Motion control is hardly a small matter to get to grips with in today’s ever-more automated age. Indeed, it has been described by one product training engineer, Matt Pelletier of Yaskawa America, Inc., as “the engineering behind automation”.
What Is Motion Control?
The term “motion control” refers to the precise regulation and control of movement and position in mechanical systems.
Motion control plays a central role in automation, enabling precise movement to be achieved in robotics, conveyor systems, computer numerical control (CNC) machines, and other industrial applications.
Through the coordination of motors, drives, controllers, and feedback systems, motion control allows for optimal positioning, velocity, and torque control.
However, in order to succeed, it is crucial for engineering professionals working with motion control to be well-armed with pertinent and actionable knowledge.
What Components Are Included in Motion Control Systems?
Motion control systems for all manner of applications tend to incorporate such components as:
- Motors for converting electrical energy into mechanical motion. Types of motors encompass the likes of servo motors, stepper motors, and DC motors
- Drives/amplifiers for translating control signals into power for motors
- Controllers for generating control signals based on programmed logic
- Feedback systems such as encoders or resolvers for providing real-time position/velocity feedback for closed-loop systems
- Mechanical components like gearboxes, couplings, or linear actuators for translating motor motion to the load – with impacts on torque delivery and precision.
What Tools May Engineers Need for Designing Motion Control Systems in Automation?
There are various categories of potentially important tools when engineers are looking to achieve the best outcomes from the motion control aspects of automation projects:
- Simulation Software
From MATLAB/Simulink to Autodesk Fusion 360, various software packages exist that greatly assist with such processes as the modelling of motor dynamics, the designing of mechanical linkages, and the testing of motion paths.
- Motion Control Software
The likes of PLC (Programmable Logic Controller) programming tools and motion libraries also play an integral role in realising the potential of motion control projects.
- Calculators And Sizing Tools
It shouldn’t take you long to find well-regarded tools online for figuring out vital parameters in relation to motion control in an automation project. One example is the RS website’s stepper motor calculator, which enables the user to calculate step angle and RPM.
- Hardware Development Tools
Included in this category are microcontroller platforms such as Arduino and Raspberry Pi, and motion controllers like National Instruments’ RIO system.
5 Tips to Help Engineers Get the Best Out of Motion Control Design Work
Follow these practical tips to help put yourself in the optimal position for success:
- Clearly define your motion requirements from the outset, including specifying position accuracy and acceleration.
- Take care to choose the right motor. While stepper motors, for instance, suit relatively inexpensive, moderate-speed and open-loop applications, you might look to a servo motor for a high-precision and high-speed task.
- Make sure you use compatible drives. You should be ensuring that driver current/voltage ratings match the motor.
- Incorporate feedback for precision. Even if you are using stepper motors, you might decide to add encoders for closed-loop control if open-loop brings a risk of missed steps.
- Invest time in testing and validation. The aforementioned simulation software can be invaluable for predicting performance and real-world testing, in order to verify accuracy.
By going through stages like these, you can help ensure as an engineer that your motion control systems are precise, efficient, and reliable. This, in turn, will greatly assist in the realisation of the best possible outcomes for end users.