A new era of linear motor development has arrived to promote the field of machine tool processing

With the rapid advancement of electronic technology, linear motors have found their way into the world of machine tools, marking a significant milestone in industrial innovation. From the 1996 International Manufacturing Technology Show (IMTS) in Chicago, the 18th International Machine Tool Exhibition in Japan, to the 1999 Paris EMO Expo and other major global exhibitions, it became clear that a new era for linear motor technology had officially begun. To meet the growing demand for higher production efficiency and better part quality, high-speed and ultra-high-speed machining has become a dominant trend in the evolution of machine tools. Modern systems require fast, responsive drive mechanisms capable of reaching speeds above 40–50 m/min, with accelerations and decelerations up to 25–50 m/s². However, traditional "rotary motor + ball screw" systems are no longer sufficient due to inherent limitations. The intermediate transmission components reduce system stiffness, leading to increased elastic deformation, which compromises stability and degrades servo performance. Elastic deformation is also a key cause of mechanical resonance in CNC machines. Moreover, these systems suffer from issues like backlash, friction, and error accumulation, limiting their maximum feed rate to around 30 m/min and acceleration to only 3 m/s². Linear motors offer a revolutionary alternative by directly driving the worktable, eliminating the need for mechanical transmission. This results in significantly improved speed—up to 30 times that of ball screws—and acceleration—10 times greater, reaching up to 10g. The system’s rigidity is also enhanced by seven times. Additionally, because there's no backlash in the reverse direction, and the armature’s low inertia allows for high-frequency response (up to 100Hz), linear motors provide superior dynamic performance. The application of linear motors in high-speed and ultra-precision machining is now widely recognized as having great potential. Currently, AC linear motors are the preferred choice for large thrust feed applications. These can be categorized into two types based on excitation methods: permanent magnet (synchronous) and induction (asynchronous). In permanent magnet linear motors, the secondary (stator) consists of permanent magnets, while the primary (moving part) contains three-phase windings mounted on the table. In contrast, induction motors use a grid instead of magnets on the secondary side, resembling the "squirrel cage" structure of an asynchronous motor. Permanent magnet linear motors outperform their induction counterparts in terms of thrust per unit area, power factor, and controllability. However, they tend to be more expensive and require more careful installation, debugging, and environmental control, such as dust prevention. On the other hand, induction linear motors are becoming increasingly popular due to their comparable performance and easier maintenance. In the field of high-speed and ultra-high-speed machining, linear motors are now commonly used in high-speed milling machines, crankshaft lathes, superfinishing lathes, grinders, laser cutting machines, and more. Recent research is focusing on integrating them into high-speed parallel mechanisms—such as six-axis and three-axis parallel machine tools—that use multiple sliding plungers to control the tool, enabling efficient machining of complex surfaces.

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