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Managing Linear Rail Guide Misalignment
Linear Rail Misalignment Management

Linear Rail Misalignment Management

Managing Linear Rail Guide Misalignment

Linear rail misalignment is a fact of life.

  • Misalignment represents one of the leading causes of premature linear guidance failure.
  • Misalignment can greatly reduce a products capability and expected life.
  • Design needs to understand the process requirements of the application to select the appropriate product.
  • And design needs to understand which linear product will provide acceptable process guidance.

Mounting preparation must be taken into consideration to assure performance

Browse, Configure and Buy Linear Rail Guides

Consideration for the linear rail mounting surface must always be addressed

  • Uneven mounting surfaces like welded frames, structural materials, etc. need extra clearance or ability to float to overcome alignment issues.
  • Higher accuracy requires less allowable deviation between rails and precision mounting surfaces are needed.

Built in Systematic Alignment

PBC Linear offers products that can simplify system alignment, offering integrated products that incorporate built in alignment.

Built in Alignment
  • Can simplify engineering design considerations.
  • Reduces material costs.
  • Reduces assembly times and costs.
  • Can lead to an overall reduction of system costs.

Products with built in alignment:

Gliding Surface Technology – GST Products
Cam Roller Technology – CRT Products
Integral “V” Technology – IVT Products

Signs of Bad Alignment
Plain Linear Bearing - Uneven Bearing Liner Wear

Plain Linear Bearing – Uneven Bearing Liner Wear

Ball Bearing - Shaft Spalling

Ball Bearing – Shaft Spalling 

Alignment Issues can lead to:
  • Systematic failures.
  • Premature wear of bearings and rail.
  • Misdiagnosis of inappropriate product selection, when in fact it is an alignment issue.
  • Production down time costs.
  • Replacement of componentry due to component failure.
  • Shortened component “life” due to premature failure.
  • Replacement of componentry thinking a more expensive “precise” solution is needed.
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Cite This Page
Source: PBC Linear - “Managing Linear Rail Guide Misalignment”
https://pbclinear.com/blogs/blog/managing-linear-system-misalignment
Last updated: October 2025