Stepper motor-driven screw linear actuators have been used for a while in a variety of applications. Integrated motor screw units used only to be available in high volume runs or were too costly to consider. Building your own with expensive couplings and support bearings, mounting, and aligning the assembly adds overwhelming costs. Helix has combined manufacturing technology, precision hybrid motors, and standard lead screw components to make low volume runs an affordable modern option.
We have taken a look at the pieces that make up the whole linear system addressing cost, quality, and performance factors for each of them.
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Eliminate costly couplings and support bearings to lower system cost, and provide for more compact, stiffer, easy to mount and align assemblies
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Stepper motors' high torque at low speeds can eliminate gearboxes for precision positioning accuracy
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Selecting the appropriate lead screw may provide self-braking in many applications, eliminating a costly brake assembly
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Stepper motors are also inexpensive to control, and there are many low-cost drives available to power and control stepper motors
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Optional motor encoders are available - fastened to the back for closing the loop, further enhancing system accuracy
Laser Welding
At Helix, we utilize laser welding to attach the lead screws and ball screws to the hybrid stepper motors. The stepper motor is beefed-up with deep groove ball bearings to maximize thrust loads and rigidity. Welded assemblies provide better alignment, don't come apart, and are lower cost. Helix has pioneered laser welding expertise to provide accurate, strong, and reliable welds.
Laser welded linear actuators are typically manufactured by inserting a turned journal of the screw into a hollow cored motor and fusing them in a rotating fixture. A NEMA 23 frame motor only takes a few seconds to do this, providing a strong bond and precision alignment. This procedure is done to assemble motors. They can be kept in stock separately and married to the customer's required lead screw for quick delivery and provide thousands of motor screw combinations.
PTFE Coating
Helix lead screws are PTFE coated in a computer-controlled environment ensuring uniform coating, long life, and the smoothest operation. Having this facility in-house also provides prompt delivery and total quality control. We also manufacture our lead screws and injection mold our lead screw nuts in a state-of-the-art manufacturing plant using the latest technology to ensure the highest quality.