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Whitepaper

Accelerating Linear Motion System Design

Introduction
Rolling element guide wheels are an excellent option for many linear motion applications. They are low cost but can
support high loads. Their large rolling surfaces enable them to operate at high speeds and in debris-filled environments
while providing low noise and low friction rolling characteristics.

LoPro Belt
Driven Actuator

Wheel Plate on Track

Plate Assembly

Guide wheel-based linear motion systems are easy to design and build into most
applications due to the robust yet minimalist assembly characteristics of the
guide wheels and components. However, pre-designed products, such as LoPro
linear motion systems based on DualVee motion technology, are available that
can significantly reduce the time and expense of designing and fabricating an
entire system from scratch. LoPro systems are available in a wide variety of
configurations that can suit most applications. Configuration options include
system size, system length, carriage wheel plate profile, track plate mounting
structures, drive element design, component materials, and add-on accessories.
Design refinements based on extensive testing and field usage experiences have
resulted in linear motion products with reliable, proven performance. This article
provides an overview of standard LoPro options and their suitability for various
applications.
Every LoPro linear motion system is composed of two essential elements - a DualVee guide wheel carriage and a DualVee track plate assembly. A guide wheel
carriage is composed of DualVee guide wheels and a wheel plate that serves as a
platform for connecting the guide wheels to the application components that
require motion guidance. The track plate assembly is composed of opposing pairs
of DualVee track mounted to a low profile but rigid aluminum substrate. Additional
optional LoPro system elements include drive systems and support beams. The
LoPro product line design is based on modular elements, so system elements can
be easily replaced or re-configured in the field.

System Size Considerations

LoPro systems are available in several system sizes to meet different load capacity, cost, and profile requirements.
Standard LoPro systems are available with a large range of system lengths to meet virtually any travel length
requirement.
There are multiple load capacity factors to consider when selecting a LoPro system. These include the load capacities of
the carriage, the nominal travel life of the carriage, and the linear thrust load capacity of the drive element. Carriage
load capacity in turn is dependent on the orientation(s) of the applied load(s). All of these ratings increase with the size
of the LoPro system size. All must be considered against the application requirements.

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Wheel Plate Options

Two types of standard LoPro carriage wheel plate designs are offered to meet specific application requirements wiper
wheel plates and basic wheel plates. All wheel plates feature arrays of threaded mounting holes that permit flexible
mounting possibilities.
Wiper wheel plate designs are highly optimized for their intended systems. They offer the most compact, low-profile
wheel plate envelope possible. Basic wheel plates have simpler, essentially rectangular profiles. They are lower cost
but are slightly taller in profile. While guide wheels are fully capable of operating on debris-covered track, track lubricators on all wheel plates maximize system life by constantly applying lubricant on the track and wiping debris off
before they can reach the wheels. Wheel covers (an option on basic wheel plates and a designed-in feature on wiper
wheel plate(s) further isolate wheels from debris while also minimizing wheel-track pinch point access.

LoPro Basic Wheel Plate

with Wheel Covers

LoPro Basic Wheel Plate

with Wheel Covers

Track Plate Mounting Options

LoPro systems are available with a variety of mounting options for track plate assemblies. Systems are available with the
track plate assemblies mounted on aluminum or steel beams, or unmounted for users to directly mount onto their
application components.
Aluminum and steel mounting beams provide a rigid structure for the track plate assembly, an important characteristic
for minimizing system deflection if the system is supporting heavy loads and/or not fully supported along its entire
length in its application. Additionally, the mounting beams serve as central mounting components for the track plate
assemblies and the drive and idler ends, enabling an entire driven system to be moved and assembled as a single unit.
Aluminum mounting beams are extruded and feature continuous length T-slots on all sides. The T-slots accept standard
T-slot hardware, permitting quick and easy assembly of application components onto the beam or mounting of the
beam onto the application. Steel mounting beams provide high strength and stiffness in a compact profile.

LoPro Linear Guide

Track Plate

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LoPro Beam Options

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Drive Element Types

LoPro linear motion systems are offered in driven and undriven configurations.
Undriven configurations are typically used where the user intends to attach
the carriages to external linear actuators or directly push them by hand. Standard
drive element options in driven system configurations include belt, chain, lead
screw, and ball screw.
A belt drive system is ideal for applications requiring high travel speeds and
long stroke lengths. The belts feature high tensile strength wires over-molded
with polyurethane. The drive belts and pulleys have complementary profile,
enmeshing teeth to enable precise position tracking between them. The
polyurethane belt material is inherently corrosion-resistant, has self-lubricating
properties, and can run quietly and at high speeds on pulleys.

AT Style Polyurethane Belt

A chain drive system is ideal for applications requiring high actuation force
and long stroke lengths. The chains are available in steel or stainless steel. Chains
require external lubrication and cannot be operated as fast as belts, but they are
constructed of steel or stainless steel, which is more resistant to elongation than
the polyurethane in belts.
Lead and ball screws drives are ideal for applications requiring higher linear
positioning accuracy and stiffness, and where high speeds and long stroke lengths
are not critical. The screw mechanism design provides mechanical advantage,
enabling higher actuation force without additional gearboxes. Drive screws are
available with various thread pitch lengths to meet specific speed and accuracy
requirements; for example, longer pitch lengths enable screws to actuate a
carriage slightly faster but with slightly lower positioning accuracy and mechanical advantage.
A lead screw is the simpler and lower cost drive screw design. The nuts in
these systems are made from polymer, which offers self-lubricating properties and
quiet performance. Additionally, axial loads applied directly to lead screw nuts
generally cannot cause back-driving on the screw, enabling lead screw-driven
systems to maintain the positions of externally axially-loaded payload without an
external brake.

ANSI Roller Chain

Lead Screw and Polymer Lead Nut

Ball screw systems have re-circulating balls between the nut and screw. When
a ball screw is rotated, the balls transmit linear force from the screw threads to the
nut threads while simultaneously rolling between them, providing lower friction
motion characteristics than the sliding mode of motion between lead screws and
their nuts. Ball screws offer higher linear precision, stiffness, and load capacity
characteristics than lead screws.

Ball Screw and Ball Nut

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Material Options
Since LoPro systems are a popular linear motion solution in many applications featuring
corrosive operating conditions, corriosion-resistant components are a popular option.
Corrosion-resistant LoPro systems feature stainless steel wheels, track, drive system
components, and fasteners. Aluminum components in all LoPro systems are anodized
as standard, which imparts good corrosion-resistance and aesthetic characteristics.

Other Options
Stainless Steel Hardware

Accessories

Since LoPro systems are manufactured and sold in large quantities, an additional benefit
of using them is that popular add-on accessories are already designed and available.
These components require little if any customization, and can be obtained quickly and
at low cost. These accessories include system mounting components, motor mounts,
gantry system components for assembling individual LoPro systems into larger multi-axis
systems, and proximity sensors.
There are times when users require attributes that standard options cannot provide. In
these cases, special customization capabilities are available, ranging from slightly
modified components to heavily customized complete systems. Experienced applications
engineers are available to assist with these needs.

Conclusion
Pre-designed LoPro systems can enable users to realize the benefits of guide wheel-based linear
motion more quickly and easily than designing and fabricating custom systems on their own.
LoPro system can be cost-effective, reliable solutions for users when they understand the
attributes of each LoPro system option and pick the ones that best meet their application
requirements. The modularity and ready availability of standard LoPro system components
simplifies field servicing and configuration changes.

GROUP

Author Bio
Leslie Lui is a Mechanical Design Engineer with Bishop-Wisecarver
with more than 9 years of machine design, motion control,
and power transmission experience. He holds a BS degree in
Mechanical Engineering from the University of California,
Berkeley.

Multi-Axis Gantry System

Comprised of Standard
LoPro Parts

About
Bishop-Wisecarver Group is a woman-owned family of WBENC certified companies in its
second generation, and has remained one of the most respected names in custom automation
solutions and guided motion technology since 1950. The San Francisco Bay Area company
manufacturers, stocks, and distributes guided motion components and systems for linear,
rotary and curved track applications. Bishop-Wisecarver products are used worldwide in
industries such as packaging, medical device manufacturing, wood processing, food
processing, and semiconductor fabrication.

BISHOP-WISECARVER - Expertly Designed, Delivered to Perform

888.580.8272 | www.bwc.com