Discover the Latest in Intralogistics & Packaging Automation – December Issue Out Now!  Click Here to Read.

Discover the Latest in Intralogistics & Packaging Automation – December Issue Out Now!  Click Here to Read.

default-banner

Modern motion control systems are more complex than their predecessors

Ajey Phatak, the Country Manager of Marketing at Beckhoff Automation Pvt Ltd, has been a driving force in promoting Open Automation technology in India for over 15 years. With a rich background in technology marketing and a passion for innovation, Ajey has played a pivotal role in advancing PC-based automation within the Indian industry.

[object Object]

Ajey Phatak, Country Manager Marketing, Beckhoff Automation Pvt Ltd.

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

Motion control technologies are rapidly advancing, especially in industrial applications where precision, efficiency, and flexibility are important.

Modern motion controllers use smart and connected systems (Industrial IoT) that use edge computing and IoT integration with smart sensors. These offer nanometer-level precision, which is essential for industries like semiconductor manufacturing, electronics assembly, and medical devices. High speed controllers with ultra-fast processing speeds are becoming popular, especially in high-speed automation tasks in packaging, textile, and automotive industries.

Integrated motion control and robotics is another trending concept, e.g., use of cobots and integrated motion control systems integrated with multi axes robots.

Use of decentralised control architecture for motion control systems using PC based control and distributed drive. Instead of relying on a central control system, decentralised motion control is becoming popular, where control elements are distributed across the machinery. This improves flexibility, reduces cabling, and enhances the modularity of systems.

Adaptive Control Systems – AI-driven motion control systems can adapt to changing conditions in real-time, improving precision and efficiency. Machine learning algorithms can also predict failures, optimise energy usage, and enhance overall performance.

Use of energy-efficient drives, for reducing energy consumption without compromising performance and Regenerative braking systems are becoming more common.

Use of real-time communication protocol – EtherCAT (Ethernet for Control Automation Technology) – are becoming the standard for high-performance motion control systems, offering faster, more deterministic communication between devices, which is essential in synchronised, multi-axis control.

Machine safety is also becoming a priority. Motion control systems are incorporating advanced safety protocols like Safe Torque Off (STO).

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

Summary of key differences:

Feature

Traditional Motion Control

Modern Digitally-Driven Systems

 

Control Architecture

 

Centralised

 

Decentralised/Distributed

Communication

Analog/Proprietary

Digital, Ethernet-based, IoT-enabled

Precision

Limited

High Precision (Nano-level)

Programming

Rigid, custom

Flexible, modular

Integration

Isolated

Seamless with automation systems

Energy Efficiency

Low

High, with regenerative features

Scalability

Limited

Highly scalable and modular

Safety

Mechanical safety

Integrated functional safety features

Diagnostics

Reactive

Predictive and real-time monitoring

User Interface

Basic

Advanced, with remote control capabilities

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

Emerging technologies like Artificial Intelligence (AI) and Machine Learning (ML) are playing a transformative role in the development of modern motion control systems. By leveraging these technologies, motion control is becoming more adaptive, intelligent, and efficient, leading to significant improvements in automation and industrial processes. AI and ML play significant role in the development of motion control systems.

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

Motion control solutions play a vital role in promoting energy efficiency and sustainability in industrial operations. By optimising how machines move and operate, modern motion control systems help reduce energy consumption, minimise waste, and extend equipment life cycles. There are several ways motion control solutions contribute to energy efficiency and sustainability.

Motion control solutions offer a broad array of benefits that support energy efficiency and sustainability in industrial operations. They help industries optimise energy use, reduce waste, and meet environmental targets, ultimately contributing to both cost savings and a reduced environmental footprint.

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

When companies adopt or upgrade motion control systems, they often face a variety of challenges, including compatibility issues, system complexity, and integration with existing infrastructure. These challenges can slow down implementation, increase costs, or create operational bottlenecks if not addressed properly. Below are the common challenges along with a focus on compatibility issues with different protocols.

Many companies have legacy systems that are based on older technology or proprietary standards. Upgrading or integrating a new motion control system with existing infrastructure can be difficult, especially when different communication protocols are involved. Older systems may use proprietary or outdated communication protocols that are incompatible with modern standards like EtherCAT, PROFINET, or Ethernet/IP. This creates issues with interoperability and data exchange.

Integrating new technologies into the custom-built motion control systems setups can be complex. Proprietary systems often use exclusive communication protocols that are incompatible with industry standards. This creates difficulties in expanding or upgrading the system using products from other vendors.

Motion control systems, particularly those integrated with modern technologies like AI, IoT, and advanced robotics, can be expensive to implement or upgrade. Cost of Upgrading can be seen as a challenge. Selecting systems with built-in compatibility for multiple protocols (e.g., EtherCAT and PROFINET) can reduce the need for additional investments in converters.

Training and expertise requirements increase with modern technology. Modern motion control systems are more complex than their predecessors, often requiring specialised knowledge of programming, networking, and system integration. Companies may struggle to find or train personnel with the necessary expertise to operate and maintain these systems.

Engineers may need to learn multiple communication protocols (e.g., Modbus, PROFINET, EtherCAT, etc.) to ensure smooth operation, which increases the training burden.

Adopting open standards and protocols (e.g., OPC-UA, EtherCAT, or PROFINET) can help avoid vendor lock-in and promote interoperability with third-party solutions.

As businesses grow, their motion control systems must scale accordingly. Expanding a system without causing disruptions or requiring significant reconfiguration can be challenging.

Systems based on proprietary or less flexible protocols may not scale well, as adding new components can require expensive and time-consuming upgrades. Protocols like EtherCAT and PROFINET offer better scalability, as they allow for easy addition of new devices and controllers without major reconfigurations. Modular systems with decentralised control architectures are also more scalable.

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

Real-time data and predictive analytics play a crucial role in optimising motion control solutions by enhancing performance, minimising downtime, and improving overall efficiency in industrial operations. These technologies enable systems to monitor conditions in real-time, predict potential issues, and adapt dynamically to changing environments, which leads to better control, resource optimisation, and reduced operational costs.

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

Modern motion control systems are highly customisable and adaptable, making them suitable for a wide range of applications across different industries and scales of operation. Advances in hardware and software technologies, communication protocols, and modular design principles have made it easier to configure, scale, and optimise these systems for specific requirements.

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

Ajey Phatak has been actively promoting Open Automation technology in India with Beckhoff for the past 15 years. He has made significant contributions to promoting and marketing PC-based automation technology in Indian industry since 2007, by using and learning digital marketing techniques.

A post graduate in Applied Electronics from Pune University and Management Graduate with over 30+ years experience in field of Technology Marketing, Concept Selling in Industrial Electronic products, Ajey was part of a team in pioneering efforts in the 1980s in promoting use of LEDs in industrial devices like alarm annunciators. Special efforts to promote electronic/digital overload relays (vs bimetal) for AC induction motor protection, and other technology products in the 80s/90s and established its sales in the Indian and international market. 

____________________________________________________________________________________________

For a deeper dive into the dynamic world of Industrial Automation and Robotic Process Automation (RPA), explore our comprehensive collection of articles and news covering cutting-edge technologies, roboticsPLC programmingSCADA systems, and the latest advancements in the Industrial Automation realm. Uncover valuable insights and stay abreast of industry trends by delving into the rest of our articles on Industrial Automation and RPA at www.industrialautomationindia.in