Motion Control Systems Enable Flexible Automation
Industrial automation has revolutionized the manufacturing industry and motion control systems are an integral part of many of today’s automated machines. Motion control, which is a sub-field of automation, is a system composed of several components that work together to provide precise and repeatable movements in CNC machines, assembly line robotics, material handling machinery, packaging equipment and other applications that demand flexible automation systems.
This blog will discuss the benefits of motion control technology and how it enables flexible automation that allows today’s manufacturers to make changes on the fly and get products to market faster in order to remain competitive.
What are the Components of a Motion Control System?
A typical motion control system includes multiple components, each of which serves a unique purpose in realizing precise, repeatable and controlled movement in industrial machinery.
Here are four of the key motion control system components:
Motors
After receiving the control command, the motors initiate movements accordingly.
Sensors and feedback devices
Sensors and feedback devices provide real-time positional and speed data back to the controller to ensure that any movements are within set parameters and send the signal to make necessary adjustments.
Motion controllers
These components provide control commands to the drives and generate trajectory plans for complex movements.
Motor or servo drives
Motor and servo drives are used to convert control commands into higher power voltage or current signals that drive the motor.
These essential components are combined to create a motion control system that manages and directs the speed, acceleration, position and torque of individual axes of a machine, allowing precise and repeatable movements.
Some common applications for motion control systems include welding, assembly or cutting machines, robotics, packaging and palletizing equipment, material handling systems, 3D printers and other industrial machinery that must be tightly controlled, but also offer flexibility when a change is required.
The Benefits of Motion Control Systems
The integration of motion control systems with automation provides numerous benefits, including:
- Precision: The sensors and feedback devices permit precise and repeatable motion.
- Energy efficiency: By offering tight control within pre-set parameters, power consumption of the equipment is often optimized.
- Reduced cycle times: Motion control systems streamline processes to allow faster production rates, significantly reducing cycle times.
- Improved product quality: The ability to repeatedly and precisely perform motions leads to higher quality products.
- Minimized waste: Due to the precision and repeatability, there are fewer defects and errors, which reduces waste and scrap.
- Flexibility: Motion control systems can be adapted to different tasks and can easily be scaled up or back based on demand.
Using Motion Control to Create Flexible Automation
Motion control systems are programmed to control the position, speed, torque and velocity of automated equipment; however, it is possible to change these parameters and scale them up or down based upon the current requirements of the application, allowing the creation of flexible automation systems.
In addition to the ability to modify speed, acceleration, torque and position of the system, programmable motion control systems can be adapted and reconfigured to accommodate adjustments in production requirements including product variations, seasonal products, and customization.
The adaptability of motion control systems permits agile and flexible automation systems that enable manufacturers to quickly pivot to accommodate changes in market demands and reduce time to market.
The Role of Motion Control Systems in Adaptive Automation
In addition, advanced motion control systems play a significant role in the adoption of adaptive automation technologies, which will bring even more flexibility and agility to the manufacturing landscape. Adaptive automation is a flexible automation system that can adapt to changing conditions based on real-time data, improving precision and efficiency and permitting more manufacturing agility.
Within adaptive automation systems, motion control systems can automatically adjust parameters, such as position, speed, acceleration and torque, to reach a different level of performance, while the motion control system’s feedback devices continuously monitor to ensure that the newly requested performance level is maintained.
Motion control systems are essential elements in today’s more flexible automation systems. The ability to provide precise and repeatable movement allows manufacturers to increase efficiency, product quality and throughput. And, as the manufacturing industry demands more flexible automation systems in order to remain competitive, motion control systems are expected to play a pivotal role in the adoption of adaptive automation. Please contact the experts at JHFOSTER to discuss motion and flow control products, robotics motion controllers and other key motion control components.