Features that make a difference

In high-performance motion systems, increased dynamics, higher continuous forces and extended duty cycles inevitably result in rising thermal loads within the axis. Although direct drive technology enables these performance levels without the need for mechanical transmission elements, heat generation remains a key factor that influences long-term positioning accuracy, position stability, and process repeatability. Even small temperature variations can introduce thermo-mechanical gradients that affect structural geometry, encoder alignment and feedback consistency, ultimately limiting the machine's achievable performance.

To ensure stable operation under these conditions, the motion system incorporates an Advanced Cooling System, which is designed for continuous, high-dynamic operation. The motor units are optimised for efficient heat dissipation, enabling thermal energy to be removed directly at the source before it can propagate through the structure and impact performance-critical components.

Unlike conventional cooling approaches, which focus primarily on motor safety, the cooling architecture is integrated across the entire motion platform. It is highly efficient to remove thermal energy out of the system to ensure that all key components operate within a controlled and consistent temperature range. Distributed temperature sensing provides continuous monitoring of the thermal state of each axis and enables system-wide thermal supervision.
Reducing thermal gradients and stabilising the temperature distribution within the motion platform minimises thermally induced drift in both the mechanical structure and the feedback reference. This preserves closed-loop stability, even during extended periods of higher-load operation.

The result is a motion system that maintains dynamic performance and positioning accuracy with drastically reduced thermal degradation, enabling reliable operation in high-throughput industrial and precision applications requiring long-term stability.

External cable management systems require additional installation space and introduce moving components outside the actual motion system. During operation, continuous cable motion leads to mechanical wear of cables, cable carriers and guiding elements. In sensitive production environments, the resulting abrasion particles can contaminate the surrounding process area and negatively affect process stability and product quality.

By routing all power, signal and media lines completely inside the motion system, these effects are eliminated. The enclosed cable path prevents wear particles generated by cable motion from reaching the process environment while simultaneously protecting cables from external influences and accidental damage.
The controlled routing of all cables ensures defined bending radii over the entire travel range. Mechanical stress on the cables is reduced, resulting in lower wear and increased cable lifetime, particularly in applications with long travel distances and high duty cycles.

Integrating the complete cable management into the motion system also minimizes the required installation space and eliminates external cable loops that may interfere with adjacent equipment or limit the usable workspace. The result is a compact and robust motion platform optimized for demanding automation and precision applications.

In high performance motion systems a key control feature is to precisely know the actual Position in Realtime.

That means there are two important criteria to evaluate position feedback systems:

1. How accurate and repeatable are the position data?
   Important specifications: Accuracy; Cyclic Error; Pitch; Hysteresis; Thermal Expansion Coefficient
   
   
2. How fast are the position data available for the controller plus additional data characterizing  dynamic behaviour?
   Important specifications: Maximum Speed; Maximum Acceleration
   For digital interfaces: Maximum Frequencies and Maximum Data transfer rate
   
   

Besides a standard feedback system, our axes offer multiple optional feedback systems in order to provide the best fitting solution for many different applications. Our UPF (Ultra Precision Feedback) option uses special Laser Interferometer Technology, eliminating disturbing influences of air pressure and humidity. The design also almost eliminates the influence of thermal gradients (*). It is completely integrated in the stage body and protected against external particles.

achievable data:

• Accuracy:                                                0,04 µm / 40 mm
• Resolution:                                              pm - Level
• Bidirectional Repeatability:                 < 0,001 µm
• Pitch:                                                         < 0,2 µm
• (*) Thermal Expansion Coefficient:    - 0,7 x 10^-6 1/K
• Interface:                                                  analog differential
• Data rate:                                                  < 10 µs

Braking systems in precision motion platforms must provide reliable holding performance without compromising positioning accuracy or introducing unnecessary thermal loads. Conventional electromagnetic spring-applied brakes require continuous electrical power to remain released during normal operation. The resulting power dissipation generates heat directly within the motion system, creating additional thermal gradients that can affect positioning stability. In vacuum environments, where convective heat transfer is not available, this thermal energy cannot be dissipated efficiently and therefore becomes a significant limitation.

To avoid these effects, the motion system utilises a braking principle that only requires energy when the brake changes its operating state. Electrical power is applied to engage the brake and again to release it, while no continuous energy input is required to maintain either condition. Eliminating permanent power consumption prevents unnecessary heat generation within the braking system and significantly reduces the thermal load introduced into the motion platform during normal operation.

The brake is designed exclusively as a safety function to securely hold the axis in the event of power loss or emergency conditions. Position control and process stability remain entirely under closed-loop servo control, avoiding the positioning inaccuracies that can result from using mechanical brakes as part of the motion control process.

The same braking principle also enables controlled dynamic braking of air bearing systems. Rather than abruptly stopping the axis, braking energy is introduced in a controlled manner to support rapid settling while preserving the dynamic characteristics of the frictionless guidance system. The result is a braking system that combines reliable fail-safe operation with minimal thermal influence on the motion platform, enabling stable positioning performance under demanding operating conditions, including vacuum applications.