IEN: What improvements are expected in motion-related technologies in customized solutions for optimal application form factors?

Derstine: Optimizing motion solutions for a specific application takes into account many factors that can impact the effectiveness of the final solution. Customers prefer to utilize standard off-the-shelf components that can be configured and programmed for their full range of application solutions. One of the key factors is how effectively integrated the motion is with the rest of the machine control. Typically a host (PC or PLC) controller is used along with one or more operator interface stations to affect overall machine control, communicate with the operator, and provide valuable status information for the system. A well-integrated motion and machine logic solution that utilizes open standards improves the customer's engineering efficiency. One of the few open standards for motion programming is being driven by PLCopen and endorsed by the OMAC User's Group. The PLCopen Motion Control Library specifies an independent library of function blocks for motion control using IEC 61131-3 language standards that are independent of the underlying control system architecture. An integrated solution also can minimize programming effort and allow greater reuse of programs for different applications.

IEN: . . . Common standards for interfaces, programming, and physical connections?

Derstine: As mentioned above, customers want to use solutions that employ open standards for programming that allow them to minimize training and learning curves resulting from using motion controllers from different suppliers. The wiring cost associated when deploying motion solutions on large machines can be prohibitive. On long production lines, physically distributing the motion control can reduce wiring time and cost and provide modular machine solutions. Using fiber optic interfaces on distributed motion architectures can greatly minimize the effects of electrical noise and improve system reliability.

IEN: . . . Smaller motion device footprints? Feedback technology? Other areas?

Derstine: In an effort to reduce machine real estate on the factory floor, there is always pressure to reduce the physical size of control components. With the advanced magnet materials and advanced manufacturing techniques, servo motors continue to push the envelope by delivering higher torque and speed in increasingly smaller motor frame sizes. This has the added benefit of reducing the motor's inertia, allowing for higher machine cycle rates and improved productivity.

IEN: How can users implement preventive or predictive monitoring in motion solutions?

Derstine: Real-time monitoring of motion systems allows users to anticipate component failure and take preventive action when it is most advantageous, such as during an off shift or scheduled maintenance period. Monitoring the torque or current demand of the motor over time can help predict changes in the machine such as increased friction, worn mechanics, or machine jambs that can lead to premature component failure or machine downtime.