We can accurately say that motion control has been around for a long time and that this is a mature approach to automation with a proven track record of success.

Emerging motion control uses unified control architecture, artificial intelligence (AI), edge computing and cabinet-free hardware to make industrial machines faster, smaller and smarter. Add independent cart technology and predictive analytics, and we can see the future of motion control.

One emerging trend has a huge impact on motion control: the unification of motion and robotics control architecture puts us in one environment with one control base. Traditionally, a control system would have a programmable logic controller (PLC) controlling the overall system with a stand-alone controller handling the motion of the robot or robots. With a single controller, we have coordinated movement that improves precision and throughput, alongside the bonus of lower costs from fewer hardware components and less integration overhead. Deployment is accelerated for both original equipment manufacturers (OEMs) and end users, reducing commissioning time greatly.

Using AI, systems learn from real-time data, automatically adjusting speed and force to handle changes in load, heat or friction. Traditionally, we would commission a drive and then set up limits with certain parameters to allow us to detect when something is performing out of specification.

One parameter that comes to mind is the following error. When a drive is commanded to go to a particular position, the following error can be used to detect when the driven assembly is having a hard time getting to the desired position. Using AI, the algorithm can be made to change parameters like force or speed to bring the following error back within normal range.

An example of this type of scenario might be when an assembly is mounted on linear bearings and travels a known path and distance. Dust or other environmental factors might cause the rails to suffer a buildup that causes the following error to stretch out beyond the normal goalposts of acceptability. The speed or force could be adjusted to tell the drive it is okay to push a little harder to compensate. There must be an additional set of goalposts to identify when additional force or speed is no longer solving the following error, but is instead indicative of a more serious issue that requires a shutdown, physical inspection and troubleshooting.

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We hear about edge computing in other aspects of automation, but where does that apply to motion control? Generally, with edge computing, the processing happens directly on the machine instead of a distant cloud server. This cuts down on delay and lets machines make instant decisions. As applied to motion control, if we put the decision-making process right in the drive itself, we cut down on the need to send information to the main processor and wait for a response before commanding the drive to execute a decision. This enhances real-time control and reduces the impact of latency.

The concept behind cabinet-free design is that we move the servo drive out of the cabinet and co-locate it with the motor and encoder. Often referred to as an integrated servo system, it combines the motor with the controller (drive) and feedback device (encoder). Everything is field-mounted, and on a multi-axis system, this can save valuable panel space. This also cuts down on long, multi-conductor motor and feedback cables. Multi-axis systems can be daisy-chained, making installation and maintenance easier to implement. The shorter distance between the drive and motor significantly minimizes signal degradation and electromagnetic interference.

A convenient benefit of an integrated servo is that the drive and motor are matched, wired and configured at the factory by the manufacturer, giving you pre-tuned performance right out of the box. Integrated servos also feature integrated encoders and fieldbus interfaces so you can get them in your favorite communication protocol—like EtherCAT, EtherNet/IP, Modbus or Profibus—for a relatively seamless deployment in your motion solution. Most of the major automation hardware vendors have a version of an integrated motor, servo or stepper to suit your design needs, with some units even integrating the motor, drive, and motion controller or PLC into one package.

As we look ahead, the evolution of motion control extends even further into advanced mechanical layouts and proactive intelligence. Independent cart technology (ICT) replaces traditional paths with flexible magnetic movement, and predictive analytics and smart sensors utilize deep data exchange to anticipate failures before they happen, ensuring ultimate machine efficiency and uptime.