Integrated guide linear actuator system

A method comprising:

• supporting a thrust tube at least partially within an actuator housing, wherein the thrust tube extends from a proximal end within the actuator housing to a distal end selectively positionable exterior to the actuator housing;
• moving the thrust tube between a first retracted position with the distal end proximate the actuator housing and a second extended position with the distal end spaced from the actuator housing, wherein the distal end of the thrust tube is subject to loading in the second extended position;
• and
• providing positional stability to the distal end of the thrust tube when subject to the loading with a guide assembly positioned adjacent the thrust tube, wherein the guide assembly includes:
• a guide shaft moveable with the thrust tube from the first retracted position to the second extended position, and
• a guide housing coupled with the actuator housing, with the guide shaft disposed at least partially within the guide housing, parallel to the thrust tube,
• wherein the guide shaft extends from a first end positioned within the guide housing to a second end positioned outside the guide housing with the guide housing substantially covering the guide shaft in the first retracted position,
• a coupling extending between the guide shaft and the distal end of the thrust tube, wherein the guide shaft and coupling are configured to provide positional stability to the distal end of the thrust tube in the second extended position, subject to the loading;
• and
• a coupling structure connected to the thrust tube at or adjacent the distal end and having a section that extends along the longitudinal axis beyond the coupling between the guide shaft and the distal end of the thrust tube, wherein the coupling structure defines an interface configured to engage a machine tool, wherein the interface comprises an end effector and the loading comprises one or both of:
• a mechanical load induced on the distal end of the thrust tube by operation of the machine tool engaged with the end effector;
• or
• a reactive force induced by a current load in an electrode coupled to the end effector at the distal end of the thrust tube.

An apparatus comprising:

• an actuator having an actuator housing, a thrust tube, and a rotor, wherein the thrust tube is configured for reciprocating motion along a longitudinal axis of the actuator housing, the thrust tube having a distal end configured for coupling to a machine tool, wherein the rotor is located in the actuator housing and is coaxial with and positioned radially outward of the thrust tube;
• a guide shaft disposed over the thrust tube, offset from the longitudinal axis and oriented substantially parallel to the thrust tube, opposite an underside of the actuator housing;
• and
• a coupling between the thrust tube and the guide shaft at the distal end, the coupling configured to move the guide shaft with the reciprocating motion of the thrust tube;
• wherein the coupling and the guide shaft cooperate to limit off-axis deflection of the distal end of the thrust tube, during the reciprocating motion;
• and
• wherein the apparatus has a center of gravity within a footprint of the actuator defined by the underside of the actuator housing, with the thrust tube in one or both of a retracted position and an extended position defined at respective limits of the reciprocating motion;
• and
• a coupling structure connected to the thrust tube at or adjacent the distal end and having a section that extends along the longitudinal axis beyond the coupling between the guide shaft and the thrust tube, wherein the coupling structure defines an interface configured to engage the machine tool, wherein the interface comprises an end effector or further comprising an electrode assembly coupled with the thrust tube at the distal end, wherein the off-axis deflection is responsive to exertion of a mechanical force by the machine tool on a workpiece, or a reaction force on the electrode assembly.

A linear actuator system, comprising:

• an actuator housing;
• a thrust tube extending from a proximal end disposed at least partially within the actuator housing to a distal end disposed at least partially outside the housing;
• a motor configured to move the thrust tube in reciprocating motion along a longitudinal axis thereof;
• a guide assembly coupled to the actuator housing, the guide assembly comprising a guide shaft configured for coordinated reciprocating motion with the thrust tube from a first retracted position to a second extended position, adjacent the longitudinal axis, and a guide housing coupled with the actuator housing, with the guide shaft disposed at least partially within the guide housing, parallel to the thrust tube;
• and
• a coupling between the guide shaft and the thrust tube, wherein the guide shaft and coupling are configured to provide positional stability to the distal end of the thrust tube, in the reciprocating motion along the longitudinal axis;
• wherein the guide shaft extends from a first end positioned within the guide housing to a second end positioned outside the guide housing, and wherein the guide housing substantially covers the guide shaft in the first retracted position;
• a coupling structure connected to the thrust tube at or adjacent the distal end and having a section that extends along the longitudinal axis beyond the coupling between the guide shaft and the thrust tube, wherein the coupling structure defines an interface configured to engage a machine tool;
• and
• a rotor positioned within the actuator housing, wherein the rotor is coaxial with and positioned radially outward of and at least partially longitudinally overlapping with the thrust tube.

A method, comprising:

• supporting a thrust tube at least partially within an actuator housing, wherein the thrust tube extends from a proximal end within the actuator housing to a distal end selectively positionable exterior to the actuator housing;
• moving the thrust tube between a first retracted position with the distal end proximate the actuator housing and a second extended position with the distal end spaced from the actuator housing, wherein the distal end of the thrust tube is subject to loading in the second extended position;
• and
• providing positional stability to the distal end of the thrust tube when subject to the loading with a guide assembly positioned adjacent the thrust tube, wherein the guide assembly includes:
• a guide shaft moveable with the thrust tube from the first retracted position to the second extended position, and
• a guide housing coupled with the actuator housing, with the guide shaft disposed at least partially within the guide housing, parallel to the thrust tube,
• wherein the guide shaft extends from a first end positioned within the guide housing to a second end positioned outside the guide housing with the guide housing substantially covering the guide shaft in the first retracted position,
• a coupling extending between the guide shaft and the distal end of the thrust tube, wherein the guide shaft and coupling are configured to provide positional stability to the distal end of the thrust tube in the second extended position, subject to the loading;
• a coupling structure connected to the thrust tube at or adjacent the distal end and having a section that extends along the longitudinal axis beyond the coupling between the guide shaft and the distal end of the thrust tube, wherein the coupling structure defines an interface configured to engage a machine tool;
• and
• positioning a rotor within the actuator housing, wherein the rotor is coaxial with and positioned radially outward of and at least partially longitudinally overlapping with the thrust tube.