Rafael,

This is an idea on how to provide linear motion to a single axis: 
http://www.oemdynamics.com/hld_animation/hld_intro.html

The Harmonic Linear Drive (HLD) article was posted in Machine Design on 
6/16/08: 
http://machinedesign.com/ContentItem/719/72741/ScanningforIdeasNovelRecirculatingBeltPowersLinearActuator.aspx

The large pulley and small pulley sets are connected together.  This 
provides a speed difference at the outer radius of the pulleys.  If the 
large and small pulleys were the same size then their circumference 
speed difference would be zero and the carriage would not move.  If the 
smaller pulley had 49 teeth and the large pulley had 50 teeth the pulley 
edge speeds would be 49 and 50 respectively.  This would make the 
carriage move at a rate of 1-(49/50) = 0.02 or 2% of the rate of the 
large pulley edge radius speed.

I have always been a fan of rotary harmonic drives due to their "near 
zero backlash" and the example above is just a linear version of it.  
The linear system provides fast acceleration using low mass components 
although belt speeds can be high compared to the carriage speed (30-50x 
faster).  If the timing belt in a Honda type R engine can accelerate 
from 700 RPM to 9000 RPM in 1/2 sec then a properly selected belt should 
work fine in a linear motion control application.

I think the HLD system could work well with a direct drive DC motor 
because a DC motor can accelerate quickly to 3000 RPM and provide 560" 
per minute of travel speed with 3" dia pulleys (49 tooth & 50 tooth).  
My Bridgeport VMC has max travel speeds of 300 IPM.  It is far from 
being state-of-the-art but gives me a baseline for other projects.

High quality DC motors with built in encoders can be cheap if you look 
in the right place.  I have quite a few Ametek drive motors from old 
tape drives that I picked up for $5-10 ea. at a local army surplus 
store.  I'm a sucker for high quality motion control that's nearly free.
 

Dennis

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