The portfolio includes fully motorized, software-controlled systems as well as mechanical stages that can be motorized. This gives users the option of choosing either a complete motorized system or a configuration based on mechanical stage setups.

The product range includes off-the-shelf motorized stages and accessories for system assembly and procurement. For multi-axis applications, software-controlled stage families such as those from Zaber support integration and control through features including daisy-chain connectivity and virtual configuration tools that can be used to review system setups in advance.

For applications that require mechanical stability and positioning accuracy, Edmund Optics offers TECHSPEC motorized stages with monobloc construction intended to reduce alignment error and support repeatable motion. These systems are designed to work with other TECHSPEC components, allowing combinations of motorized and manual axes in the same setup, along with piezo-assisted motion for fine positioning applications.

The range includes motorized stage configurations for both linear and rotary motion across different application types. Options are also available for vacuum and life science environments, along with related accessories. Edmund Optics also offers a broader catalog of optics, imaging and photonics components, allowing users to source motion and optical system components from one supplier.

For more information, visit edmundoptics.com.

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A redesigned personal space

The personal space has been updated to improve navigation and make key information easier to access.

The main menu has been moved to the top of the page, allowing users to browse more easily through cards that provide access to personal information and the cart, with a layout designed to improve clarity and reduce search time.

An optimized search bar

The search bar has been updated to improve result accuracy and help users locate relevant products more quickly.

Using AI and a database of more than 130,000 Rollon product codes, the search can recognize full or partial references, including entries starting from six characters and provides a brief overview of the matched reference. This update helps speed up the process of identifying suitable components.

myRollon: a digital tool for linear motion selection and configuration

myRollon is designed to help users identify suitable linear motion solutions, configure products based on application requirements, and access technical resources. The platform includes three main tools:

• Selection Tool: Analyzes operating conditions, dimensions, and loads to suggest suitable solutions based on performance and cost and generates a technical report for each search.
• Configurator & Interchange: Allows users to define product configurations, generate product codes and request quotations. It also enables users to enter an existing product code and receive a compatible alternative from Rollon’s portfolio.
• Product Center: Provides access to 3D CAD files, technical documentation, installation guides and additional product information.

Users can save, revisit, and modify their activities on myRollon at any time, supporting a flexible workflow for engineering and design tasks.

For more information, visit rollon.com.

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Festo has expanded its ELGD rodless electric actuator family to address these requirements. The updated ELGD-TB toothed belt and ELGD-BS ball screw models offer increased load capacity, stiffness, and configuration options while maintaining a compact design. The actuators also provide higher force capability, longer stroke lengths, and additional mounting options, allowing OEMs to increase performance without modifying the surrounding machine structure.

Machine builders have access to a wider range of axes designed for quick configuration, global availability, and compatibility with Festo servo drives and motion tools. The expanded ELGD family is part of the Festo FAST program, with standard models stocked in the U.S. for shipment within one day.

The ELGD family supports a range of electric motion applications, including pick-and-place, packaging, laboratory automation, assembly, gluing, and light machining. The actuators can be used as standalone axes or integrated into gantry and Cartesian systems with Festo drives and controllers. Each unit is tested to verify performance based on Festo’s design tools, helping ensure that system performance and accuracy meet specified requirements.

The ELGD family integrates with Festo’s digital engineering tools to support specification, sizing, and configuration of electric motion systems. The Electric Motion Sizing tool allows engineers to select actuator, drive, and motor combinations for single-axis applications. ELGD axes are also included in the Festo Handling Guide Online, which supports multi-axis configuration of axes, drives, motors, and accessories.

Clean, sealed, and easy to integrate

The expansion includes new ball screw and toothed belt versions designed for higher forces, longer strokes, and increased rigidity. Stroke lengths reach up to 8.2 ft for ball screw drives and 27.9 ft for toothed belt versions. For lower-force applications, the wide-body ELGD-WD weighs about 30% less than larger units while maintaining similar rigidity and guide load capacity.

The bearing and carriage design supports smooth motion, reduced vibration, and increased torque capacity, allowing machine builders to configure axes for both precision and high-speed applications.

The actuators integrate with the newest Festo CMMT-AS and CMMT-ST servo drives and EMMT-AS servo motors and EMMT-ST stepper motors. Festo also offers motor mounting kits for third-party motors.

For customers that need under-machine mounting, the ELGD now includes an option for direct mounting installation. The under-machine mounting option simplifies the design in tight envelopes.

A stainless-steel cover strip with magnetic deflection protects against particle ingress and wear for a longer and more trouble-free service life. And the actuator includes a breathing port that allows a flow of sealing air, typically 0.1 to 0.2 bar, creating positive internal pressure to prevent contamination in dirty work environments. ELGD also supports cleanroom, laboratory, and industrial applications where cleanliness and reliability are critical by applying vacuum to the breathing port.

OEMs benefit from the company’s global engineering and manufacturing network, standardized components and digital tools that shorten project timelines.

For more information, visit festo.com.

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Very briefly, I want to say from 1987 to about 1988, I played such games with such a setup in my bedroom of all places. It was a massive hand-me-down Texas Instruments beast from my engineer uncle Rob that put the load capacity of its laminate-oak computer-station perch to the test. Most likely it was a TI-99/4A with a TI-99 Peripheral Expansion Box … complemented by an old TV for a monitor, a sickly-beige keyboard, and (of course) a black and red joystick ruggedized to withstand abusively aggressive steering from sweaty little hands. I can work to confirm hardware details with family members if any Design World readers care to know for certain.

Into the expansion box would go a 5.25-in. disk labeled DOS followed by another labeled Parsec or Munch Man or something else equally hilarious. I’ve only just learned that “DOS” may have been TI’s disk operating system called Disk Manager (integrated with TI BASIC and Extended BASIC) and definitely not IBM’s MS-DOS for PCs.

Far and away my favorite game was TI invaders — Texas Instruments’ version of Space Invaders. A close second was Home Bound, an off-brand Frogger-like adventure. My mom or somebody copied the code wrong, so if your frog died, it really died — and it was back to the tedium of reloading the Disk Manager and then reloading the game with a determined vow not to mess up again.

An informal survey of my cousins via text has revealed that some of us were especially traumatized by the TI game called Hunt the Wumpus. Blindly bumbling through a cave system, the player endured tense fear of being suddenly devoured by the lurking Wumpus. 8-bit-esque In the Hall of the Mountain King by Edvard Grieg accompanied the deadly jaws closing ‘round.

 Unlike more mainstream systems, these computers demanded patience during a slow boot sequence that felt like an eternity to a 10 year old. In hindsight, I also realize the user interface and startup menus were also quite weird: DO YOU NEED INSTRUCTIONS? CONTROLS: ARROW KEYS. USE S/D TO LICK BEE. FREE FROG EVERY 1000 POINTS. GOOD LUCK… PRESS ANY KEY.

For me, the kooky games on this inscrutable system were early lessons in algorithmic thinking while making programming feel at least approachable. I don’t think it’s a coincidence that several Gen-Xer cousins in my family who got to goof around with these old TIs are in engineering and other technical fields requiring a good deal of persistence and tolerance for muddling through.

— Lisa Eitel · linkedin.com/in/elisabetheitel

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Rebecca McWilliam · Director of engineering — Iris Dynamics | irisdynamics.com

Linear motors behave differently than rotary motors — so how does their electrical power consumption relate to force and heat? Well, current through the windings of tubular linear motors generate magnetic fields that interact with the shaft’s permanent magnets. This interaction prompts force and motion output. There’s a caveat, though — current passing through the windings also generates heat that must be dissipated to prevent damage to the magnetic shaft, integrated electronics, and windings themselves. Even when damage isn’t imminent, this thermal behavior impacts the motors’ performance in advanced automation, robotics, and precision motion systems. Fortunately, there are way to reduce the thermal load with motion design, duty cycling, and cooling (whether passive or active).

Motor power and heat-generation definitions

For this discussion, we define steady-state temperature as the resultant motor temperature for a given power input that fluctuates no more than ±1° C over 30 minutes. Maximum force is that output by a linear motor when operating at maximum power. Continuous force is that output by a linear motor when operating at a given power.

Maximum power is that dissipated by a linear motor when operated at its peak output, which is only sustainable for a short period of time. Continuous power is the power dissipated by a linear motor when operated at steady state temperature for an indefinite period of time without overheating. Maximum continuous power is that dissipated by a linear motor in a room with still air at 20° C that brings the linear motor to a steady-state 70° C.

Long periods of high power draw, transient high-force events, hot environments, and impeded airflow can all cause excessive motor heating and thermal shutdown.

Force-power relationship: Motor force output is proportional to current, while resistive heating power scales with current squared — Force² ∝ Power. So, modestly reducing motor-force demand dramatically reduces heating. For example, halving force demand trims power dissipation to 25% while doubling the force increases heating fourfold. So, integrating mechanical components such as gears, pulleys, or leadscrews imparts an exponential reduction in thermal power.

Thermal limitations: Linear motors can be thermally limited by integrated electronics, magnets in the shaft, copper windings, and (in some cases) the need to maintain safe operating temperatures for machine personnel who may touch the motor. Most heat generated by a linear motor originates in the coil — with the amount directly proportional to power input and force output.

Tubular linear motors like other linear-motor subtypes have long thermal time constants (to minutes long) thanks to large thermal mass and relatively slow conduction from windings to housing to ambient air. So, they can tolerate high-force demands that are brief sans immediate risk of overheating, because the windings’ heat takes so long to raise the overall motor or integrated electronics’ temperature to dangerous levels. However, this also makes average power over some multi-minute interval a key expression of thermal stability.

Despite a long overall time constant, spikes in power draws can cause windings to exhibit rapid and localized heating. After all, copper coils react almost instantly to current heating — far faster than thermal energy can spread into the stator or chassis — meaning they can exceed their safe temperature limits even before the housing becomes warm.

Measures to prevent motor overheating

To prevent windings from overheating, feedback can keep input power to below thermal thresholds or cut power entirely if needed. Feedback can come from:

• Temperature sensors directly bonded to the coils for accurate feedback. Note that PCB-based temperature sensors can protect against accidental overdriving, but there’s a delay between coil energization and measurable warming of the PCB.
• A motor driver that integrates a joule counter. These use a thermal model to estimate realtime winding temperature and enforce safe limits.

Thermal shedding is another way to keep motors within thermal limits — by flowing heat from windings to stator to chassis (housing) to environment. Ambient temperature, airflow, and enclosure design directly affect how effective this shedding is. Fans boost convective cooling … and external motor fins, heat sinks, and conductive mounts boost conductive and radiative heat transfer. These together affect heat shedding and the continuous and intermittent force a motor can safely deliver.

Maximum vs. continuous power draw: Winding design, supply voltage, and electronics dictate maximum instantaneous power while motor thermal limits dictate maximum continuous power. Higher powers are okay for brief periods if average power remains below the continuous rating. For example, outputting 120 W for 60% of the time and 70 W for 40% of the time results in an average power of 100 W.

Thermal capacity: Motor copper, epoxy, and chassis can all safely absorb a certain amount of heat … yet eventually, heat saturates the assembly with heat energy Q = C⋅ DT where C is the motor’s overall thermal capacity and DT is the change in temperature.

Thermal shedding: The efficiency with which heat transfers from motor windings to the environment ultimately governs the continuous force rating. This largely depends on motor housing surface area which in turn depends on motor size.

K_f’ motor force constant: This expresses the efficiency with which a motor turns power into force in Newtons per square root Watts. A motor with a higher K_f’ means the motor will output more force for a given power draw. K_f falls as winding resistance climbs, and resistance increases with temperature (as power loss P_loss = I²R) so generating a given force at hotter temperatures takes more current. In fact, this is the cause of thermal runaway.

Ambient temperature: When a linear motor must operate in a hot factory setting or in a confined space, its force must be derated, and a larger motor may be required. The required amount of derating depends on ambient temperatures:

As ambient temperature approaches the motor’s thermal limits, the acceptable amount of time for maximum power is more and more brief until it’s only instantaneously possible.

Ways to mitigate heat issues

Decrease average power: Effective thermal management starts with reducing average power draw because root-mean-square RMS force rather than instantaneous peak force causes sustained heating. Reduction is possible with gentler accelerations, smoother motion commands, reduced holding duty cycles, or and more mechanical advantage (as with spring or pneumatic assistance).

Reduce duty cycle: Shortening the duration of high-force events or spacing them farther apart can dramatically lower overall power draw and thermal load even when peak forces stay high. Rest periods leverage the motors’ long thermal time constants so accumulated heat is more effectively shed.

Decrease peak force: Lower peak-force demand reduces instantaneous current spikes that can cause rapid coil heating. Lowering peak force by half trims power draw by three-quarters. For example, outputting 200 N with a force constant of 15 N/√W takes 178 W. Outputting 180 N with 15 N/√W takes 144 W. Outputting 100 N with 15 N/√W takes 44 W.

Pneumatic and spring support: Where springs and pneumatics complement tubular linear motors to reduce power consumption, some controls’ PID loops settle to prompt only the force needed to hold position. Springs can introduce temperature-related performance drift, but for many tubular linear motors, spring-force offset can help trim power consumption. Plus, as long as the motor can apply enough force to fully compress or extend the spring, the latter is easy to calibrate so the axis still allows force sensing.

Cooling airflow: Some tubular linear motors have cooling fins on their housings for a large heat-dissipating surface area. If a fan is also used, its cooling effectiveness increases with stator size (and surface area). A single fan can increase continuous maximum power threefold (for smaller motors) to fivefold (for larger motors). More airflow boosts continuous maximum power, though with diminishing returns … especially in enclosed spaces where climbing ambient temperature can degrade cooling effectiveness.

Tubular linear motors mounted so all housing sides are exposed allows uniform convective cooling. Any installation that obstructs airflow to housing sides reduces the effective cooling surface.

Water cooling: Some tubular linear motors are IP68 rated, so can be cooled with water over the cooling fins. Water spray, constant overflow, or even full submersion can dramatically boost thermal performance.

This article is an adaptation of an Iris Dynamics piece. Check out other Iris Dynamics tutorials at irisdynamics.com/engineering-resources.

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Pneumatic actuators are clean-running but generally lack the force for pressing. Air-over-oil hydropneumatics can in some case meet the force and accuracy requirements of presses but tend to have low efficiency. Screw-based electromechanical actuation is another option delivering high precision, but presses’ shock and impact loads often preclude their use … or accelerate screw wear and accuracy degradation.

Related: Fluid Power World article library on presses

Yet another option for presses is hybrid electric-hydraulic actuation. Components of this type directly integrate a fluid cylinder with a servomotor that drives a pump. The latter in turn generates hydraulic pressure within the sealed actuator assembly so there’s no need for a centralized hydraulic power unit, external hoses, or reservoirs.

Output from these hybrid actuators is 100 to 150,000 lb precisely controlled to deliver specific positions, forces, speeds, and dwell times set by servo-level programming. The power-on-demand operation makes for energy consumption that’s lower than that of traditional hydraulic systems. Plus, a sealed actuator body minimizes maintenance requirements and prevents leaks.

Thanks to their hydraulic force transmission, hybrid actuators can also tolerate the shock loads commonly encountered in pressing applications.

Feedback with hybrid actuation

Digital transformation (DX) initiatives are putting ever-increased emphasis on digitally connected manufacturing. Such functions require actuation technologies for press equipment (such as hybrid actuation) with integrated force and position feedback, realtime monitoring, and cycle-level data collection. That’s especially true where manufacturing environments need traceable process data for quality verification and predictive maintenance.

Manufacturing operations are also moving toward more product variety and faster changeovers. Presses in such settings must quickly adapt to different process parameters.

Programmable hybrid actuation fits the bill for such flexible production lines with modifiable force, position, speed, and dwell profiles. Such actuators can even include force and position sensors for realtime cycle traceability, process validation, and automated pass-fail quality checks. Such connectivity also lets operations synchronize multiple hybrid electric-hydraulic actuators on especially high-force applications or machines that need to distribute force across large tooling structures.

Kyntronics | kyntronics.com

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NB Corporation of America has sales branch offices on the East and West coasts and continues to expand its sales network. Its NB Linear Systems use ball or roller elements to reduce friction compared with sliding bearings and support smooth, precise positioning. The design uses larger rolling elements and long raceways to increase load capacity and extend travel life, supported by Nippon Bearing’s global manufacturing presence.

For more information, visit nbcorporation.com.

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THK’s GL-N actuators are compact linear actuators intended for space-limited automation, positioning, and inspection applications. The series integrates guidance with the actuator to support controlled linear motion.

The GL-N-BS model uses an aluminum base and caged-ball LM guides and adds a QZ lubricator for the ball screw, which is intended to extend lubrication intervals and reduce routine maintenance.

The GL-N-B model uses an aluminum base and caged-ball LM guides for the guide system.

For more information, visit tech.thk.com.

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Both sensors are designed for industrial environments where dust, oil, lubricants and vibration are present. They carry an IP67 rating and offer accuracy better than 10 microns.

Key features

• Contactless magnetic measurement
• Reference marks or end positions can be set at user-defined locations
• Multiple or coded reference marks are available
• Accuracy better than 10 microns
• Rated IP67

IKS9

The IKS9 is an incremental sensor with AB signals and a reference channel. It supports push-pull and RS-422 (line driver) outputs and offers resolution down to 20 nanometers, depending on pole pitch. It connects via cable with an inline M12 connector.

Bogen says the IKS9 is intended for applications that require position, distance and speed measurement. The company lists use in robotics, handling systems, automation and medical technology. It can be used with magnetic tape for linear measurement and with magnetic rings for rotary measurement.

IKS15

The IKS15 provides a 1 Vpp sine/cosine output with a reference signal. It supports signal lengths of 1, 2, or 5 mm and offers AB plus reference. It also connects via cable with an inline M12 connector.

The company positions the IKS15 for automation, measurement and control applications that need configurable feedback. Like the IKS9, it can be paired with magnetic tape for linear measurement or magnetic rings for rotary measurement and it is listed for robotics, handling systems, automation and medical technology.

For more information, visit bogen-magnetics.com.

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No matter permutation, motors and their gearing connect to linear actuators via couplings such as zero-backlash bellows or elastomeric jaw couplings. Then the motor frame or gearbox housing mounts to the actuator body via machined aluminum or steel brackets. These are either standardized National Electrical Manufacturers Association (NEMA) mounts, metric flange mounts, or custom adapters to align the motor output shaft, coupling, and actuator input. Bracket flanges, pilot bores, tapped bolt patterns, or slotted bases enable fine-tuned alignment.

Gearboxes and motors may be separately specified for customization, but over the last two decades it’s become increasingly common for design engineers to specify motor-gearbox assemblies pre-integrated by the supplier for easy installation with minimal misalignment or backlash. Pre-integrated units also optimize performance by reducing actuator tolerance stack-up and boosting actuator-assembly stiffness.

For speed reduction and to suit application requirements, linear actuators employ planetary, spur, worm, and bevel gearing (as well as right-angle variations). For example, spur gearing offers simplicity and compactness with moderate torque and speed reduction for mid-range precision applications. Spiral and hypoid bevel gearing offers compact right-angle transitions and high torque density for space-constrained designs or linear actuators to mount on and operate vertical axes.

Most precision linear actuators with critical accuracy and repeatability requirements use ac motors (including servomotors) to get dynamic performance, torque density, and position control via closed-loop feedback and integration with a motion controller. However, another third or so of industrial linear actuators use dc motor variants such as brushless or stepper motors. Small linear actuators (especially those with leadscrews) employ brushed dc motors as well, though not usually for precision automation. Rather, these actuators often work in consumer products, powered elements in automotive interiors, and medical equipment.

Mount geometry for linear actuators

Most NEMA and metric motor mounts attach to the actuator drive end. Variations that accept right-angle or bevel gear drives feature side mounts; these can reduce actuator-assembly length in space-constrained machinery.

Mount brackets are made of machined aluminum or steel. Typical geometries include a square or circular flange with a center pilot bore (a precisely machined circular boss) and mounting holes in a standard array; four-bolt arrangements are common for average-sized motors. Mounting holes can be slightly elongated to facilitate slight adjustments.

The most common NEMA mount sizes are those for NEMA 17, 23, 34, and 42 motors. The numbers indicate the approximate dimensions of the motor faceplate. For example, a NEMA-23 motor has a 2.3 x 2.3-in. mount flange, and a NEMA-34 has a 3.4 x 3.4-in. flange. Even the bolt-circle diameters and tapped-hole patterns are standardized to allow interchangeability across motor brands and models.

Metric motor mounts follow International Electrotechnical Commission (IEC) standards or manufacturer-specific metric dimensions defined by flange diameter — 60 mm, 80 mm, 90 mm, or 115 mm, for example. The circular flange has a center pilot bore encircled by symmetrically spaced bolt holes or slots. Common sizes are IEC56, IEC71, IEC80, IEC90; again, these names denote specific flange diameters and bolt-circle patterns.

The special case of 12-volt linear actuators

Linear actuators are typically characterized by their drive mechanism — belt drive, ball or leadscrew drive, pneumatic drive, and so forth. But it’s not unusual for rod-style electric actuators to be classified by the input voltage — commonly 12 or 24 volts — of their integrated motors. These actuators provide thrust force, much such as a pneumatic or hydraulic cylinder. In fact, rod style electric actuators are widely used to replace pneumatic or hydraulic cylinders, due to their simplicity and the potential cost savings that can be realized by switching from fluid power to electrically driven motion.

As the name implies, a 12-volt linear actuator includes a 12-volt dc motor integrated into or tightly coupled with the actuator body. 12-volt actuators are driven almost exclusively by one of two mechanisms — a ballscrew or a leadscrew. Most designs incorporate gearing or use a gear motor to optimize the thrust and speed characteristics of the actuator. The most basic design includes a limit switch at each end of the stroke, meaning that the actuator fully extends and retracts, with no intermediate positioning. However, most manufacturers offer programmable limit switches as an option, for intermediate positioning capabilities.

Because these electric rod-style actuators are often used to replace hydraulic or pneumatic cylinders, some of their basic design features follow the precedents set by the other technologies. Mounting is a good example. A 12-volt linear actuator is typically mounted in the same manner as a pneumatic or hydraulic cylinder, with most having both clevis and trunnion mounting options. In some 12-volt linear actuator product lines, you’ll find body sizes and mounting options that meet ISO, NFPA, and other standards, which makes the conversion from a pneumatic or hydraulic actuator to an electrical actuator much simpler in existing applications.

Performance and selection: One of the most crucial differences between rod style and slider type actuators is that rod style actuators provide only thrust force. Their primary use is for pushing or pulling a load, via a tube or rod that extends and retracts from the actuator. While a plain bushing guides the rod, there are no linear guides to support and carry the load. In most applications, support and guiding for the load is provided by tracks or rails independent of the actuator. This operating principle explains why these actuators have several different monikers, including electric cylinders, thrust type actuators, and rod style actuators.

Sizing and selection of a 12-volt linear actuator is fairly straightforward, because the motor is preselected and integrated into the actuator. The first parameter to be considered is typically thrust, as it will often dictate the overall body size of the actuator. Next is stroke length, since a small actuator may meet the thrust requirements, but may not be able to achieve the necessary stroke length.

Like slider type linear actuators, rod-style actuators driven by a ballscrew or leadscrew can back drive. When the application requires vertical operation, remember to check that the vertical load doesn’t exceed the back driving torque of the screw.

With an initial actuator selection based on thrust force and stroke, the speed and duty cycle requirements can then be checked. The allowable force and speed combinations are typically provided by the manufacturer, in the form of a performance curve or chart. Once it’s confirmed that all other parameters are within the actuator’s capabilities, it’s important to check the needed duty cycle, or on time  — because motor heating can be a limiting factor for the actuator’s performance.

Suitable applications: Virtually any time a load must be pushed or pulled, without being guided or carried, a rod style actuator is a good choice. This includes opening and closing sliding doors in applications such as rail cars and machining centers. In the medical industry, 12-volt actuators are often used for ergonomic positioning of worktables or patient beds.

In conveying operations, these actuators are commonly used to stop or divert product along the conveyor, depending on the process requirements. And because they’re fully enclosed and available in IP-rated or hygienic designs, rod-style actuators are suited for the pharmaceutical and food and beverage markets, where purely thrust operations  (such as inserting, labeling, or stamping) are typical.

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