Test & measurement
automation solution that could hold positioning tolerances on the order of a few microns to support delicate operations. Cleanliness was a necessity - new actuators could not contaminate the product (e.g. by shedding grease or particles) or be vulnerable to contamination from the environment. Space constraints needed addressed. With many process steps packed into a single line, the actuators needed a compact form factor to fit into tight spaces without sacrificing stroke or performance. The OEM sought a solution that could meet all these demands: high accuracy and stiffness for precise, repeatable motion; a compact, lightweight design for easy integration; and a robust lubrication and sealing approach for clean, reliable operation.
A PRECISION ACTUATOR DESIGNED FOR MICROMETER ACCURACY The OEM turned to global linear motion specialist Rollon for a linear motion system that could deliver micrometer-level precision under high dynamic loads. Rollon’s answer was the Precision System TH series – a family of ball- screw driven linear actuators engineered for
ultra-high accuracy and repeatability. The TH actuators use a precision ball screw drive (in various lead options) to achieve excellent thrust transmission and minimal backlash, enabling positioning repeatability within ±5 µm. This level of accuracy was crucial for the battery cell line, where actuators needed to repeatedly hit exact positions (often within a few microns) to align components and present them for sensor inspection.
Each TH actuator is built for rigidity and smooth motion. The carriage runs on two or four recirculating ball-bearing guide blocks on parallel ground raceways, with the bearings and carriage factory preloaded. This construction maximizes stiffness and eliminates play, so the actuator can start and stop precisely without overshoot or chatter. The robust guide system also ensures alignment accuracy even under frequent motion reversals on very short strokes. In the battery cell application, strokes of only 50–100 mm were common, with rapid back- and-forth cycling. The TH actuators were able to maintain ±5 µm precision through these high- frequency motions – a testament to the system’s design for high dynamics and repeatability.
Critically, the TH series achieves this precision in a compact, lightweight form factor. The actuator body is an anodized aluminium extrusion, which is both self-supporting and very light. The anodized aluminum construction not only contributes to compactness but also avoids corrosion (no oxidation), which is beneficial in sensitive manufacturing environments.
CENTRALISED LUBRICATION AND CONTAMINATION CONTROL One of the standout features of the Rollon TH actuators in this case was their innovative lubrication and sealing system, which directly tackled the OEM’s contamination concerns. Each TH unit includes a centralised, optimised lubrication mechanism that services both the ball screw and the guide bearings through dedicated channels. This design ensures that lubricant is distributed evenly and retained where needed, greatly extending maintenance intervals and preventing the dry-running conditions that had plagued the previous actuators. By prolonging the life of the ball screw and carriage bearings, the centralised lube system keeps motion smooth and consistent over time. In practical terms, this
Continued on page 26... Instrumentation Monthly September 2025 25
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