Upendra Vanarase, Managing Director, Trio Motion Technology India Private Limited.

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

Over the years, machine complexity has drastically increased due to changing consumer demands, which results in the changing manufacturing landscape. Advanced motion control, robotics and fifth-generation automation solutions have thus become increasingly important for machine builders. Machine builders and automation vendors looked at the control systems architecture before selecting the motion components. However, this scenario is changing with the changing manufacturing landscape and the increased need for accurate, fast, reliable and precise motion control algorithms. Motion-First automation solutions are the latest trend witnessed in various industries such as packaging, food and beverage, metal, pharmaceuticals, printing and textiles. Motion-First machine automation helps machine builders optimise productivity, precision and accuracy who are dependent on the motion cycle of their machines. Trio’s Motion-First machine automation combines high-speed, modular, multi-axis motion coordination with machine control and extended device integration. This helps machine builders with a single source automation provider for complete solutions, including controllers, servo drives & motors, I/O, HMI, and SCARA robots.

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

Today, most motion control systems used in complex industrial applications in packaging, F&B, metal, printing, and pharmaceutical industries are digitally driven. Traditional motion control is a thing of the past. With the need for vertical and horizontal connectivity, machine builders have already moved on to digitally driven motion control, as it offers not only speed, accuracy and precision, but also connectivity with IT systems. With fifth-generation motion control such as Trio’s Motion-First automation solutions, machine builders benefit from lower maintenance, ease of IIoT integrations, higher flexibility in programming, faster and efficient performance, precision with digital feedback and long-term savings. Moreover, these modern motion control systems offer ease of integration with various robotics, conveyor and transfer systems, enabling machine builders with added flexibility in system architecture, efficiency, performance and costs. There is still a lot of confusion among users between PLC-based motion controllers and real motion controllers.

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

Technology is rapidly evolving, and motion control systems, too, are evolving with these advancements. Over the years, AI and ML algorithms have become increasingly used in various industrial applications. They are used in data acquisition systems, vision inspection solutions, maintenance solutions, path planning, warehousing solutions and safety and security solutions amongst others. Another technology that is greatly impacting the way machine control systems behave is the digital twin. With ML and digital twins, machine builders are able to understand how the machine and motion profiles or robots behave even before the machines are manufactured and machined. This helps them drastically reduce the machine development time and commissioning time. It helps them reduce waste and enhance efficiency and productivity. It also helps in reducing machine downtime. As technology continues to evolve, other advanced technologies will help make motion control systems even faster, more precise and more efficient. As Trio, we already have an AI-based diagnostic tool that only needs to fit in the Indian market based on the economy. Interested users can see a live demo in our advanced technology lab in Pune.

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

Energy efficiency, sustainability, and security have become integral to factories' requirements of machine builders. The entire machine and the automation solution need to be efficient. Motion components and software programs are the most significant stakeholders in a machine that help machine builders become more efficient and sustainable. Motion control and the program precisely manage machinery's speed, position, and torque, helping reduce unnecessary energy consumption. They also enable real-time monitoring and adjustment of motor functions, ensuring optimal energy consumption. This level of precision minimises idle times, reduces waste, and optimises machine performance. Another area where motion control and the software program work hand-in-hand to support sustainability is the reduction of mechanical wear and tear through smoother operations and better control. Thus, reducing the need for frequent maintenance and part replacements reduces material consumption and waste generation. Opting for regenerative braking features boosts energy efficiency by capturing and reusing excess energy produced during deceleration.

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

Typically, upgrading existing motion control systems might require a complete revamp starting with the software upgrade. This is the biggest challenge in adopting or upgrading a motion control system. Communication protocol also plays a vital role in choosing a specific motion control system. However, some protocols, such as EtherCAT, make life easier for many machine builders and factories to choose between different motion control systems, enabling ease of integration in existing systems. Trio control and motion solutions are based on the motion-first approach, and real-time EtherCAT is used as the backbone for all their communication needs. Thus, any machine builder or factory using EtherCAT in their machines makes it easy to adopt Trio Motion Technology solutions. This seamless transition and freedom of choice of vendor for motion control solution is made possible with the widely used EtherCAT technology. Moreover, Trio solutions also support OPC UA for vertical connectivity solutions, making IIoT, AI and ML integrations seamless.

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

Predictive data is built on real-time data from various moving parts in machinery. It provides insights into system behaviour, possibly predicting possible system failures due to wear and tear. These insights help in reducing machine downtime and failures. These insights play an essential role when it comes to motion systems. The predictive analysis detects higher vibrations and temperature, suggesting that the bearing or the moving part will likely fail due to its wear. The motion control systems can use this input to reduce machine speed in order to reduce wear on these areas. This gives maintenance teams adequate time to execute a planned downtime to replace the worn-out parts. This is just one example of how predictive analysis can be used with motion control to keep the machinery operating without unplanned downtime.

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

Everyone desires scalability, and machine builders and factories are no different. Without scalability, machine builders will find it extremely hard to adapt to the ever-evolving manufacturing landscape. With scalable motion control systems, machine builders can use the same motion control system with a PLC or a PC. Moreover, this scalability is where Trio introduced the Motion-First approach. With Trio’s Motion-First automation solutions, machine builders in the packaging, food and beverage, metal, pharmaceuticals, printing, and textiles industries benefit from choosing the right motion solution for their machinery. This helps them with higher efficiency, scalability, performance and profitability. With its Motion-First machine automation, Trio helps machine builders optimise productivity, precision and accuracy. Machine builders can combine high-speed, multi-axis motion coordination with machine control to achieve seamless and extended device integration. Additionally, machine builders can use one controller for motion, robots and other machine tasks. Moreover, with this approach, machine builders have a single source automation partner for complete solutions, including controllers, servo drives & motors, I/O, HMI, and SCARA robots.

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

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