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.
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
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:
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.
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.
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.
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.
In the world of modern engineering, where precision and efficiency reign supreme, the significance of coatings on neodymium (neo) and other rare earth magnets cannot be overstated. These tiny powerhouses of magnetic strength play pivotal roles in countless applications, from electric vehicles to medical devices and beyond.
Coatings act as a barrier, safeguarding the integrity of the magnet and preserving its magnetic properties over time. Tailored coatings can enhance specific characteristics, such as temperature resistance or adhesion, further expanding the versatility of rare earth magnets across diverse industries.
At Allstar Magnetics, we understand the critical role coatings play in maximizing the potential of rare earth magnets. With our expertise and cutting-edge solutions, we stand ready to partner with you in harnessing the full power of these remarkable magnets while ensuring their durability and reliability in any environment.
We are happy to answer any coatings questions you may have.
Recommended reading: See how Allstar Magnetics applies the same engineering rigor and supply chain expertise to solve single-source challenges—delivering lower costs, reduced risk, and reliable JIT supply in this supply chain optimization case study. Read next
With our enhanced capacity we can help take your design(s) from concept to full scale production. Contact our Technical Sales team today to find out more.
Bottom line: Now that summer, vacations, and holidays are winding down; Today is a great day to solve supply chain issues, reduce risk, and design the next generation product.
We look forward to continuing to serve your needs as experts in the magnetic industry. Please feel free to contact your sales rep directly or send us a note at sales@allstarmagnetics.com for any concerns or questions.
Allstar offers rapid prototyping of custom machined permanent magnets and magnet assemblies. Companies often advertise rapid prototypes and then miss promised delivery dates. At Allstar we specialize in on-time-delivery and will meet your deadline requirements. Typical lead time is 4-5 weeks for magnets and 2-3 weeks for ferrites.
Custom designed magnetic assembly was a cost prohibitive and manufacturing nightmare until the customer brought the design to Allstar – see how they solved the issues.
Rare Earth (NdFeB & SmCo), Alnico, and Ferrite Custom Magnetic Assemblies or Build-to-Print
Did you know that Allstar is a vertically integrated manufacturer of both permanent magnet assemblies and soft magnetic wound parts?
Allstar uses depth of knowledge, superior customer service and excellent on time delivery to streamline critical elements of the product lifecycle for both soft magnetics and permanent magnet applications. Focusing on crucial value-added needs like inventory stocking, design, prototyping, and volume solutions, has helped Allstar Magnetics remain a leader in next generation magnetic applications.
For our customers looking for custom wound assemblies, we have the equipment and engineering support to produce quantities from prototype to full high-volume production. Allstar Magnetics stocks a large selection of ferrite cores and hardware as well as custom assemblies tailored for quick turn and rapid prototypes.
Why choose Allstar? Â We offer quality, speed, and engineering experience all with great customer service. Â Understanding the best way to specify magnets, hardware and test magnetic assemblies is a key support feature we offer.
Permanent Magnet Assemblies
Allstar Magnetics specializes in permanent magnet such as Alnico, Neodymium, Samarium Cobalt, Ceramic, Bonded Magnets, Magnetic Separators, Magnetic Assemblies, Radial Rings & Linear Magnetic Tracks.
