Automotion Components Linear Guideways

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Rail sizes

Carriage lengths

General Guidance

Load capacities – explained

• A number of load figures are stated for load capacity:

Dynamic Load – this is the main fi gure considered for linear guideways. It is the moving load that the system can bear. It takes account of the total moving load as well as considerations such as impact, vibration and fatigue.

Static Load – this is a load that is constant for an extended time (i.e. the dead load the system can bear before any movement). It can be in tension or compression.

For these linear guideways the radial and axial load capacities are the same.

Moment loads are twisting loads generated by off set loads in either X, Y or Z planes. Moment loads can be reduced by adding further carriages or rails to reduce any twisting of the carriage due to the load off set.

What lengths can be provided?

• We have standard rail lengths. These are based on the hole pitch of the rails and end machining to provide an equidistant length to the first and last hole centre.
• However we can cut the rail (from stock) to any length required – we just need to know the distance required to the first hole.
• In general our cutting procedures allow for a ±2mm accuracy on the overall rail length. If greater accuracy than this is required then we have to machine the end accurately (rather than cut it) and this involves extra time and cost.
• Standard maximum length for each rail size is around 4 metres. Rails can be joined together but the preparation needs to be made in our workshop. The rails will be marked clearly with the ends to be placed adjacent to each other.

Mounting the carriages to the rails

• In general the carriages will be supplied separately to the rails. To install the carriage onto the rails, offer the carriage up to the rails and slide it onto the rail itself.

The rotating balls in conventional profile rail guides have point contact between each other. The rotation speed at the contact point is double the speed of the balls. The contact area (A) is so small that the surface pressure (P) tends towards infinity. This leads to heating and wear of the balls and the linear guide system.

The chain system in our new linear guides have a relatively large contact area (A), this significantly reduces the surface area pressure (P). The rotation speeds at the contact surfaces of ball and chain are the same. The ball chain is used to transport the lubricant and to create a lubrication film on the balls. The design of the carriage allows effective supply of lubricant from the lubricant connection to the circulation areas of the ball chains.

This design of the of the ball chain ends in connection with the spacer ball closes the circulation and makes the movement of the carriage smooth and quiet.

The new ball chain system also allows the balls to be continuously supplied with lubricant, which reduces wear of the metal. This significantly extends the service life of the system and reduces lubricant and the maintenance intervals.

Technical Specs

Load capacity overview - L1016.F Flanged carriages

Load capacity overview - L1016.U Unflanged carriages

Load capacity overview - L1016.UL Unflanged low height carriages

Radial clearance/preload

Radial clearance describes the value for the radial movement of the carriage at a constant vertical load, while the carriage moves in longitudinal direction.

Preload is defined as an effective load on the rolling element in the interior of the carriage in order to remove an existing clearance or to increase the rigidity.

The linear guideways are available in the two different preload classes K0 or K1, see table below.

The preload influences the rigidity, precision and torque resistance and also affects the service life and displacement force.

The radial clearance for the respective preload classes are listed below.

Precision means the guide accuracy or the maximum deviation of the carriage based on the side and support surfaces during the movement along the rails.

Flanged

Unflanged

Lubrication

Linear guideway rails must generally be lubricated before commissioning. They can be lubricated with oil or grease. The correct lubricant selection has a large influence on the service life and the function of the rail, insufficient lubrication and tribocorrosion can ultimately lead to total failure.

As well as reducing friction and wear, lubricants also serve as sealant, noise reducer and corrosion protection for the linear guide. Diff erent lubricants for special applications are available upon request (e.g. lubricant with FDA approval for use in the food industry).

Our linear guideways are coated with an anti-corrosion resistant oil at the factory. This coating needs to be removed prior to installation, then lubricated as follows:

Grease lubrication

We recommend the use of a lithium emulsified lubricant NLGI Class 2 for lubrication.

Oil lubrication

We recommend a synthetic oil for operating temperatures between 0°C and +70°C.

Lubrication nipple

The following lubrication nipples are supplied.

Other lubrication nipples, such as lubrication adapters with hose inlet or with quick-coupling, are available on request.

Lubrication nipple	Size
NLB01	15
NLB02	20 25
NLB03	30 35
NLB04	45 55

Surface treatment

There are numerous application-specific surface treatments available for profi le rails of the linear guideway product family, for example, black oxide coating (X), hard chrome plating (XC) or nickel plating (NIC) and an FDA-approval type for use in the food industry. For more information please contact us on 0845 850 99 40.

Resistance of the seals f

Coefficient of friction μ

The given static load capacity (C₀) for each carriage represents the maximum permissible load value, which if exceeded causes permanent deformations of the raceways and adversely affects the operating performance.

Checking the load must be done as follows:

• Through determination of the simultaneously occurring forces and moments for each carriage.
• By checking these values with the corresponding load capacities.

Calculation of service life

The dynamic load capacity C is a conventional variable used for calculating the service life. This load corresponds to a nominal service life of 50 Km. The relationship between calculated service life L_Km (in Km), dynamic load capacity C (in N) and equivalent load P (in N) is given in the formula below.

Contact factor f_c

The contact factor f_c refers to applications in which several carriages pass the same rail section. If two or more carriages are moved over the same point on a rail, the static and dynamic loading values must be multiplied with the numbers from the table below.

Temperature factor f_t

If the temperature affecting the system exceeds 100°C, the temperature factor f_t must be included in the service life calculation.

Note 1: For temperatures above 80°C, the seals and end caps must be designed for higher thermal resistance.

Note 2: Special processing to ensure the movement of the guides is required for temperatures above 120°C.

The given radii and shoulder heights in the table must be observed when assembling rails and carriages on the stop edges to ensure perfect seating of carriages or guideways.

Values in mm. HR* is the maximum height when using side seal on carriage.

The bolt sizes to be used and optimum tightening torques for rail assembly are listed in the table below.

Assembly process

Table assembly 1

Set the table carefully on the carriage and tighten the fixing screws only lightly.

Table assembly 3

Tighten the fixing screws on the main side and the lateral side completely tight to finish the installation. Note: To attach the table uniformly, tighten the fixing screws diagonally (1, 2, 3, 4). This method saves time when straightening the guide rail and makes the manufacture of positioning pins unnecessary, which considerably reduces assembly time.

Manual rail clamps

• Many of our customers wish to lock their moving element in position on the rails. Whilst this can be relatively simply achieved with the use of an adjustable clamping handle and thrust pad, we also offer a clamping element which can be integrated into your rail/system design.
• This is available in the standard manual version as well as (on request) a pneumatic version for linear guideways only (not compact rail systems).
• These manual clamps have a holding force of up to 2,000N.
• They are relatively compact in shape. Please bear in mind the extra space required for the clamping element when calculating the total stroke you require.