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Flexible planetary gearheads: Quiet, extremely robust

FAULHABER GPT gearheads for miniature and micro motors deliver high power density, exceptional flexibility, and excellent cost efficiency. Designed for seamless integration with diverse motors and encoders, these compact planetary drives feature hardened stainless steel components that reliably withstand extreme torques and abrupt load changes. Offered in standard, low-noise, and high-torque variants, they ensure precise, durable performance across wide operating temperature ranges.
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What is a low-waving linear motion guide?

If you are having a problem with your linear guides not always staying perfectly straight during use, it may be due to a phenomenon called waving -- a problem that is particularly critical in high-precision markets such as semiconductor and LCD equipment-related applications or machine tools. Thankfully, THK has an answer.
Read the full article.

NORD serves up sweet energy and cost savings for industrial bakeries

NORD DRIVE-SYSTEMS offers robust, highly configurable drive solutions designed to optimize efficiency, ensure hygiene, and reduce the TCO for automated bakery systems. From industrial-scale mixing and portioning to baking, cooling, and packaging, NORD's modular product portfolio delivers precise, reliable performance across every stage of production.
Read the full article. You may learn something even if you are not in the baking industry.

Key considerations for battery-powered motors

Battery-powered motor applications require careful design considerations to pair motor performance and power consumption profiles in concert with the correct battery type. This Power Electric article covers power requirements, performance considerations, and battery choices to assist you in selecting an efficient motor and a battery with the appropriate capacity. Good technical info.
Read the Power Electric technical article.

Driving next-gen pump and fan applications: Sinamics G210X

The Sinamics G210X is a new frequency converter for advanced pump, fan, and compressor applications, combining easy engineering with robust design. Integrated functions, seamless TIA Portal integration, and a web server reduce PLC effort to speed up commissioning, operation, and diagnostics. IP55 protection, 3C3 coating, and S2 system redundancy ensure reliable operation in demanding environments.
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New Exlar food-grade actuator

Curtiss-Wright's Actuation Division has expanded its Exlar line with hygienic electric actuators using FDA-approved materials and finishes. Designed for food, beverage, packaging, and pharmaceutical automation, the new GTF unit enables economical USDA, 3-A, BISSC, and EHEDG certification. Its IP69K washdown option, inverted roller screw, and compact servo-driven design deliver reliable, high-performance motion for hygienic machinery.
Learn more.

New Texas conveyor system is 42 miles long!

SEW-EURODRIVE is helping power one of the most ambitious bulk material handling projects in North America through its contribution to the Dune Express conveyor system, a record-setting 42-mile single-flight conveyor across the Permian Basin.
Read the full article.

Compact servo drives for harsh environs

Built on Copley's proven NanoPlus platform, the compact, 1.2-oz R-Series Nano servo drives withstand extreme temperatures, vibration, shock, and humidity. Available in R47 (CANopen) and R48 (EtherCAT) models, they suit space-constrained, harsh environments such as mil/aero robotics and gimbals. This commercial off-the-shelf series provides a hardened option without defense-specific development lead times.
Learn more from Copley Controls.

Hybrid actuator with force up to 14,726 lb

Kyntronics' new all-electric HyCore hybrid actuator is a compact, low-cost alternative to traditional hydraulic, pneumatic, and electro-mechanical systems. Engineered for OEMs, it delivers up to 14,726 lb of force. The self-contained design eliminates leaks and wear, providing precise control, shock-load tolerance, and high efficiency. It simplifies integration and lowers operating costs for mobile equipment, packaging, assembly automation, and more.
Learn more.

SDP/SI motion products: Best sellers

SDP/SI's best sellers aren't just popular -- they're proven. These are the motion components their customers return to time and again for precision, reliability, and unbeatable value. From belts and pulleys to gears, bearings, and couplings, each product has earned its place through consistent performance in real-world applications.
Learn more and see the full products list.

Automated part grinding and finishing in one unit!

Grinding large fabrications is a classic dull, dirty, and dangerous task perfectly suited for automation, yet traditional setups require multiple costly robots. At Automate 2026, Güdel debuted a single-robot solution that utilizes two extra degrees of freedom to finish massive surfaces without complex part repositioning.
Read the full article.

Rockford RBS ball screws and nuts now available

Automation-Direct now offers US-manufactured RBS ball screws and nuts for precise linear motion in OEM and maintenance applications. Achieving over 90% efficiency, they feature low friction, high accuracy, and minimal wear. Available in various diameters, lengths, and leads, these precision-matched components handle axial loads with minimal backlash, providing a dependable solution that reduces maintenance and extends operational life. Great prices too.
Learn more.

Next-gen conveyor transports 3,000-kg payloads

Building on its established portfolio of twin-strand conveyors that are currently used in a variety of industry verticals, Bosch Rexroth is introducing the TS 7plus transfer system, which is the world's first freely configurable, fully electric conveyance solution to workpieces weighing up to 3,000 kg. TS 7plus transports material via conveyor rollers on freely configurable modular sections with lift/transverse, rotary, and positioning units, as well as stop gates. Great for automotive, battery, aerospace/defense, and more.
Learn more.

Next-generation air bearing linear slide

The A-123 noncontact nanoposi-tioning stage integrates a brushless motor, air bearings, and a 1-nm encoder, supporting 40-kg payloads over 750-mm travel. Its pressurized air film eliminates the friction, wear, and vibration of mechanical stages, ensuring zero particle generation. Customizable with options such as granite bases and isolation systems, it is ideal for semiconductor metrology, inspection, photonics, and more.
Learn more.

How to implement redundancy in stepper motors

Some of the recent research activities in the area of electric motor drives for safety-critical applications (such as aerospace and nuclear power plants) are focused on looking at various fault-tolerant motor and drive topologies. After discussing different solutions, this article focuses on a miniature permanent magnet (PM) stepper motor design that provides increased redundancy.
Read this informative FAULHABER article.

Satellite plasma thrusters could be much more powerful -- if they were smaller

The glow of the plasma from the H9 MUSCLE Hall thruster during a test with krypton propellant. [Credit: Plasmadynamic and Electric Propulsion Laboratory]

 

 

 

 

By Kate McAlpine, University of Michigan

Traditionally, it was thought that Hall thrusters, an efficient kind of electric propulsion widely used in orbit, need to be large to produce a lot of thrust. Now, a new study from the University of Michigan (U-M) suggests that smaller Hall thrusters can generate much more thrust -- potentially making them candidates for interplanetary missions.

"People had previously thought that you could only push a certain amount of current through a thruster area, which in turn translates directly into how much force or thrust you can generate per unit area," said Benjamin Jorns, U-M associate professor of aerospace engineering who led the new Hall thruster study presented at the AIAA SciTech Forum in National Harbor, MD, Jan. 24, 2023.

His team challenged this limit by running a 9-kW Hall thruster up to 45 kW, maintaining roughly 80% of its nominal efficiency. This increased the amount of force generated per unit area by almost a factor of 10.

Whether we call it a plasma thruster or an ion drive, electric propulsion is our best bet for interplanetary travel -- but science is at a crossroads. While Hall thrusters are a well-proven technology, an alternative concept, known as a magnetoplasmadynamic thruster, promises to pack much more power into smaller engines. However, they are yet unproven in many ways, including unit lifetime.

Hall thrusters were believed to be unable to compete because of the way they operate. The propellant, typically a noble gas like xenon, moves through a cylindrical channel where it is accelerated by a powerful electric field. It generates thrust in the forward direction as it departs out the back. But before the propellant can be accelerated, it needs to lose some electrons to give it a positive charge.

The team at the PEPL lab poses for a photo near the new Hall thruster. Leanne Su, lead author of the study, kneels with a print of the mission patch. From left in the back: Christopher Sercel, Thomas Marks, Madison Allen, Parker Roberts, Will Hurley, Benjamin Jorns (U-M associate professor of aerospace engineering and senior author of the study), and Tate Gill. [Credit: Marcin Szczepanski/Michigan Engineering]

 

 

 

 

Electrons accelerated by a magnetic field to run in a ring around that channel -- described as a "buzz saw" by Jorns -- knock electrons off the propellant atoms and turn them into positively charged ions. However, calculations suggested that if a Hall thruster tried to drive more propellant through the engine, the electrons whizzing in a ring would get knocked out of the formation, breaking down that "buzz saw" function.

"It's like trying to bite off more than you can chew," Jorns said. "The buzz saw can't work its way through that much material."

In addition, the engine would get extremely hot. Jorns' team put these beliefs to the test.

VIDEO: Advances in Thruster Technology Lead the Way to Mars. [Credit: Michigan Engineering]

"We named our thruster the H9 MUSCLE because, essentially, we took the H9 thruster and made a muscle car out of it by turning it up to 11 -- really up to a hundred, if we're going by accurate scaling," said Leanne Su, a doctoral student in aerospace engineering who presented the study.

They tackled the heat problem by cooling it with water, which let them see how big a problem the buzz saw breakdown was going to be. Turns out, it wasn't much trouble. Running with xenon, the conventional propellant, the H9 MUSCLE ran up to 37.5 kW, with an overall efficiency of about 49%, not far off the 62% efficiency at its design power of 9 kW.

Running with krypton, a lighter gas, they maxed out their power supply at 45 kW. At an overall efficiency of 51%, they achieved their maximum thrust of about 1.8 Newtons, on par with the much larger 100-kW-class X3 Hall thruster.

"This is kind of a crazy result because typically, krypton performs a lot worse than xenon on Hall thrusters. So it's very cool and an interesting path forward to see that we can actually improve krypton's performance relative to xenon by increasing the thruster current density," Su said.

Ph.D student Will Hurley leaves the chamber where the new Hall plasma thruster is tested at the PEPL lab. [Credit: Marcin Szczepanski/Michigan Engineering]

 

 

Nested Hall thrusters like the X3 -- also developed in part by U-M -- have been explored for interplanetary cargo transport, but they are much larger and heavier, making it difficult for them to transport humans. Now, ordinary Hall thrusters are back on the table for crewed journeys.

Jorns says that the cooling problem would need a space-worthy solution if Hall thrusters are to run at these high powers. Still, he is optimistic that individual thrusters could run at 100 to 200 kW, arranged into arrays that provide a megawatt's worth of thrust. This could enable crewed missions to reach Mars even on the far side of the sun, traveling a distance of 250 million miles.

The team hopes to pursue the cooling problem as well as challenges in developing both Hall thrusters and magnetoplasmadynamic thrusters on Earth, where few facilities can test Mars-mission-level thrusters. The amount of propellant exhausting from the thruster comes too fast for the vacuum pumps to keep the conditions inside the testing chamber space-like.

Published February 2023

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