part and comprise three motor windings. The shortest linear motor in the series therefore consists of one segment or three motor windings. Depending on the force requirements, the linear motors can be assembled from up to 15 segments, so that peak forces up to 6,750 N are possible in a compact design. The coil part therefore always comprises a multiple of this smallest modular unit. As a result, the linear motor series is systematically and symmetrically extended, resulting in the following constructive advantages:

  •    –   The series connection of identical and space-optimized segments results in a compact design of the coil parts. The defined width and installation height of the AL8000 meet maximum force requirements in the shortest possible housing and thus achieve a very high force density. Since the new linear motors are optimized for such a high force density, this effect becomes clearer with increasing force demands. The coil part is therefore extremely short, and as a result, the travel path and thus the entire machine can be designed shorter and for a minimized footprint.
  •    –   The modular coil concept also enables an exactly symmetrical structure of the coil parts, i.e., they always have the same drilling pattern grid within one of the widths due to always using the same stator segments. Thus, regardless of the length of the coil part, the respective distances are identical both within a longitudinal row and within a transverse row of the drilling pattern. In this way, the machine manufacturer can use a uniform drilling pattern for the machine carriage and flexibly use the longer or shorter AL8000 within a width without having to make any structural changes. It is also possible to manufacture a machine carriage for the largest motor in the 130 mm width across all widths and to install each coil part of the smaller width AL804x (80 mm) in addition to the shorter versions of the same width. However, the symmetrically uniform structure does not only bring constructive advantages. In addition, an even force build-up and a homogeneous heat distribution over the entire coil part is also realized, which enables optimal machine operation.
  •    –   In addition to the coil parts, the magnetic plates also have a uniform drilling pattern within a width group, so that magnetic plates of different lengths can be used flexibly within a width.

If the entire linear axis is considered, cables and the associated drag chains are also required in addition to the linear motor and the mechanical components. Here, too, the AL8000 linear motor offers advantages for the machine manufacturer by combining the power supply with the thermal protection contact. Due to the merging of the two cables, one cable is omitted, which would otherwise have to be installed from the linear motor through the machine to the control cabinet. This not only significantly reduces material expenditure, but also minimizes installation effort and space requirements in the drag chain.

New concept for a wide range of applications

The new, highly dynamic AL8000 series offers linear motors in a compact design with maximum flexibility for the machine manufacturer. Their use reduces the space required in the machine in several respects and leads to a cost reduction. Currently, the AL8000 portfolio comprises 28 different coil parts, which are divided into three different widths.

This broad spectrum covers almost every force and speed requirement and thus enables a suitable drive solution for almost every linear application. Especially since specific customer requirements can also be flexibly addressed for very special requirements outside the standard portfolio. In this case, any linear motor can be designed within the modular coil concept.

Source

Related Articles


Changing Scene

  • Tri-Mach Announces the Purchase of an Additional 45,000 sq ft. Facility

    Tri-Mach Announces the Purchase of an Additional 45,000 sq ft. Facility

    Recently, Tri-Mach Inc. was thrilled to announce the addition of a new 45,000 sq ft. facility. Located at 285 Union St., Elmira, ON, this facility expands Tri-Mach’s capabilities, allowing them to better serve the growing needs of their customers. Positioning for growth, this additional facility will allow Tri-Mach to continue taking on large-scale projects, enhance product performance testing, and provide equipment storage for their customers. Read More…

  • HELUKABEL Group Builds New Facility for Automation Cable Solutions

    HELUKABEL Group Builds New Facility for Automation Cable Solutions

    The HELUKABEL Group recently announced it is going to build a new facility in Haan, Germany that will house its robotic dress pack and drag chain system subsidiaries under one roof. The new building will also serve as the headquarters of HELUKABEL’s Rhine-Ruhr sales branch, and is planned to be completed by 2025. Robotec Systems’ core business is robotic dress pack solutions and has been a HELUKABEL subsidiary since 2012 operating out of Duisburg, a suburb of Duesseldorf in northwest Germany. Read More…


Sponsored Content
Fire Protection for Lithium-ion Battery Energy Storage Systems

Lithium-ion storage facilities contain high-energy batteries combined with highly flammable electrolytes. In addition, they are prone to quick ignition and explosion in a worst-case scenario. Such fires can have a significant financial impact on organizations. Rapid detection of electrolyte gas particles and extinguishing are the key to a successful fire protection concept. Since December 2019, Siemens has been offering a VdS-certified fire protection concept for stationary Li-ion battery storage systems.

Click HERE to learn more.


For a Multiplied Value Unified

PB-62-Excelpro-MultipliedValue-400.jpg

During the last few years, the Excelpro Group has welcomed AIA Automation, Envitech Automation and Conrad Lavoie Electrical, all of which have become ‘Member of the Excelpro Group’.

It was with great excitement that in November of 2022, Excelpro announced that these three companies officially became Excelpro. This decision is part of a strategy to enhance the Excelpro Group’s brand in its market.

These companies already collaborate on various client projects. This merger brings together the complementary strengths of the employees and ensures a global synergy of the activities throughout the Group.

Read More


Service Wire Co. Announces New Titles for Key Executives

Bruce Kesler and Mark Gatewood have been given new titles and responsibilities for Service Wire Co.

Bruce Kesler has assumed the role of Senior Director – Business Development. Bruce will be responsible for Service Wire’s largest strategic accounts and our growing Strategic Accounts Team.

Mark Gatewood has been promoted to the role of Vice President – Sales & Marketing. In this role, Gatewood will lead the efforts of Service Wire Company’s entire sales and marketing organization in all market verticals.

Read More


Modern Niagara Partners with Global Sustainability Platform Worldfavor

Worldfavor is a global sustainability platform, digitizing and automating the collection, calculation, aggregation and visualization for analysis and reporting of ESG data. Now, Worldfavor is proud to welcome Modern Niagara as a new customer. Modern Niagara is the first Canadian construction company to partner with Worldfavor.

“Worldfavor was founded to be the best platform for sharing, accessing and gaining insights from corporate ESG information. Worldfavor’s mission is to make sustainability mainstream and with that we offer solutions to accelerate sustainability through the value chain. Modern Niagara is the first Canadian construction company to partner with Worldfavor. 

Read More


JMP Parent Company, CONVERGIX Acquires AGR Automation, Expanding Global Reach

Convergix Automation Solutions has completed the acquisition of AGR Automation (“AGR”), a UK-based provider of custom, high-performance automation design and systems integration primarily to the life sciences industry.

Following Convergix’s acquisitions of JMP Solutions in August 2021 and Classic Design in February 2022, AGR marks the third investment in Crestview’s strategy to build Convergix into a diversified automation solutions provider targeting the global $500+ billion market, with a particular focus on the $70 billion global systems integration and connectivity segments. Financial terms of the transaction were not disclosed.

Read More


Latest Articles