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The importance of preloading linear bearings in high performance motion systems. It differentiates between non-recirculating and recirculating bearings, and explores the effects of preload on each type. The document also covers the methods of achieving compliant preloads and their benefits, such as improved accuracy and repeatability. The research was conducted by a team in january 1998.
Tipologia: Manuais, Projetos, Pesquisas
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Preloading anti-friction linear bearings has been looked upon as more of an art than a science. This is primarily due to the fact that many variables in the mounting and assembly process make ‘torque’ ad- justments less practical and adjustments by ‘feel’ or by hand more effective. As bearings are mounted on imperfect surfaces, with in- consistent threads for mounting and preloading the bearing, it is difficult to es- tablish a foundation that will yield uniform results. This has not stopped people from striving to adopt scientific methods of preloading, with torque wrenches, or force gauges, however, it typically comes down to fine hand adjustments.
The purpose of preloading a bearing is to bring stiff- ness to a system (or axis) by taking out the clearance (or backlash) and generating the required life. In- creased preload brings increased stiffness, which in turn yields much higher responsiveness. In devices such as high performance positioning systems and state-of-the-art machine tools, bearing preload is criti-
cal to establishing a system that can meet the dynamic requirements of a servo system. As high stiffness lin- ear bearings are applied to high performance motion systems, it is important to understand the difference between a proper preload and an excessive preload. Simply adding preload to increase stiffness can result in the creation of inaccuracies, which will affect re- peatability and resolution.
As the methods and effects of preload vary based on bearing type (non-recirculating lin- ear and recirculating linear) it is important to separate the implications of preload on the two types of bearings. The dis- cussions regarding non-recirculating linear bearings refer primarily to crossed roller bearings, as these bearings are the most stiff of mechanical bear- ings and are often utilized in high performance motion systems. Recirculating bearings refer primarily to lin- ear ball guides, as these bearings are quite common in motion control and machine tool applications.
January, 1998
Non-Recirculating Linear Bearings
By “non-recirculating”, it is meant that all bearings remain in preload all of the time. The design of this bearing structure is ideal for very high smoothness (low friction) applications as bearings do not recir- culate in and out of a preloaded condition. Specifi- cally with crossed roller bearings, which offer a line contact that yields exceptional load capacity (stiff- ness) and very high accuracy, preload is an important consideration as it greatly impacts the bearings per- formance.
Crossed rollers, a series of cylindrically shaped roll- ers mounted on opposing 90° degree axes, posses the ability to utilize a preload in one axis bringing stiff- ness in two axes. The preload applied is typically a function of the load being applied to the bearing, and the amount of compression that a bearing will de- flect. This is normally in the range of 2% to 20% of the applied load. As mentioned earlier, the higher the preload, the higher the stiffness. However, the risk of inducing errors in resolution and repeatability occurs. Since crossed roller bearings have very high load capacities due to the full line contact, preload is nor- mally used more often than not to take out all of the bearing play without inducing any friction. This is permissible and quite common, as most applications use a very small percentage of the bearing capacity.
Even though applications typically use a small per- centage of the capacity of the bearing, the mechanical preload which is set on the bearing can significantly contribute to the errors within the bearing structure. Mechanical preloads are typically achieved by uti- lizing a set screw, or forcing mechanism, to move one adjustable rail perpendicular to the direction of travel, thus taking out clearance. The preload forces are usually generated in intervals that are equivalent to and in-line with the mounting screws that fasten the rail in place.
While crossed roller bearings benefit greatly from a compliant preload, it is the uniformity of preload over the entire length of the bearing that creates the primary advantage. While a compliant preload re- duces the bearing stiffness, the total capacity is still very high and more than adequate for the vast ma- jority of applications.
The process of generating a compliant preload with a non-recirculating linear bearing is achieved by creating a spring constant in the adjustable rail. The spring constant must apply to both the rail mounting surface and the rail banking surface to have value to the bearing structure. All too often spring forces are used to create a preload (or alignment) and then the mechanism being preloaded is locked down, ne- gating the spring force. While set screws are used to take out the bearing clearance, once the rollers and ways are in contact, the screws are used to ap- ply the spring force built into the adjusting wall.
Depicted in the drawing, a compliant preload iso- lates the one adjustable rail and allows it to flex with any anomalies / inaccuracies in the bearing structure or mounting surface.
**1. MOUNTING SURFACE
(^1 ) 3
1 2 4 3
**1. ISOLATED RAIL SURFACE
The primary benefits of using a flexure to mount to a re- circulating linear guide is the ability for the moving mass (or base) to grow thermally, at a different rate than the bearing. This is important, as many of the structures that use this bearing configuration are produced in aluminum and the bearing in steel. Particularly in stages that use linear motors, the motor heat is generated in the center of the slide plate and transfered directly to the aluminum slide. This causes subustantially more thermal growth than a stage using a ball screw and an external motor. As either the drive technology, the environment, or the process can generate heat, the flexure design allows for growth, elimi- nating any fighting between bearing preloads. The flexure design also maintains a spring constant with the growth to allow the parts to return to the original position.
Summary
While adding compliance to any bearing structure reduces the ultimate stiffness, the benefits can significantly out- weigh the reduction in capacity. As the linear bearings discussed have tremendous stiffness and typically have applied loads that are a very small percentage of their capacity, the opportunity to improve bearing performance is substantial. While these bearing designs have diverse applications, they are appropriate to high performance motion systems demanding high acceleration, velocity, po- sitioning accuracy, repeatability, or a combination of cri- teria. Clearly, there is measurable performance advan- tages that demonstrate the benefits of the technology. (^) TM
1
(^2 )
1. LINEAR GUIDE W/ STND. MOUNTING^4 **2. 2 PIECE FLEXURE MOUNTING