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TAILOR-MADE LINEAR TRACKS

TAILOR-MADE LINEAR TRACKS

by | Dec 3, 2024 | Allstar Magnetics News, Industry News, Products

Tailor-Made Linear Tracks

Applications of Custom Linear Tracks
in Precision Environments
Applications for custom linear track can range from use in precision manufacturing cells such as wafer manufacturing or clinical lab testing to end products such as operating beds, tables and stages for MRI and CT scanners. Linear systems are ideal for applications requiring precise alignment and positioning, such as diagnostic sample transport, food processing, vision systems, industrial automation, and collaborative robot (cobot) machine tools.

Linear Track

The definition of linear motion is to move an object in a straight line. Linear motion systems can include motors, drives, couplers, actuators, sensors, bearings, slides, tracks, and other hardware components. When precision in motion control and positioning is critical, commercial off-theshelf (COTS) solutions often fall short. Linear tracks are a prime example, where COTS tolerances may not meet the rigorous demands of high-performance systems.

From Concept to Manufacture:
A Customized Approach
Since 1989, we have specialized in the development and manufacturing of custom magnetic solutions utilizing neodymium magnets and stainless steel. Our expertise lies in building complex magnet assemblies and systems.

We utilize custom CNC tapping and specialtygrade steel backings to ensure structural integrity. Whether it’s flat or u-channel linear magnetic designs, , we refine concepts into manufacturable designs. We also take into account temperature and environmental effects on manufacturing processes, as well as adhesive specifications for varying environmental conditions such as humidity, heat, and outgassing, and their impact on machining tolerances. Our proprietary process is not only cost effective but also highly repeatable. Our unique approach allows us to provide customers with custom-built and staged linear motor tracks tailored for highly accurate motion control and positioning systems on demand.

Dynamic Performance in Custom
Linear Motion Systems
Linear motion systems have a wide range of dynamic performance. By customizing the motor and direct drive systems, high speed and acceleration can be achieved with exceptionally smooth velocity regulation and low ripple. They can also be customized to handle heavy or bulky load applications. Overall, linear systems have a lower cost of ownership due to less moving parts, reduced mechanical wear and reduced system operating costs.

The Cost vs. Performance Trade-off in
Custom Design
Designing a custom linear track involves a critical trade-off between cost and performance. COTS tracks are inexpensive but are limited to standard lengths, standard flat and U-channel sizes and set tolerances for position accuracy. Custom linear tracks requires design time, custom tooling, and custom manufacturing processes. If the volumes are small to medium, then the solution might not be cost effective unless you consider the total cost of ownership.

Many high-volume contract manufacturers do not have the experience or the safety training to handle strong rare earth magnets that are part of the sub-assemblies. There are safety, training, and manufacturing consideration when working with rare earth magnets.

Custom Linear Tracks For a Wide
Range of Applications

  • Diagnostic Sample Transport
  • Food Processing
  • Custom Assembly Processes
  • Robot/Cobot Systems
  • High Load Applications
Custom Linear Track Solution
Hall Effect Joystick

Hall Effect Joystick

by | Dec 3, 2024 | Allstar Magnetics News, Industry News, Products

HALL EFFECT JOYSTICK
Client: A leading manufacturer of control systems used in industrial automation.

Project Overview:
The client approached Allstar Magnetics to develop a precise, reliable, and durable joystick solution for use in their control systems. They needed a joystick that could withstand demanding environments while maintaining accuracy and durability. Allstar proposed the Hall Effect Joystick as a solution, utilizing magnetic fields to deliver superior performance in control systems across various industries such as aerospace, industrial machinery, and medical devices. The goal was to create a joystick that would enhance user experience, improve operational efficiency, and ensure resilience in challenging conditions.

Allstar’s Approach: Allstar Magnetics collaborated closely with the client’s engineering team to integrate the Hall Effect Joystick into their control systems. The process involved design development, rapid prototyping, and rigorous testing to meet the specific requirements of precision, durability, and reliability. By using Hall Effect sensors instead of traditional potentiometers, Allstar was able to offer a joystick solution that provided contactless operation, extending the product’s life expectancy and minimizing wear and tear.

Conclusion: Allstar Magnetics’ expertise in Hall Effect Joysticks and their innovative use of magnetic fields enabled the client to enhance their control systems with a solution that was durable, precise, and resilient in challenging environments. The partnership led to a scalable, cost-effective product that met the high demands of industries such as aerospace, industrial automation, and medical devices. Allstar’s commitment to quality and collaboration continues to make them a trusted partner in the development of next-generation control systems.

Key aspects of the project included:

  1. Consultative Design Support: Allstar worked with the client from the initial design phase, selecting materials and ensuring that the joystick would meet both functional and regulatory requirements. The team refined the design to maximize performance in terms of magnetic field detection, voltage conversion, and control signal precision.
  2. Durable, Non-Contact Design: The Hall Effect Joystick utilizes a magnet beneath the actuator to generate a magnetic field. As the joystick moves, the Hall Effect sensor detects changes in the field without physical contact. This contactless design ensures extended durability, offering a lifespan of over 10 million cycles with minimal maintenance required.

  3. Prototyping and Testing: Multiple prototypes were developed and tested under various environmental conditions, such as exposure to dust, moisture, and extreme temperatures. Allstar adjusted the design based on testing feedback to ensure the joystick’s performance met the client’s requirements for indoor and outdoor use.
  4. Scalable Production: Once the design was finalized, Allstar scaled production to meet the client’s volume needs. This process was optimized to ensure consistent quality, reliability, and costeffectiveness for mass production across their product lines.

Results:

  • Precision and Durability: The Hall Effect Joystick provided the client with an accurate, linear output, ensuring precise control in critical applications across industrial, medical, and aerospace sectors. Its durable, noncontact design significantly reduced wear and maintenance needs.
    • Improved Safety: The joystick’s built-in safety features, including redundant output signals and excellent electromagnetic immunity, contributed to safer operation in high-stakes environments such as medical devices and aerospace controls.
    • Enhanced User Experience: The joystick’s ergonomic design, combined with its resistance to shock and vibration, allowed for smoother operation in heavy machinery and industrial vehicles, providing a more intuitive user interface.