(Physik Instrumente: Karlsruhe, Germany) -- Physik Instrumente (PI), a global leader in motion control and high-precision automation technologies, offers custom precision gantry motion systems engineered for high-accuracy industrial applications like inspection, metrology, laser processing, micro-assembly, and high-end 3D printing. Designed and fabricated by PI’s U.S. operation in Hopkinton, Massachusetts, this system reflects PI’s commitment to reliable, locally manufactured, precision automation solutions.

Balanced design for rigidity and responsiveness

With three standard gantry product lines (A-341, A-351, A-352), including air-bearing and mechanical-bearing designs, PI’s engineering team can quickly modify and optimize gantries for specific customer applications. All designs leverage FEA-backed development to ensure structural rigidity without unnecessary mass, addressing one of the seven core engineering challenges in gantry systems: maintaining stiffness across long spans.

Absolute sensors and friction-free motors provide for accuracy and motion quality

Equipped with absolute linear encoders delivering 1 nm resolution, PI’s precision gantry systems eliminate time-consuming homing cycles and ensure outstanding positional accuracy. The ironless, friction-free, cog-free motor architecture delivers smooth, vibration-free motion with fast acceleration and exceptional velocity control.

Motion controllers with built-in gantry intelligence

Modern precision gantry systems must address complex coordination issues—especially racking caused by drive mismatches in dual-driven bridges. PI solutions mitigate such errors through ACS motion controllers that support gantry-alignment routines to compensate for angular misalignments, using virtual rotation axes. Special gantry yaw control algorithms also allow for active rotation (Theta-Z) while locking the linear axes when the gantry is equipped with flexure joints.

Dynamic capabilities for real-world performance

• Typical travel ranges: 300 mm–2 m
• Number of axes: From 2 axes to 10-plus axes; integration of hexapods and piezo nanopositioning stages
• Top speed: Up to 2 m/s on the cross-axis
• Advanced features: Dynamic error mapping, optional water-cooling, and drag-chain cable carriers for high-duty applications
• Z-axis options: Choose between ball-screw or linear-motor-based vertical motion, with magnetic or pneumatic counterbalance for load balancing and smooth vertical dynamics

Event synchronization and cable management

Timing precision is critical when coordinating motion with process steps like imaging or laser activation. The hardware-timed outputs, synchronized directly with encoder feedback, ensure flawless event positioning—eliminating image blur or part misplacement. Additionally, thoughtful cable management, including specialized drag-chain routing for clean environments, ensures reliable repeatability.

Gantry vs. split-bridge configurations

When the flexibility of an overhead gantry isn’t required, granite-based split-bridge systems are available as an alternative.

Industry-leading control platform

Every gantry is powered by PI’s ACS-based motion controller with EtherCAT integration, offering high-performance servo control, gantry-specific error compensation, and a comprehensive set of software development tools, simplifying integration and speeding time to operation.

Industries served

• Optical inspection
• Photonics test
• Laser processing
• Semiconductor metrology
• Micro-assembly
• 3D printing
• Medical component manufacturing