Sameer Gandhi, Managing Director, OMRON Automation, India.

What are the latest trends in motion control technologies, particularly in industrial applications?

The field of motion control technologies is evolving rapidly, especially in industrial applications. One of the remarkable trends is the way Industry 4.0 is transforming motion control systems. For example, the use of the Industrial Internet of Things (IIoT), edge computing, and 5G to enhance predictive maintenance, digital twins, and augmented reality. Also, there is a shift towards high-performance motors with integrated drive electronics or gear elements, offering better efficiency and precision, which are crucial for modern industrial applications.

Another notable trend is the advent of remote diagnostics and monitoring that facilitates real-time analysis and troubleshooting of motion control systems, minimising downtime and enhancing productivity. There's also a growing focus on safety and compliance, with the development of safer, more reliable components and systems to meet stringent industry standards. The role of software in motion control is expanding, with more advanced engineering support tools that facilitate the design, simulation, and optimisation of these systems. Lastly, energy-efficient components are becoming more prevalent, saving energy, reducing operational costs, and improving overall system performance. These trends are driving significant improvements in efficiency, reliability, and performance in industrial applications.

What are the key differences between traditional motion control systems and modern, digitally-driven systems?

The transition from traditional to modern, digitally-driven motion control systems has resulted in significant advancements in terms of improved efficiency, reliability, and performance in industrial applications.

Traditional systems, which often rely on analog controls and standalone operations, are being replaced by modern systems that use digital control methods and integrate seamlessly with IIoT for enhanced connectivity. These modern systems provide superior performance, greater precision, and faster response times through advanced algorithms and microcontroller technology. They also prioritise energy efficiency with smart energy management techniques, and feature sophisticated user interfaces that offer greater control and ease of use.

Also, modern motion control systems excel in maintenance and diagnostics, employing predictive maintenance capabilities to anticipate and prevent failures. This is in stark contrast to the reactive maintenance common in traditional systems. Modern systems are designed with safety and compliance in mind, incorporating features like emergency stop functions and international safety standard compliance, which may not be present in older systems. Overall, the evolution to digitally-driven systems brings significant advantages for the machine builders as well as the users.

What role do emerging technologies, such as AI and machine learning, play in the development of motion control systems?

Emerging technologies like AI and machine learning are transforming motion control systems significantly. Overall, they are making motion control systems smarter, more reliable, and more efficient.

Firstly, they facilitate data-driven decision-making by analysing large data volumes, aiding in system design, operation, and maintenance for better performance and efficiency. This leads to enhancement in predictive maintenance by analysing sensor data to predict component failures, thereby reducing downtime and maintenance costs. They also improve performance and precision, with machine learning algorithms optimising control parameters in real-time, adapting to changing conditions, and learning from past performance. AI-driven systems also offer advanced diagnostics and troubleshooting capabilities by analysing data patterns and anomalies to quickly pinpoint issues and suggest corrective actions. This enables adaptive control systems that adjust behavior based on real-time feedback, making them ideal for complex and dynamic environments.

AI is also contributing towards energy efficiency by optimising motor operations to minimise power consumption without compromising performance, leading to significant cost savings. Enhanced safety is another benefit, as machine learning algorithms can detect unsafe conditions and automatically take corrective actions.

How do motion control solutions help promote energy efficiency and sustainability in industrial operations?

Covered in Q 3

What are the common challenges companies face when adopting or upgrading motion control systems? Are there issues of compatibility with different protocols?

One of the key challenges faced during adoption and upgrading motion control systems is integration with existing systems. It is often difficult, requiring significant customisation and testing to ensure seamless operation. The initial costs can be substantial, covering new hardware, software, and necessary training. There can be supply chain issues too, particularly in sourcing key components like semiconductors, which can lead to delays and increased expenses. Sometimes companies lack the technical expertise needed to implement and maintain these advanced systems, necessitating external support. Maintenance and downtime during upgrades can further impact productivity and add complexity to the process.

Compatibility is another challenge. The issues arise from the variety of communication protocols used in motion control systems. Standardising protocols is a step forward, but ensuring all components, such as controllers, sensors, and actuators, communicate effectively remains challenging. Older systems may use outdated protocols not compatible with newer technologies, requiring converters or complete overhauls. Achieving real-time synchronisation across multiple devices, especially when using different protocols, is difficult, and ensuring interoperability between different brands and types of equipment often requires extensive testing and custom solutions.

What role does real-time data and predictive analytics play in optimising motion control solutions?

Together, these technologies significantly improve the efficiency, reliability, and lifespan of motion control systems.

Real-time data and predictive analytics play pivotal roles in optimizing motion control solutions. Real-time data offers instant feedback, enhancing precision by allowing immediate adjustments and continuous monitoring to detect anomalies early, thus preventing failures and reducing downtime. Predictive analytics enables predictive maintenance by forecasting component failures based on historical data, optimising performance through pattern recognition, and aiding efficient resource allocation by anticipating future needs.

How customisable are modern motion control systems, and how easily can they be adapted to different scales of operation?

Modern motion control systems have a high degree of customisability and adaptability that makes them suitable for a wide range of applications, ensuring they can meet the specific needs of different industries and scales of operation.

These systems are designed with modular components, allowing for seamless integration of various controllers, actuators, and sensors tailored to specific operational needs. Advanced software tools further enhance this customisability by enabling precise tuning of motion profiles, control algorithms, and system parameters. They can easily integrate with other automation and control systems, thereby enhancing their functionality within larger production environments.

From small-scale applications like 3D printing to large-scale industrial automation, their scalability is a major advantage.

(The views expressed in interviews are personal, not necessarily of the organisations represented) 

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