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Motion Control 101: Fundamentals and Emerging Trends

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KEY TAKEAWAYS

  • Motion control systems consist of key components working together to create precise and controlled movements in automated machinery.

  • Technologies advancing motion control, including advanced sensors, AI and machine learning, are contributing to more intelligent and efficient systems.
  • Real-world applications of motion control automation span diverse industries, from automotive manufacturing and aerospace assembly to pharmaceutical production and surgical robotics in healthcare, demonstrating its critical role in modern industrial processes.

What you’ll find in this guide:

  • What is motion control?
  • Technologies driving advancements in motion control
  • Real-world applications of motion control automation
  • What’s next for motion control 

WHAT IS MOTION CONTROL? 

As consumer demand for high-quality products and lightning-fast delivery continues to surge, manufacturers must modernize their operations to keep up. As a result, many manual processes are shifting to automation — and motion control is an essential part of this transition. 

The term “motion control” is multifaceted. Rather than describing a single part or tool, it encompasses a group of individual components that work together to create controlled movement in a machine. 

Key components of motion control systems

Some major parts of motion control systems typically include: 

Controller
The controller serves as the “brain” of a motion control system, directing the motors and drives on how and where to move. Controllers can receive instructions from, and provide feedback to, the main computer that controls the entire production line.

Motor drive 
This component acts as a middle-man between the controller and the motor. It interprets the controller’s signal and supplies the correct level of power to the motor to achieve the desired motion result. 

Motor
Motors are the muscles — and heart — behind all motion control systems, transforming electrical energy into mechanical energy. These critical components come in many forms and have many different applications. 

Here are some motors you may find used in motion control systems:

  • Servo motor: Provides a highly accurate and powerful way to control angular motion.
  • Stepper motor: Offers positioning without feedback sensors; useful in open-loop applications where cost-effectiveness is a priority.
  • AC synchronous motor: Rotor motion is synchronized with the frequency of the supply current and the speed remains constant under various loads.
  • AC asynchronous motor: Electromagnetic induction generates an electric current, producing torque.
  • DC motor: Brushed and brushless DC motors perform reliably at a relatively low cost for basic industrial equipment. 

Benefits of motion control systems

Motion control systems are a cornerstone of modern industrial automation, always evolving and advancing to work faster and smarter. These systems control machines and mechanical systems across industries where precision and efficiency are paramount, from manufacturing and healthcare to aerospace, automotive, and beyond. No matter the application, this technology can work quickly and accurately, increasing throughput, reducing human errors, and improving the customer experience overall. 

TECHNOLOGIES DRIVING ADVANCEMENTS IN MOTION CONTROL

Some of the technologies propelling modern motion control include:


Advanced sensors and actuators
Improved sensor technology enables more accurate and precise control of movements, detecting even slight changes in position, speed, and torque.

Artificial intelligence (AI) and machine learning (ML)
These technologies are revolutionizing motion control systems by analyzing vast amounts of data to predict optimal movements and adjustments, leading to more intelligent systems.

Edge computing and Internet of things (IoT)
Integration of these technologies enables real-time data processing and decision-making at the robot or individual machine level, reducing data processing time and improving efficiency

Miniaturization and integration of components
Compact components allow for smaller control panels that free up valuable space in industrial environments, while also simplifying system design and reducing the number of parts needed. 

REAL-WORLD EXAMPLES OF MOTION CONTROL AUTOMATION

Industrial motion control automation is hard at work around the world. At Tesla's Gigafactory, advanced motion control systems orchestrate the intricate assembly of electric vehicles, with robotic arms working in perfect synchronization to install battery packs, motors, and interior components. 

Similarly, in the aerospace sector, Boeing utilizes a quadbot, comprising four robots, to drill approximately 3,000 holes in the rear area of the 787 Dreamliner. This system also inspects holes, applies sealant, and installs fasteners.  

In the pharmaceutical industry, Pfizer has implemented state-of-the-art motion control systems in their vaccine production facilities. These systems enable precise control of robotic arms for delicate handling of vials and syringes, ensuring sterile conditions and exact dosing of vaccine components. Pick-and-place robots are also used to assist with fulfillment, performing tasks quickly, accurately, and cost effectively. 

Within the healthcare sector, surgical robotics, such as the da Vinci system, utilize advanced motion control to translate a surgeon's hand movements into precise, real-time actions of robotic arms, performing minimally invasive procedures with extreme accuracy. Additionally, motion control is revolutionizing therapeutic devices like infusion pumps and respirators by providing smooth, vibration-free operation and compact designs that improve reliability and patient comfort. 

WHAT’S NEXT FOR MOTION CONTROL TECHNOLOGY

Companies across industries are using AI to revolutionize motion control technology. ABB, Siemens, and FANUC are integrating AI into their industrial robots and control systems, enabling more intelligent and responsive movements in manufacturing processes.

Epson Robots, in partnership with Motion Ai, is integrating AI-driven solutions into their robotics systems, enhancing precision and adaptability in automation applications for semiconductor, pharmaceutical, and logistics sectors.

New encoder technologies are providing medical machine manufacturers with expanded options for position sensing and data transmission. Delta robots like the KUKA KR DELTA can achieve cycle times as fast as 0.32 seconds with high precision in pick-and-place operations for industries such as food and pharmaceuticals. 

SEE MOTION CONTROL IN ACTION AT AUTOMATE

See the cutting-edge applications of this transformative technology for yourself at Automate to discover how it could unlock new opportunities for your business. Join us for FREE

 


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