English (UK) 
简体中文 Are you also wondering - from those electronic factories, battery factories, why the two years like crazy for linear motors? Bosses have more money to burn panic? Don't worry, today we will break open the rubbing said.Linear motors what makes the production line efficiency soaring 30%What's that? Is this money well spent? Watch it and you'll understand!
A linear motor is no ordinary motor! What's so strong about it?
Traditional production lines with rotary motors + belt gears are like making Liu Xiang run three laps around the playground to get to the finish line -The power is not always there, and it's easy to "break" and get stuck.. What about linear motors? Simple and crude!Electromagnetism pushes the load straight through, cutting out all the intermediate drive chains.The device swishes out in a straight line.
A real example: a lithium battery factory in Conghua originally used gears to transport the pole pieces:
- old problemSpeed not dare to exceed 2m / s, fast on the shake, cut 0.5mm crooked directly scrapped;
- After changing the linear motor: speed dislike to 10m/s.Cutting accuracy lock ±0.1mmThe scrap rate plummeted from 81 TP3T to 0.31 TP3T.
That's not all!Maintenance-free design is the hidden benefit--No belt to break, no gears to change the oil, the life of the direct pull full 100,000 hours. Plant manager's words: "Maintenance class from every day to put out fires, to now drinking tea and touching fish!"
A comparison table is more visual:
norm Conventional Conveyor Lines Linear Motor Conveyor Line top speed ≤2m/s ≥10m/s position accuracy ±0.1mm ±0.002mm Maintenance frequency Monthly maintenance 3 years maintenance free power consumption 100% benchmark Reduction of 35%
How did the Efficiency 30% come about? Hands-on dismantling from a business
Don't believe the adverts look at the results! A true case of remodelling in a local electronics factory:
- sore pointMobile phone camera mounter is always running out of order, jamming 3 times per hour, with a capacity of less than 8,000 pieces in 24 hours;
- Upgrade programme::
- Remove the gear belt and put on the linear motor module;
- Add scale real-time correction (hairline error immediately alarm);
- Linked ERP system automatically schedules tasks;
- in the end::
- Zeroing the number of card stops, with 24-hour capacity soaring to 11,000 pieces;
- Saved 2 inspectors.The annual manpower cost is cut by $400,000;
- The meter is reversed.--Monthly power consumption was pressed down from 30,000 kWh to 18,000 kWh.
Here comes the key.The 30% efficiency gains are not to be blown away!
- 15% from speed lapping (10m/s vs 2m/s);
- The 10% came from a zero-failure shutdown (cog belt said to fall apart);
- 5% from Intelligent Dispatch (the system automatically bypasses traffic jams).
Who should be on linear motors the most? Three types of factories do not change the loss
Don't follow the trend! Let's see if you're this type of player first:
- Precision be damned.::
- Semiconductor wafer cut off 1μm, $200,000 down the drain---Must be positioned ±0.002mm.;
- Medical needle drilling, difference of 0.005mm puncture failure - linear motor scale specialised in the treatment of hand shaking;
- speedy::
- New energy battery pole piece cutting.120 metres per minute is enough capacity.A conventional motor? Shake into a sieve! ;
- insolvent::
- A factory that works 24 hours a day and loses a million dollars repairing an assembly line--Linear motor 100,000 hours without rest.
Lessons learnt from the Conghua Precision Medical Supplies FactoryEuropean order states "1 hour late delivery penalty of 100,000", the original monthly deductions, change linear motors after the delivery of accurate to the second!
A guide to avoiding the pit: don't step on these three mines when upgrading
Want to save money but afraid of getting screwed? Remember these three iron rules:
- Don't save money on testing equipment!
- Grating scale must be accompanied by a third-party accuracy report (many manufacturers mark ±0.002mm as airborne data!) ;
- Learn about a factory in Dongguan.Running for 8 hours with 20kg loadIt's the laser interferometer that counts;
- System Integration > Standalone Performance::
- Linear motors are fast, but without a WMS (Warehouse Management System), they are unicycles...Must require open API interface.;
- Terms and conditions written to the bone::
- "24-hour response" is too vague!"Two hours on site for faults, overtime chargebacks."The local factory in Conghua is most afraid of this article.
Personal views on the blackboard
After fifteen years in manufacturing, I dare say.From the chemical plant today does not upgrade linear motors, five years will be obsolete!Why so hard?
- cost account: A line is $800,000 more expensive, but the yield rate is from 80% → 99%, saving 35% of power, saving 3 labour-Payback in less than two years.;
- competition account: The next door factory changed linear motor, take Apple order premium 20%, you are still OEM cottage charging head;
- Geographical benefits: The Pearl River Delta linear motor factories are piled up (1 hour from Dongguan to Conghua).Repair faster than takeoutThis advantage cannot be envied by mainland factories!
So yeah, bosses biting the bullet on linear motors aren't people being stupid-They're talking about life and death in five years.. Manufacturing this business with poor efficiency 30%? That's a tractor racing a high speed train!
