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Motion control typically refers to accurate position/velocity/torque capabilities operating in either open or closed loop modes. Open loop systems send motion commands without feedback. Closed loop systems have feedback devices to verify or adjust the resulting motion for more accurate control.
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Motion Control
Motion control is automation that deals with the precision movement of machine components or the accurate positioning of an object, such as robot arms, rotary tables, indexing conveyors, and CNC machines. Motion control typically consists of three main components:
- A motion controller, which can be a dedicated controller or a PLC, controls movement based on the programmed motion profile.
- A drive, or amplifier, translates signals from the motion controller into higher power signals used to control the motor. Some drives provide closed-loop control for more precise movements.
- Motors take signals from the drive and perform the corresponding physical movements. Motors come in several types including stepper and servo motors; motor-ready linear actuators convert rotary into linear motion.
Numerous other mechanical components are used with motors to perform the desired motion including belts, gearboxes, ball screws, and couplings.
Motion Control Components Overview
Motion Control
Pulse Train Output Motion PLCs
PLC -based pulse train output (also refered to as pulse/direction output) motion controllers accurate, coordinated motion between multiple servo and/or stepper systems using pulsed electrical signals.. These controllers can be separate units used in conjunction with a PLC, or the PLC itself can provide the motion control and high-speed I/O needed. Using the advanced capabilities of a PLC, motion can be easily synchronized between multiple axes or numerous individual motion systems can be accurately controlled.
- LS Electric XGB PLCs offer up to 6 axes of pulse-based motion via built-in high-speed I/O. Use the free XG5000 programming software to configure and program the control logic for advanced motion as well as PLC applications. Configure axes with XG-PM motion software that is included with XG5000 programming software. Then use the XG5000's 70+ motion function blocks (in ladder or structured text) to perform various types of motion.
- ProductivityMotion components were specifically designed to work with Productivity series PLCs, offering plug-and-play connectivity and coordinated motion between up to 4 axes on each PS-AMC4 motion controller. Rack-based and stackable high-speed I/O, counter and PWM modules are also available for basic motion applications.
- BRX PLCs offer built-in motion control using embedded high-speed I/O and, if needed, HSIO expansion modules. Coordinate up to 3 axes using the built-in I/O or up to 4 axes on each HSIO module. Timer/counter, PWM, and table-driven functions are also available with the BRX PLC.
- CLICK PLUS PLCs offer up to 3 axes of motion control using a high-speed output slot module in slot 0 of the CPU. In keeping with the CLICK philosophy of a simple/easy-to-learn instruction set, there are three motion instructions that provide capabilities for relative/absolute positioning, velocity mode, trapezoidal and s-curve moves, simple registration, linear and circular interpolation and a number of homing routines.
EtherCAT Motion PLCs
Newest Additions!
- XMC motion controllers
EtherCAT-based PLCs and motion controllers provide accurate, coordinated motion between multiple servo and/or stepper systems using Ethernet communication methods. . I/O capabilities can be expanded as needed for traditional PLC functions.
- LS Electric XMC motion controllers are fast and powerful controllers purpose built for motion control. Select a specific XMC controller for either 8 or 16 axes of EtherCAT motion control (with up to 18 virtual axes). These brick-style controllers have built-in discrete and analog I/O and two external encoder inputs to enable full-closed-loop control. Expand the I/O capabilities with up to 32 EtherCAT remote I/O racks (using XEL-BSSCT bus couplers). The XMC can update 16 axes of motion and more than 8000 I/O points on every scan of the PLC.
- LS Electric XGB PLCs are powerful compact controllers built with motion in mind. Add EtherCAT positioning modules for up to 16 axes of EtherCAT based motion control. Expand the motion capabilities even further with embedded high-density I/O (on select models) to provide 4 high-speed inputs and up to 12 high-speed outputs at up to 200kHz.
- Both XGB and XMC controllers utilize the powerful XG5000 software to configure and program the control logic for advanced motion as well as PLC applications. XGB PLCs also require configuration of motion axes using the XG-PM motion software that is included with XG5000 programming software (All XMC motion controller axes are configured directly in XG5000). Then use the various function blocks available to perform numerous types of motion including position control, speed control, feed control, circular arc interpolation, linear interpolation, and ellipse interpolation.
SureServo2 Servo Systems
Newest Additions!
- SureServo2 460V systems
The SureServo2 family of brushless servo systems is fully digital and offers a rich set of features to cover a broad range of motion control applications. There are 26 standard servo motors that can be operated in combination with one of 16 standard servo drives.
The SureServo2 family includes standard accessories such as: servo motor encoder cables, servo motor power/brake cables, direct mount and DIN-rail mount I/O break-out kits for easy connection of external command and I/O signals, optional battery backup for the encoder, optional external braking resistors, and optional AC input filters.
- 16 standard system systems from 100W to 15kW
- Support for 110 VAC and 220 VAC single-phase input power on systems from 100W to 2kW
- Support for 230VAC three-phase input power on systems from 100W to 15kW
- Support for 460VAC three-phase input power on systems from 400W to 15kW
- Professionally manufactured cables for motor power, encoder feedback, and brake (optional)
- Compatible with most AutomationDirect PLCs; or any other host controller or HMI
- Servo drives feature on-board motion controller with registration, electronic camming, and event-based logic control
- Option modules for networking capability
- External encoder support
- Servo drives feature Safe Torque Off (STO)
- Free set-up software
- Field upgradeable firmware ensures the servo drive always stays up-to-date
- Two-year warranty
LS Electric iX7 EtherCAT and ModTCP Servo Systems
New!
LS Electric iX7 servo systems offer advanced multi-axis motion control functions over EtherCAT® and ModbusTCP networks.
- 9 standard servo systems from 100W to 3.5kW
- Low and medium inertia motors
- Multiple input power options:
- 110VAC single-phase up to 400W
- 230VAC single-phase up to 2.2kW
- 230VAC three-phase in all sizes
- Use with any CANopen over EtherCAT (CoE) compatible PLC/host controller or any controller with ModbusTCP capability
- Fully digital with 1kHz velocity loop response
- Multiple auto-tuning modes
- Easy setup and diagnostics over EtherCAT or or via free DriveCM PC-based software
- Field upgradeable firmware ensures the drive can always be upgraded to the latest operating systems
- Software-based oscilloscope feature that can monitor a variety of command and status signals, including output speed, torque, power and more
- Servo drives feature Safe Torque Off (STO)
- Two-year warranty
LS Electric L7C Servo Systems
LS Electric L7C basic servo systems provide the most requested features - setup wizards, auto tuning, built-in indexer and more - in an extremely cost-effective package.
- Five standard servo systems from 100W to 1kW
- 200-230 VAC single-phase input power on all systems
- Fully digital with up to 1kHz velocity loop response
- Control via high-speed pulse train, analog speed or torque signal, or internal indexing
- Up to 64 indexes can be stored in the servo drive and initiated by digital inputs (or via Modbus)
- Use with CLICK, Do-more BRX, Productivity, or LS XGB PLCs or any other host controller or HMI
- Multiple auto-tuning modes
- Easy setup and diagnostics with built-in keypad/display or the DriveCM PC-based software
- Professionally manufactured cables for motor power, encoder feedback, and brake (optional)
- DIN-rail mount I/O break-out kits for easy connection of external command and I/O signals
- Field upgradeable firmware ensures the drive can always be upgraded to the latest operating system
- Software-based oscilloscope feature that can monitor a variety of command and status signals, including output speed, torque, power, and more
- One-year warranty
LS Electric L7P Servo Systems
LS Electric L7P intermediate level servo systems provide all the features of the L7C series including setup wizards, auto tuning, built-in indexer and more, but with a wider range of motor sizes and drive input power.
- Twelve standard servo systems from 100W to 7.5kW
- 230 VAC or 460 VAC three-phase input power (systems up to 2.2kW accept single-phase 230 VAC input power)
- 19-bit (524,288 ppr) absolute encoder built in on every motor
- Fully digital with up to 1kHz velocity loop response
- Control via high-speed pulse train, analog speed or torque signal, or internal indexing
- Use with CLICK, Do-more BRX, Productivity, or LS XGB PLCs or any other host controller or HMI
- Multiple auto-tuning modes
- Easy setup and diagnostics with built-in keypad/display or the DriveCM PC-based software
- Field upgradeable firmware ensures the drive can always be upgraded to the latest operating system
- Software-based oscilloscope feature that can monitor a variety of command and status signals, including output speed, torque, power, and more
- Two-year warranty
LS Electric PHOX EtherCAT DC Servo Systems
LS Electric PHOX DC servo systems offer single or multi-axis motion control with DC input power and multiple control options (including EtherCAT).
- 4 standard servo systems from 100W to 300W
- Low inertia motors
- 24-80VDC input power
- Perfect for mobile applications or when sharing a DC power source between multiple axes
- Perfect for mobile applications or when sharing a DC power source between multiple axes
- Supports multiple control modes:
- CANopen over EtherCAT (CoE)
- Pulse train
- Velocity and torque control (analog or setpoints)
- Internal indexer
- External encoder feedback (full closed-loop control)
- Fully digital with 1kHz velocity loop response
- Multiple auto-tuning modes
- Easy setup and diagnostics over EtherCAT or or via free DriveCM PC-based software
- Field upgradeable firmware ensures the drive can always be upgraded to the latest operating systems
- Software-based oscilloscope feature that can monitor a variety of command and status signals, including output speed, torque, power and more
- Two-year warranty
High-Precision Inline Strain Wave Gearboxes
Strain wave technology allows for a higher gear ratio and efficiency in an inline form-factor. These gearboxes are designed to work with SureServo2 and SureStep motors.
- High gear ratios compared to similar-sized planetary gearboxes (up to 160:1 for stepper gearboxes and 200:1 for servo gearboxes)
- Low heat and noise generation
- Large selection of output shaft diameters
- Lifetime zero backlash
- Pre-lubricated for life
Precision Gearboxes for Servomotors
The PGA series of inline planetary gearboxes has a thread-in mounting style, along with a level of precision and torque capacity that is best in its class. The PGB series of right-angle planetary gear reducers offers similar technical specifications to the PGA series and provides an excellent solution when space and clearance requirements are limited. PGD series gearboxes with compact design and hub style output are ideal for equipment that requires high-speed, high-precision indexing movement. The LS Electric MSS series of high precision gear reducers are specifically designed to mate to LS Electric L7C & L7P series servo motors.
- Thread-in mounting style
- Best-in-class backlash
- Four gear ratios available (5:1, 10:1, 15:1, 25:1) additional gear ratios for PGD models (35:1 and 50:1)
- PGA, PGB and PGD series gearboxes easily mate to SureServo motors, mounting hardware is included
- MSS series gearboxes mate to LS Electric servo motors
- A range of gear ratios available
- Uncaged needle roller bearings for high rigidity and torque
Stepper Systems
Newest Additions!
- Ever Motion Solutions stepper drives and accessories
Leadshine® stepper drives offer basic features and general-purpose performance. Leadshine drives work with all SureStep stepper motors to provide an even more cost-effective system.
SureStep® is a high performance open-loop stepping system that provides simple and accurate control of position and speed, and offers a low cost motion control solution with up to 1800 oz-in of torque (select SureStep integrated stepper motors/drives have integral encoders that allow for closed-loop control).
- Standard SureStep stepper drives require a pulse input stream from a PLC or indexer (motion controller) to enable very precise motion control.
- Advanced SureStep stepper drives also accept pulse inputs, but they also can be commanded by an analog speed signal or by serial communications.
- Linear actuators with NEMA stepper motor and integrated lead screw are also available.
Ever Motion Solutions® stepper drives provide the highest performance levels with both open- and closed-loop control options. Ever stepper drives offer advanced features such as the monitoring of back EMF signals from the stepper motor to detect stalls without an encoder. Ever stepper drives work with all SureStep motors to provide peak stepper system performance.
Precision Gearboxes for Small NEMA Motors
The SureGear PGCN series is a great gearbox value for servo, stepper, and other motion control applications requiring a NEMA size input/output interface. Features include:
- Wide range of ratios (5, 10, 25, 50, and 100:1)
- Low backlash of 30 arc-min or less
- 20,000 hour service life
- Maintenance free; requires no additional lubrication
- NEMA sizes 17, 23, and 34
- Includes hardware for mounting to SureStep stepper motors
- Optional shaft bushings available for mounting to other motors
Linear Motion Slides and Actuators
Motor-ready linear actuators and sliding components turn rotary motion into linear motion, providing a variety of X-Y and X-Y-Z positioning system solutions. Options for mounting stepper or servo motors as well as a full selection of accessories are available to complete a linear motion system.
- Ball screw driven actuators - capable of high speeds and duty cycles
- Lead screw driven actuators - provide high performance for light or heavy loads at an economical price
- Belt driven actuators - provide simple, dependable motion along a longer axis
- Undriven linear slides - used in multi-axis systems and run parallel to a linear actuator of the same travel length, typically used to stabilize the X-axis
- XYZ gantry components in all four styles
Stepper Motor Linear Actuators
Stepper motor linear actuators are stepper motors that incorporate a lead screw as the rotor, which translates motor torque into linear thrust. These actuators are often used with undriven linear slides or linear shafts/linear supports.
- NEMA 17 and NEMA 23 frame units available in a range of lengths and lead screw pitches
- Up to 193 lbs of thrust and speeds up to 18 inches/second
- Extension cables and other accessories available
Drive Couplings
Drive couplings are used to couple the shafts of various mechanical devices and compensate for misalignment.
- Jaw / Spider Couplings
- Double Loop Couplings
- Oldham Couplings
- Beam-Style Servo Couplings
- High-gain servo couplings
Bore Reducers
For use in all SureMotion drive coupling hubs to reduce bore size.
- Split-collar design with 2 set screw flats will not mark shaft
- 25% greater holding power than standard split collar
- Hardened stainless steel
SureServo1 Servo Systems (SVA-Series)
SureServo1 has been replaced by SureServo2 (more features, less cost). Please do not specify SureServo1 systems for new applications.
The SureServo® 1 family of brushless servo systems offers eight standard servo motors that can be operated in combination with one of three standard servo drives.
The SureServo1 family includes standard accessories such as: servo motor encoder cables, servo motor power/brake cables, ZIPLink kit for servo drive's CN1 connector, optional external regeneration resistors, and optional AC input filters.
- Eight standard servo systems from 100W to 3kW
- Use with AutomationDirect CLICK, DirectLOGIC, or P3000 PLCs; or any other host controller
- Servo Drives feature on-board indexer and adaptive tuning modes
- Free set-up software
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