Sensor adjustment with polymer-based linear technology: an introduction
Bastian Mehr | 8 April 2020 (Edited by Shizu Yamaguchi)
Linear adjustment systems for sensors and cameras are used in a wide variety of applications, ranging from machine vision to inspection systems, test setups, and custom camera rigs. In this blog post, we’ll explain how polymer-based linear adjustment systems offer a simple, clean, and reliable way to position sensors and cameras. Practical considerations for design are discussed to help you find the right solution, starting with a comparison between polymer-based linear systems and traditional ball bearing designs.
Polymer-based and ball-bearing-based designs
A key difference between these systems lies in how movement is generated.
Polymer-based linear systems use a sliding mechanism in which plastic liners move directly along aluminum or stainless-steel guide surfaces. Solid lubricants are embedded within the plastic liners, enabling quiet, smooth, and dry-running operation, in addition to having a high resistance to dirt, dust, corrosion, and contamination.
Unlike recirculating ball bearing systems, these linear systems do not require grease, which reduces debris buildup and lowers the risk of lubrication-related failures. Industry studies estimate that roughly 70–80% of bearing failures are associated with lubrication and contamination issues (combined).
In addition, polymer-based linear bearings are especially well suited for short-stroke applications. In conventional recirculating ball bearing systems, very short strokes may not allow the balls to fully recirculate through the lubrication path or oil film area, reducing lubrication effectiveness over time. Polymer-based bearings avoid this limitation because they operate without external lubrication, making them more reliable in repetitive short-stroke movements.
As a result, igus polymer linear systems are particularly suitable for precision positioning applications involving frequent small adjustments, such as sensor positioning and camera alignment, where environmental disturbances such as dirt, dust, moisture, vibration, or contamination can negatively affect the performance and reliability of conventional lubricated ball bearing systems.
Options for linear systems offered by igus
igus offers many options to suit various application requirements. Units that are assembled from individual components are available, as are those that are ready‑to‑install, depending on your needs.
Typically, these linear systems are built of aluminum, but where additional corrosion or chemical resistance is required, stainless steel versions are available. Both types operate without grease or oil and are therefore maintenance-free.
Compact linear units such as the SLW or SHT series are particularly well suited to sensor and camera adjustment tasks. They provide stable, precise linear motion and can be configured for manual adjustment using a trapezoidal thread and hand wheel or automated adjustment using a motorized drive.
In addition, service‑life calculators and downloadable CAD data support efficient integration.
Manual versus motorized adjustment
The choice between manual and motorized adjustment depends largely on how often repositioning is required.
Manual adjustment is typically sufficient when sensors or cameras are set just once at the start or adjusted only occasionally. Motorized adjustment may be preferred when positioning needs to be changed remotely or more frequently. Both options can be implemented within polymer-based linear systems, allowing consistent performance regardless of the chosen adjustment method.
Additional design considerations
Although linear systems offered by igus are durable and easy to use, certain design factors should be taken into consideration.
Polymer liners allow small amounts of elastic give, making careful control of clearance and expansion essential.
In dynamic applications, oscillations generated by motors or surrounding processes can be transmitted to the sensor or camera if not properly managed. These effects can be reduced during installation by selecting tighter tolerance classes for bearing liners or by using adjustable pillow blocks to set clearance more precisely.
The mass of the moving components and their centre of gravity must also be considered. If these factors are overlooked during system selection and sizing, the system may feel sluggish or less precise.
Online tools and technical support across Canada are available to support correct component selection and system dimensioning.
What’s next
We’ve now covered how these polymer-based linear systems are different from ball bearing-based systems, in addition to their design considerations and options.
We welcome you to get in touch with our technical team by phone at 1-800-965-2496, live chat at www.igus.ca, or web appointment. Feel free to request an in-person or web meeting with your local representative. We are looking forward to assisting you with your application.
