Research on stroke optimization method for a linear cable drive mechanism configuration

Abstract In the fields of high-end equipment and precision manufacturing, precise cable drive mechanisms are widely utilized due to their advantages of high efficiency, flexible layout, and lightweight design. However, in linear motion configurations, issues such as cable dislodgement, derailment, and wear frequently occur, significantly constraining transmission accuracy and reliability. To address these challenges, this study investigates the configuration design and parameter optimization of linear cable drive systems. By establishing a kinematic model of cable wrapping around input and guide pulleys, the variation pattern of the cable bevel angle is analyzed. A groove matching design and stroke optimization method centered on bevel angle constraints is proposed. Experimental results demonstrate that the linear cable drive platform based on this method achieves an effective stroke of 500 mm and a repetitive positioning accuracy of 7.5 μm, while significantly suppressing derailment and dislodgement phenomena. This research provides a theoretical foundation and key technical support for the design of long-stroke, high-precision cable drive systems.