The trends within the motion control industry now see a reduction in the control cabinet and a trend toward junction boxes and PC-based control. Developed together with numerous customers, GALIL and Phoenix Contact now offer a smaller, compact motion control solution that is smart, flexible, and space saving. The PC-based Digital Motion Control system from GALIL under the banner OPTIMA and ECONO is fitted into a slot within a PC. The corresponding external field connections are connected to an Interconnect Module that is 25% smaller than classic designs and allows for DIN-Rail or panel mounting.

Power usage within the motion control system sees the use of Three Phase 480 Vac for robots, and the standardizing of 24 Vdc for all input and output devices like sensors, limit switches, safety relays, and actuating devices. This allows for two voltages within the control since the step-down transformer (big, bulky, and a heat source) will not be needed. Today's generation of switch-mode power supplies offers a direct step from three phase 480 Vac to a single 24 Vdc output and offers many new features which guarantee system up-time even if one of the three phases is lost.

Space is critical to the application and so relays in widths of 1/4 and 1/2 inch packages are now used to power 6A @ 250 Vac loads. Relays with reduced power consumption and space requirements offer an 80% reduction in current consumed and up to 60% space saving.

Speed in installation, short run times, and reduced fault finding are now guaranteed with pre-wired swing arms and cable to the PLC, PC, and embedded control devices. The trend is also heading toward modular, multichannel devices such as the new IOC 7007 developed by GALIL. In future, motion controllers will have as much, if not more, flexibility than their Industrial PLC counterparts.