drylin® Linear Motion Technology

By purchasing complete linear actuator systems from a single source, companies can reduce engineering time and costs, minimize assembly time on the factory floor, and shorten lead times by managing just one part number from one supplier.

A complete linear actuator system typically includes the base actuator along with essential components such as motors, drive controls, proximity sensors, power and data cables, and power supplies. Additional accessories like brake resistors and encoders may also be required, depending on the application. The most common types of linear actuators are lead screw and belt-driven systems, although igus also offers rack-and-pinion actuator solutions for specialized motor control needs.

The main advantage of designing your own linear system instead of purchasing a complete off-the-shelf actuator is greater design flexibility. Custom-built systems allow engineers to select components that fit specific size, load, and motion requirements, rather than being restricted to the standard dimensions of pre-configured actuators. This approach provides more freedom to optimize performance, space utilization, and overall system design.

The most common ways to drive linear bearing systems include lead screw, belt-drive, and rack-and-pinion mechanisms. Lead screw systems, using a lead screw and nut, convert the rotary motion of a motor or hand wheel into precise linear motion. Fine-pitch lead screws provide higher force and greater positional accuracy, while multi-start or high-helix lead screws enable faster travel speeds with fewer revolutions but lower actuation force, sometimes requiring additional gearing to increase torque. Belt-drive systems are another popular option, offering higher speeds and longer stroke lengths than lead screws. Other drive technologies include rack-and-pinion, chain drives, and pneumatic or hydraulic actuators, each selected based on the speed, load, and precision requirements of the application.

Not all linear bearing systems require programmable motors. Simple linear axes can be driven by DC motors that move between limit switches and are controlled manually using a push button or joystick. These basic setups are ideal for straightforward motion tasks and do not require programming. However, applications that involve complex or automated motion - beyond simple travel between proximity sensors - will need a programmable drive controller to define speed, position and motion profiles. Drive-control options such as the igus D1, D7, D8, and D9 series are designed for these programmable motion control applications.