MOTION SYSTEM TRENDS
Feature-rich controllers
tackle new applications
CONTROLLERS ARE CENTRAL TO motion control systems. They’re
often referred to as the brains of the system, evaluating feedback from the environment and responding in accordance with a control program to complete an assigned task. Today’s controllers have more built-in functions, are more powerful, and are being used in diverse applications. We asked some of the top controls manufacturers what trends they’re seeing in the industry. Below are their responses. Where do controllers of automation see new uses? Where do PLCs endure and where are they yielding to PLC functions onboard other controller options?
Christian Fritz, Head of Business Development, maxon We see a continued trend towards the distribution of control functionality. Driven by the miniaturization of embedded control hardware, networking technologies and protocols, system integrators are building highly modular mechatronic systems, that consist of intelligent subsystems. These systems do not replace the PLC or main control system but provide autonomous operation and decision making and simplify the highlevel control application. The result are systems that are more flexible (customer variations), easier to maintain (uptime) and allow for local decision making (increased performance).
Michael Burgert, Product Manager, Dunkermotoren “PLCs are the masterminds for all processes in machinery and equipment. They know and control every process detail.” This used to be the common understanding ever since PLCs ascended the throne of all process and automation equipment. And it made sense because processor costs were high and distributed intelligence would have cost far more than centralized processing power. Today, PLCs are no longer on the throne; there is no more throne. Hierarchies are about to dissolve and decentralized intelligence has already taken over many fields, which makes sense. With smaller and inexpensive processing power, even sensors can analyze themselves and generate warnings if they consider their signal levels poor. Integrated motors cannot only analyze their condition and forward this information but they can autonomously execute tasks and even control other motors or sensors. Every motor can be perfectly adapted to its task and communicate with all surrounding devices and with PLCs, if necessary. In many cases, PLCs are not necessary because decentralized intelligence can handle all the tasks of machinery and equipment. Imagine a packaging machine. Every station: material transport, goods transport, cutting and welding can be handled as autonomous tasks. Each station communicates with the other stations about status, condition and possible errors. Of course, PLCs will not vanish completely. There will always be tasks that are extremely complex and need a lot of processing power. But these PLCs will be on the same level as all other devices. Within the network, PLCs will more be the “pal that does the complex computing” instead of Mister Know-it-all. In what industries or application areas has your company seen increased activity or demand? Robotics
Giovanni Campanella, Systems Manager, Texas Instruments As robots are more and more a commonplace in factories it's important that they become more intelligent, autonomous, safer and efficient. All of this is enabled with precise motor control, differentiated sensing technologies and processing at the edge, all with robust real-time communication. TI offers various technologies that enable modern robotic systems ranging from TI mmWave sensors for detecting obstacles around the robot to Sitara processors running AI at the edge with multiple high-speed peripherals that enhance the designs of industrial robots. This cutaway view shows maxon’s EPOS2 70/10 controller, featuring dual-loop positioning and speed control.
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DESIGN WORLD — MOTION
3 • 2020
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