LINEAR MOTION RAIL SELECTION


•Profile rail with rollers When applications require maximum rigidity, designers may opt for rollers over balls. Rollers provide enhanced stability and load capacity with minimal rolling friction, thanks to their larger contact surface. However, profile rail with rollers also come at a higher cost and


intolerance for installation variances, making them most


cost effective only for the most demanding applications in terms of


accuracy and moment load capacity. These include industrial automation, machine tool equipment, precision measuring and industrial robots requiring the


greatest possible accuracy on assembly height and width tolerances, between ±5µm and ±20µm.


MANAGING OTHER DESIGN TRADE-OFFS While the selection of rail track architectures has the greatest impact on costs, other choices affecting project budgets that are within the designer’s control include material selection, maintenance, standards compliance, and training.


• Material selection Material selection can be critical in cost management, influencing both the initial and operational costs of profile rail. Aluminium offers the lowest cost but is best for lower accuracy ranges. Hardened steel strikes a better balance


among cost, durability and performance for a broader range of uses. Environments requiring high corrosion resistance or unique properties should consider stainless steel or advanced coatings, which come with a higher cost.


• Maintenance Maintenance-related decisions that can impact cost include load capacity versus size, where high load capability rails can handle heavier loads but may be larger and require more expensive and frequent maintenance. Likewise, higher accuracy demands, especially in profile rail with balls and rollers needing high speed and precision, will also involve higher maintenance costs. Maintenance-related functions that impact


cost from the designer’s perspective include the addition of features like wipers, scrapers, oil reservoirs, lube blocks, coatings, sealing and pre-loading. Whether OEMs build such functionality into their products depends on their assessment of the market demand for it.


•Strategic standards compliance Depending on location, leveraging standards strategically can help reduce costs. There are, for example, established standards for linear motion features such as rolling guides, rails and ball screws. Someone revising or rebuilding a machine in a region subject to standards that require a higher tolerance, for example, may be able to reduce cost significantly by building in a location governed by more forgiving standards, especially if the standards call for higher tolerances than the application needs.


•Training


Plant managers and supervisors can also play a role in cost containment by optimising human resources. The success of every factor discussed thus far depends on the experience and talent of the individual who is implementing it. For example, inadequate surface preparation


can reduce the value of anything running on it to zero. It is up to the personnel officials to determine whether to obtain those services in-house, train teams that do not have them or bring in outside specialists. This is even more complex and critical in this age of talent shortages, where individuals may have to be trained in multiple tasks.


OPTIMISING THE SELECTION In navigating the complex decision-making process for profile rail selection, starting with a cost-effective, double-faced architecture can provide a practical baseline. From there, designers can incrementally explore more advanced options based on the specific needs of their application. By considering the broader spectrum of design trade-offs, including material choices, maintenance functionality, regulatory standards and training, designers can optimise their selections to balance upfront costs with total operational expenses. To further assist design engineers in making the right choices, device vendors such as Thomson Industries provide design resources, including a team of application engineers who assist in identifying the optimal solution, online product selector tools, technical collateral, white papers, webinars, and video instruction.


Thomson Industries www.thomsonlinear.com/en/index


MODULAR LINEAR ACTUATOR RANGE HELPS NEW AUTOMATED SYSTEM PRODUCE ‘RIGHT-SIZE’ PACKAGING SOLUTIONS


In the packaging sector, millions of parcels leave warehouses daily, often half-empty and filled with unnecessary air and filler materials. This inefficiency leads to wasted carton material, inflated shipping costs, and excessive carbon emissions. So when packaging OEM, Opitz Packaging


Systems of Germany, had a vision to design a fully automated system capable of resizing every carton to match the true size of its contents, it turned to IMI’s Industrial Automation team to create an award-winning, high-performance motion system. In an engineering partnership, Opitz and


IMI’s Industrial Automation sector designed the desired motion architecture to include multiple actuator series as part of one fully integrated, high dynamic, system The IMI Bahr modular linear actuator platform


serves as the foundation of the patented carton volume reducer system, seamlessly integrating IMI Bahr actuators at every stage of the innovative packaging process. These include supporting the cutting and upper closure function for dust-free carton cutting and flap folding.


www.designsolutionsmag.co.uk Tape is applied to individual parcels with


precision and speed, followed by parallel actuator systems that ensure a smooth carton flow across various formats. Finally, actuators enable precise glue application to guarantee secure parcel sealing in readiness for warehouse dispatch. As a result of the innovative motion


system, Opitz has seen a raft of efficiency and sustainability benefits. There is now up to 85% less air per package, alongside a reduced carton filler material and carbon emission footprint. Operational efficiencies have surged with multi-format cartons capable of being processed through one high speed, accurate and reliable automated system. “Our collaboration with Opitz exemplifies how engineering innovation can address real-world challenges,” said Cihan Halavurt, general management for IMI Bahr products. “By integrating our high-performance motion systems, we’ve created a solution that reduces waste, lowers carbon emissions, and enhances efficiency for the packaging industry.” Adding to this, Florens Fuchs, head of


procurement, Opitz Packaging Systems, said: “This partnership has allowed us to bring our vision of a right-size packaging solution to life. The results speak for themselves – up to 85% less air per package, reduced filler materials,


and a significant reduction in CO2 emissions. We’re delighted to have set a new standard for sustainable packaging.” The Opitz motion system has now been


recognised by the German Packaging Institute and won a German National Innovation Award for the automated ‘right-size packaging solution’. It was recognised for its sustainability contribution by reducing packaging waste and CO2 emissions.


IMI www.norgren.com/en FEBRUARY 2026 DESIGN SOLUTIONS 35


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