A robot that independently adjusts its movement when a product is positioned differently than expected. A machine that detects abnormalities in components before a failure occurs. Physical AI makes these types of applications possible by connecting artificial intelligence with physical movement. At the same time, higher demands are being placed on the components that enable every movement. Particularly in fast, precise movements, it becomes clear how well intelligent control systems and mechanics are aligned.
What is physical AI?
Physical AI is the collective term for AI systems that perceive, decide and act in the physical world. While a language model such as ChatGPT formulates a response, physical AI controls a physical action. A robot arm that recognises an unfamiliar product and independently selects the correct gripping angle is a good example. The same applies to an autonomous mobile robot that adjusts its route as soon as something blocks its path.
Such a system consists of roughly three layers. Sensors collect data about the environment. An AI model interprets that data and determines the next step. Drives and mechanical components then translate that decision into physical movement. However, it is ultimately the mechanics that determine how accurately and reliably the system operates in practice.
An error also has immediate consequences here. An incorrect response from a chatbot can often simply be ignored. A positioning error by a robot, on the other hand, can lead to rejected products, damage or downtime.
What is changing in machine building because of physical AI?
Richard Eshuis, general manager at LM Systems, sees three clear shifts in practice among machine builders working with intelligent robots and AI-controlled machines:
- Higher speed and precision. With intelligent robots, demand for higher speeds and more precise movements is growing. As a result, the correct selection and sizing of components have become increasingly important. A linear guide that is slightly undersized may go unnoticed in a less demanding application. However, at high accelerations and with constantly changing movement patterns, such a choice becomes apparent.
- From scheduled to predictive maintenance. Maintenance at fixed intervals does not always take into account how intensively a machine is used. We work with THK OMNIedge, a condition monitoring system that supports predictive maintenance. This sensor technology is available for linear guides, ball screws and rotating components.
For linear components, the system monitors factors such as lubrication condition and detects signs of damage. This allows maintenance to be scheduled more effectively based on the actual condition of a component rather than solely on the calendar. Condition monitoring is not the same as autonomous movement, but it does demonstrate how valuable measurement data is becoming in modern machines. - Complete modules instead of individual components. Machine builders want to develop machines faster. They also want to be able to adapt a machine easily to different products or production processes. Complete linear modules with integrated guides and drives are well suited to these requirements. They simplify both engineering and assembly.
Challenges in linear motion technology
However, AI does not change the basic principle of linear motion technology. A linear guide is still a linear guide, after all. What is changing, however, are the requirements machine builders place on these components.
Component stiffness, for example. A rigid system reduces vibrations and positioning errors, even when a robot abruptly changes direction. In addition, rapid acceleration and deceleration require components that can withstand varying dynamic loads. Every acceleration generates forces on ball-type linear guides and ball screws. These forces are ultimately transferred to the contact surfaces between the balls and raceways.
Under varying loads, the service life of a component also depends partly on lubrication. Choosing the correct lubricating grease and the right quantity is therefore just as much a design decision as selecting the type of linear guide.
Where mechanics and control come together
In our view, the real added value of physical AI emerges at the intersection of precision mechanics and intelligent control systems. Intelligent software can achieve little with a mechanical system that does not respond accurately enough. Conversely, a high-quality linear guide can only reach its full potential when the drive system and software are properly matched to it.
Drive systems and linear motion technology must therefore function as one well-coordinated system. Designing the two separately creates the risk of a machine that works well on paper but falls short in practice.
Our practical perspective
Physical AI therefore does not require different linear motion technology. It does, however, require a different approach to designing and building machines. Our engineers at LM Systems help with the selection and sizing of linear guides, ball screws and modules. This can also include calculations of factors such as load, stiffness and expected service life. This provides a well-founded basis for selecting the mechanical configuration of the machine. Contact us for more information.