In industrial automation, repeatability isn’t just a feature — it’s a necessity.
When you’re running thousands of parts every day, even a 1 mm shift or 1-second delay can cause serious quality issues or rejections.
That’s exactly the problem one of our customers — a textile machine builder in Tiruppur — faced before switching to our electric motion units.
Let me tell you what happened.
The Challenge
Their old setup used pneumatic cylinders to move components back and forth in a dyeing machine. For the first few cycles, it worked fine. But as the air pressure fluctuated and the cylinder got warm, the movement started to vary.
Sometimes it stopped 2 mm ahead.
Sometimes it didn’t retract fully.
The machine operator had to keep adjusting the sensors and valves all day.
Result?
Inconsistent product quality and high fatigue for operators.
Our Solution
We replaced their pneumatic system with our electric motion unit – built with:
- Servo motor + ball screw drive
- Closed-loop control for position accuracy
- Programmable stroke, speed, and timing
- Repeatability up to ±0.01 mm
We integrated the unit with their existing PLC panel — no major changes. Within a day, they were running production.
What Changed?
The difference was immediate.
- The machine moved to exactly the same position every time
- No more trial-and-error adjustments
- Product quality became consistent across batches
- Operator effort reduced drastically
Their repeatability went from ±2 mm to ±0.01 mm — and they’ve been running the same unit for over a year now without a single failure.
Why Electric Motion Wins in Repeatability
Unlike air or hydraulic systems, electric motion doesn’t depend on fluid pressure, temperature, or external factors.
The servo motor knows where it needs to go — and it goes there. Every time. Without fail.
This is what makes electric motion the best choice for applications like:
- Assembly and fitting lines
- CNC automation
- Packaging machines
- Inspection and testing stations
- Pick-and-place mechanisms
Final Thought
If your machine gives different results in every cycle, it’s not just a hardware issue — it’s a repeatability issue.
And our electric motion units are built specifically to solve that.