Design Considerations Accuracy & Repeatability
Accuracy Instead of providing you with an in-depth discussion on
The difference between accuracy and repeatability is widely each of these errors, we would like to give you just a little
misunderstood. Accuracy in a positioning system is much insight on each. Understanding that these errors exist will
harder to achieve than repeatability, and it is also more help you realize that every positioning system manufactured
expensive to accomplish. Applications like part insertion, will exhibit some, or all, of these errors. Even systems you
pick & place, and simple inspection stations require good design yourself will have inaccuracies associated with it.
repeatability, not necessarily accuracy. Why? Because once LINTECH takes many steps to minimize these errors in our
you have programmed the electronic motion controller & positioning tables, thus providing you with a cost effective,
mechanical positioning table to position a load to a given accurate, and repeatable positioning system.
location, you are typically more concerned as to how well
the system can return to that location. Repeatability of the Linear bearing & structure inaccuracies include:
overall system becomes important for the application. The * angular (roll, pitch, & yaw)
inaccuracies in the above systems can be offset by instruct- * vertical runout (flatness)
ing the electronic motion controller to move a little bit * horizontal runout (straightness)
more, or a little bit less. On the other hand microscope XY
inspection stands, semiconductor wafer probing machines, Some of the sources of these errors are:
and coordinate measuring machines require both good * straightness of the linear rail
repeatability and high accuracy. Why? Because for these * entry & exit of recirculating balls in the linear bearings
applications to be successful, they need to be very accurate * variation of the preload when moving along the rails
(in the truest sense) when making a move from one location * contaminants between linear bearings & rails
to another. Many positioning system applications in the real * machining of the rail mounting surface on the table
world require high repeatability, not necessarly high * machining of the base, carriage, and other components
accuracy.
Accuracy is described as how well a positioning system Yaw
Axis
makes a true relative move in reference to an absolute 3D
X
location. In essence, if we lived in a perfect world, when a
Y
positioning system makes a 1.0 inch (25.4 mm) move, it
truly moves 1.0 inches (25.4 mm). However, there are
mechanical errors associated with every positioning system.
These errors will cause the positioning system to be less
than perfect when making moves. Move distances that will Pitch
Roll
be something different than what were truely desired. Axis
Axis
horizontal runout
(typical yaw deviation)
Z
Accurate Not Accurate
Repeatable Repeatable
Y Straightness
X
Flatness
vertical runout
(typical pitch deviation)
Linear Axis Bearing & Structure Errors
Accurate Not Accurate
Not Repeatable Not Repeatable
A-30 LINTECH ® Positioning Systems
Design Considerations Accuracy & Repeatability
Accuracy - Continued For both screw and belt driven tables position accuracy is
Linear bearing & structure inaccuracies will cause a not a linear relationship. In fact, all the error within any 12
positioning system to move something other than what is inch (300 mm) segment of travel could occur in say just 2 A
desired. LINTECH includes these errors in the overall inches (50 mm). Also, the value in/ft error is a maximum
"Position Accuracy" value described below. LINTECH also (no worse than) value. Some 12 inch segments could have a
provides flatness & straightness specifications for each table value better than the stated position accuracy. Following is
series. These values can be used as a general gauge to the an example of the potential position accuracy for a given
overall linear bearing & structural quality of a positioning table.
table. The better these values are, the better the accuracy &
repeatability of the positioning table will be. * 48 inch travel table with a 0.003 in/ft position accuracy
Travel Actual Error Occured Total System
Inaccuracies in the linear drive mechanism of a position- Length Error Between Error
(inches) (inches) (inches) (inches)
ing table also contributes to its overall position accuracy.
LINTECH provides acme screw, ball screw, and belt driven 0 to 12 .002 2 to 5 .002
linear positioning tables.
12 to 24 .001 7 to 9 .003
Linear drive mechanism sources of errors include: 24 to 36 .003 1 to 6 .006
* lead error of the screw
36 to 48 .001 4 to 11 .007
* end support mounting of the screw
* nut and screw quality & wear
* lead error of the belt
* belt stretch
* end pulley quality & alignment
The lead error of the belt, or screw is a main factor affect- Desired
Positioning
ing the accuracy of a positioning table. It is important to Error Move
realize that these inaccuracies are not linear. These errors in
fact are non-linear, and their value is typically given in the
Actual
form of inches/foot (microns/300 mm). Move
Position accuracy is a value given by LINTECH for each
single axis table series that can be used to estimate what the
potential accuracy (or inaccuracy) will be for any given
travel. Because LINTECH provides many different acme
screw, ball screw, and belt drive options, along with many
different standard table travel lengths, this position accuracy
value is given in the form of inch/ft (microns/300 mm).
This allows you to quickly estimate what the position
accuracy might be for a given table series, linear bearing,
drive screw (or belt), and travel length.
The key here is to realize that position accuracy is an
estimation. Typically, no two positioning tables (even Assumed
Positioning Error
Linear
though they are manufactured with all the same compo- Positioning
nents) will exhibit exactly the same position accuracy Error
throughout their entire travels. Actual
Positioning
Error
Testing (or mapping) of a given positioning table could be
performed to determine what the true accuracy is over each
12 24 36 inches
inch of travel for a given system. However, this testing (300) (600) (900) (mm)
should be performed with the positioning table mounted in Move Distance
the user's application with all loads attached to the carriage.
Position accuracy of a system can change based upon
mounting surfaces, loads, and environment conditions which
includes temperature.
LINTECH ® Positioning Systems A-31
Design Considerations Accuracy & Repeatability
Accuracy - Continued
Rotary positioning table accuracies deal with the bearings
that carry the load, the worm gear used to drive the load, Runout
and all associated precision machined components. (vertical) CL Wobble CL
(axis runout)
Runout is defined as the vertical deviation (inches or mm)
measured throughout one full rotation of the table top. The
300 series rotary table has a precision option that provides a
smaller runout deviation over the standard unit.
Wobble (axis runout) is defined as the angular variation
from the true centerline of rotation throughout one full
rotation of the table top. The 300 series rotary table has a
precision option that provides a smaller angular variation
over the standard unit.
Concentricity (radial runout) is defined as the deviation
(inches or mm) between a perfect circle and the path the
table top takes throughout one full rotation of the table top.
The 300 series rotary table has a precision option that
provides a smaller radial deviation over the standard unit. Concentricity
(radial runout)
Position accuracy of a rotary table is directly related to the
precision machined worm gear assembly. The arc-second
accuracy value is not dependent upon gear ratio. However, Rotary Axis Errors
over time (wear of the worm gear) the accuracy can change
depending upon the application.
A-32 LINTECH ® Positioning Systems
Design Considerations Accuracy & Repeatability
Repeatability Horizontal Applications - Unidirectional Repeatability
The repeatability of a positioning system is defined as how
accurate, over successive move attempts, a table can return A
to a known, previously traveled location. The direction of Travel to the desired
location is always from
travel can either be from one side (unidirectional), or from the same direction
both sides (bidirectional). Highly repeatable systems (which
may or may not be accurate) return to a known location
with very little deviance from one move to the next.
The bearings, table structure, operating environment, table
orientation and the drive mechanism all play a part in the
repeatability of a positioning table for a given application.
Horizontal Applications - Bidirectional Repeatability
Mounting high quality precision bearings to a precision
machined table structure will help make a positioning (Unidirectional Repeatability + Backlash)
system more repeatable. Operating a positioning table in an
environment that has wide swings in temperature (and/or
large vibrations), will adversely affect the repeatability of a Backlash
Travel to the desired
system. Mounting a table in a vertical orientation has the location is from either
benefit of eliminating (with no reversing force) backlash. direction
The drive mechanism can (and will) influence the repeat-
ability of a positioning table. Using a higher accuracy grade
screw for example will typically yield a better repeatability
for the system. Besides playing a part in the unidirectional
repeatability of a table, it can have a larger impact on the
bidirectional value by dealing with backlash. Backlash in a
belt driven positioning table consists of stretching, wear
and tension of the belt, along with the individual manufac-
turing tolerances of the belt & pulley assembly. Backlash in
a belt driven table is virtually impossible to eliminate. Vertical Applications (No reverse force)
Backlash in a screw driven positioning table can be
eliminated by using a preloaded nut assembly, thus the Bidirectional = Unidirectional
unidirectional & bidirectional repeatability will be the same. Repeatability Repeatability
For applications requiring good bidirectional positioning, a
preloaded nut assembly should always be used. Backlash in
a worm gear assembly is also virtually impossible to
eliminate. Therefore, to maintain a high level of repeatabil- Reverse Force
ity, approach a known location from the same direction. An upward force acting on
a nut; such as when
inserting a part (moving in
It should also be noted that the overall repeatability of a a downward direction) into
another part.
positioning table within a given application is highly
location is from either
dependent on the electronic motor/drive controller.
Travel to the desired
The majority of applications require a highly repeatable
positioning system, and not necessarily an accurate one.
Therefore, more attention should be given to the repeatabil-
direction
ity specification of a table than position accuracy.
Reverse Load
LINTECH ® Positioning Systems A33
