Industrial Automation Magazine India

Motion control systems are becoming more customisable and adaptable

Published on : Monday 06-11-2023

Yash Sultania, Director, Durga Mechatronics.

What is motion control technology, and how does it play a crucial role in various industries and applications?

Motion control technology refers to a broad range of techniques and systems used to control the movement of machines, devices, or components in various industries and applications. It is a crucial component of automation and robotics and plays a vital role in improving efficiency, precision, and safety in many sectors.

What are the key components and principles behind motion control systems, and how do they contribute to precise motion management?

The key components of Motion Control Systems are:

1. Motion Controllers: These are specialised electronic devices or computer systems that generate motion commands and control the movement of motors or actuators.

2. Sensors: Motion control systems often rely on sensors such as encoders, accelerometers, and position sensors to provide feedback on the position, speed, and orientation of moving objects.

3. Actuators and Motors: These are devices responsible for executing the desired movement or motion. Common types include servo motors, stepper motors, and hydraulic or pneumatic actuators.

4. Feedback Systems: These systems use sensor data to provide real-time feedback to the motion controller, allowing for precise adjustments and corrections.

How has motion control technology evolved over the years, and what are the latest advancements or trends in the field?

1. Advanced Control Algorithms: Motion control systems now incorporate advanced algorithms, such as predictive control and adaptive control, to optimise motion trajectories, reduce vibrations, and improve energy efficiency.

2. Machine Learning and AI: Artificial intelligence and machine learning are being used to enhance motion control by enabling systems to learn from data and adapt to changing conditions, improving overall performance and efficiency.

3. Industry 4.0 and IoT Integration: Motion control systems are increasingly connected to the Industrial Internet of Things (IIoT), enabling remote monitoring, predictive maintenance, and real-time data analysis for better decision-making.

4. Robotics and Cobots: Motion control is a critical component of robotics and collaborative robots (cobots), which are becoming more prevalent in manufacturing and other industries. These systems require precise and adaptive motion control for safe and efficient operation alongside humans.

5. Energy Efficiency: There is a growing emphasis on energy-efficient motion control systems to reduce power consumption and environmental impact, particularly in industries like electric vehicles and renewable energy.

6. Customisation and Flexibility: Motion control systems are becoming more customisable and adaptable to various applications, allowing for easier integration into diverse industries and tasks.

7. Safety Features: Enhanced safety features, including collision detection and avoidance, are being incorporated into motion control systems to prevent accidents and protect both equipment and operators.

8. Multi-Axis and Parallel Kinematics: Advancements in multi-axis and parallel kinematic systems enable complex and highly dynamic motion control in various applications, such as 3D printing and advanced machining.

How does motion control technology contribute to energy efficiency and sustainability in industrial operations?

1. Optimised Motion Profiles: Motion control systems can generate optimised motion profiles for machines and robots. By minimising unnecessary movements, reducing acceleration and deceleration times, and smoothing motion trajectories, these systems reduce energy consumption. This is especially important in applications such as CNC machining and robotics, where precise and efficient motion is crucial.

2. Regenerative Energy: Some advanced motion control systems incorporate regenerative energy capabilities. When a motor decelerates or stops, regenerative braking can convert the kinetic energy back into electrical energy, which can be reused or dissipated as heat. This feature reduces the overall energy consumption of the system.

3. Variable Speed Drives: Variable frequency drives (VFDs) are commonly used in motion control applications to adjust motor speed and power consumption based on the load and demand. By operating motors at optimal speeds rather than constant speeds, VFDs save energy, especially in applications like conveyor systems and pumps.

4. Load Sensing and Feedback Control: Motion control systems often use feedback from sensors to continuously adjust motor output to match the load's requirements. This load sensing and feedback control ensure that motors are not overworking or consuming excess energy when it's not needed.

5. Predictive Maintenance: By monitoring the performance and condition of motion control components, predictive maintenance systems can detect issues early and schedule maintenance before major failures occur. This reduces downtime and prevents energy waste associated with inefficient or malfunctioning equipment.

6. Energy Monitoring and Reporting: Many motion control systems now come equipped with energy monitoring features. They track energy usage and provide data on energy-efficient operation. This data can be used to identify areas for improvement and make informed decisions about energy-saving measures.

7. Material Efficiency: Motion control technology can contribute to sustainability by improving material efficiency. In processes like additive manufacturing (3D printing), motion control ensures precise material deposition, reducing waste and minimising the use of raw materials.

8. Reduced Emissions: By optimising processes and reducing energy consumption, motion control technology indirectly contributes to lower greenhouse gas emissions associated with industrial operations, aligning with sustainability and environmental goals.

9. In summary, motion control technology enhances energy efficiency and sustainability in industrial operations by optimising motion, reducing energy waste, and providing data for informed decision-making. As industries continue to prioritise environmental responsibility, motion control systems will play an increasingly important role in achieving energy-efficient and sustainable manufacturing and automation processes.

What challenges or limitations are associated with motion control technology, and how are they being addressed or mitigated?

1. Complexity and Cost: High-performance motion control systems can be complex and costly to design, install, and maintain. This can be a barrier for smaller businesses or applications with limited budgets. However, the industry is working on simplifying and modularising motion control solutions to reduce costs and complexity.

2. Integration Issues: Integrating motion control systems into existing automation setups or industrial processes can be challenging. Compatibility issues between components, communication protocols, and software can arise. Manufacturers are developing standardised interfaces and communication protocols to facilitate integration.

3. Maintenance and Reliability: Motion control systems require regular maintenance to ensure they operate reliably. Wear and tear on components like motors and encoders can lead to downtime. Predictive maintenance techniques and the use of durable components are helping address this issue.

4. Complex Kinematics: In applications involving complex kinematics, such as multi-axis robotics or parallel kinematic systems, achieving precise control can be challenging. Research and development efforts are focused on improving control algorithms and hardware to handle complex motion.

5. Environmental Considerations: Industrial environments can be harsh, with exposure to dust, moisture, and temperature extremes. Motion control systems need to be robust and protected against environmental factors. Manufacturers are designing ruggedised components and enclosures for harsh conditions.

6. Safety: Ensuring the safety of operators and equipment in motion control systems is crucial. Safety features, such as emergency stop functions, safety-rated controllers, and sensors, are being integrated into motion control systems to mitigate risks.

7. Latency and Responsiveness: In applications where real-time control is critical, such as robotics and gaming, latency can be a limitation. Advances in control algorithms and hardware, along with faster communication networks, are reducing latency and improving responsiveness.

Overall, motion control technology continues to advance, with ongoing research and development efforts aimed at addressing these challenges and limitations. As the technology becomes more accessible, flexible, and reliable, it will continue to play a crucial role in automation and precision control across various industries.

How does motion control technology integrate with other technologies such as robotics, automation, and artificial intelligence, and what synergies are created as a result?

Motion control technology often integrates with other technologies such as robotics, automation, and artificial intelligence (AI) to create synergies that enhance the capabilities and performance of systems and processes. Here's how these technologies integrate and the synergies they create:

Integration with Robotics:

1. Enhanced Precision: Motion control technology provides robots with precise control over their movements. This ensures that robots can perform tasks with a high level of accuracy, which is crucial in applications like pick-and-place, assembly, and surgical robots.

2. Path Planning: Robotics often involves complex path planning and trajectory generation. Motion control systems work in tandem with robot control algorithms to calculate and execute these paths efficiently.

3. Coordination: In multi-robot or collaborative robot (cobot) environments, motion control technology enables coordinated movements and synchronised actions among robots, enhancing efficiency and teamwork.

Integration with Automation:

1. Increased Efficiency: Motion control technology is a fundamental component of industrial automation systems. It allows for precise control of machinery, conveyor systems, and material handling equipment, leading to improved production efficiency and reduced labor costs.

2. Seamless Workflow: Motion control systems can be integrated into larger automation control systems, ensuring that all components work seamlessly together. This integration optimises workflow and reduces bottlenecks.

Integration with Artificial Intelligence (AI):

1. Machine Learning and Adaptive Control: AI algorithms can be integrated with motion control systems to adapt and learn from data, allowing for real-time adjustments and optimisations of motion trajectories. This results in improved performance and energy efficiency.

2. Predictive Maintenance: AI-driven predictive maintenance can monitor the condition of motion control components and predict when maintenance is required, reducing downtime and enhancing system reliability.

3. Computer Vision: When combined with computer vision systems, motion control technology can enable robots and automated machinery to respond to visual cues and adapt their movements based on the objects they encounter. This is valuable in applications like object recognition and sorting.

4. Cognitive Robotics: Cognitive robotics, which combines AI and motion control, allows robots to make decisions based on sensory input and adapt their movements in complex and dynamic environments. This is essential for applications like autonomous vehicles and drones.

Synergies Created:

1. Increased Precision and Efficiency: The combination of motion control technology, robotics, and AI results in highly precise and efficient systems that can perform tasks with a level of accuracy and speed that would be challenging for humans alone.

2. Adaptability: Integrating AI with motion control enables systems to adapt to changing conditions or unforeseen obstacles, making them more versatile and capable of handling dynamic environments.

3. Data-Driven Optimisation: Motion control systems generate a wealth of data. When combined with AI, this data can be used to optimise processes, predict maintenance needs, and improve overall system performance.

In summary, the integration of motion control technology with robotics, automation, and AI creates synergies that result in more capable, efficient, and adaptable systems. These synergies are driving advancements in industries such as manufacturing, healthcare, logistics, and beyond, leading to increased productivity and innovation

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

Mr Yash Sultania is the director of Durga Mechatronics Pvt Ltd. – one of the largest distributors of Industrial Power Transmission products in India. He currently serves as the head of automation division of the company. He is a Btech from IIT- Gandhinagar & a MBA from IIM- Indore.