Design World Motion Control Trends Handbook | March 2026

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Micrometer Positioning Stages

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Del-Tron’s micrometer positioning stages and crossed roller positioning stages are available with travels ranging from .25” to 2.0”and are available in X, XY and XYZ configurations carrying loads ranging from 4 lbs to 160 lbs. All model numbers are available with inch or metric micrometers and mounting holes. Most models are available with locking micrometers and all models can be supplied with our Posi-Lock friction locking mechanism to secure the table. Positioning accuracies range from 0.0005” per inch of travel straight line accuracy on our ball slide positioning stages to 0.0001” per inch of travel straight line accuracy on our crossed roller positioning stages.

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Del-Tron’s Posi-Drive™ lead screw actuators are compact and economical, taking the work out of designing linear motion systems. Available in 3 size profiles, our lead screw actuators require no alignment of components and install with standard fasteners. They are fitted with anti-backlash lead screws and multi-beam couplings with high speed misalignment capability and standard NEMA motor mounts. Available in one, two or three axis configurations these stages travel up to 12”. The crossed roller slide option increases load capacity up to 180 lbs. and 100 million inches of travel is possible at 1/2 rated load.

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SureStep stepper motor linear actuators incorporate a lead screw as the rotor. These actuators translate precise rotational movement into linear motion. They are maintenance-free and are a great cost-saving option for linear motion applications.

INTEGRATION IS THE NAME OF THE GAME

I’ve been in the field of motion control so long that I remember when the marketing and use of pre-integrated linear actuators was new trend. Preintegrated smart motors came next in the early 2000s … and then several suppliers found themselves in legal battles over the intellectual property to make such motors feasible.

automotive and aerospace applications. Other linear-motion technologies to complement robotic workcells are eighth-axis (vertical) RTUs and proprietary cobot feeders. The latter are automated racks for machinetending applications.

Now, the latest trend in pre-integrated motion solutions is that for robotic joints. At the most recent MD&M West, at least a dozen suppliers had on display their particular iteration of frameless motor combined with strain-wave or planetary gearing and of course two encoders — one to close the loop on position (for motion controls) and the other to inform motor commutation.

Most striking though is the trend towards completely pre-integrated motion systems to complement robotic workcells. These pieces of equipment help in machine tending, assembly, and (most challenging) the robotic coordination with conveyors.

One such example? Seventh-axis systems — also called robot-transfer units or RTUs. These have existed for some time but really began proliferating in about 2014 … roughly in tandem with the spread of robotics beyond high-end

Conveyors are of course their own kind of pre-integrated motion system with belt or power roller, motor, braking, and control elements all needing consideration for workcell coordination. Here, it’s increasingly common for some robot manufacturers’ software plug-ins (as covered in this year’s Design World Trends feature on software) to configure and control conveyors and their accessories. Basically, conveyors get added to the programming with inputs and outputs for starting, stopping, referencing speeds, and monitoring status. Such integration acts as a handshake between conveyor and robot and even lets operators concurrently run multiple conveyors off one controller. Robotic applications run with simpler controls need workpieces to be in an exact location on the conveyor. But something needs to impart precision to the operation, and usually that’s a servodrive. In contrast, lineartransfer systems — perhaps the most unapologetically pre-integrated solution of all — use direct-drive linear-motor tracks for repeatability to ±0.075 mm. That kind of performance is good enough for directly interfacing with assembly stations. •

Image: ADOBESTOCK / GORODENKOFF

SOFTWARE ECOSYSTEMS FOR MOTION

Some of the latest developments in software ecosystems aim to make motion systems easier to design and commission. Artificial intelligence (AI) has made rapid inroads here. For motion systems specifically, the trend is to use AI for:

• SERVOTUNING — before a system is put into service.

• PREDICTIVE MAINTENANCE — when a system is running in service.

The most advanced design and control software today tailored to semiconductor, photonics, aerospace, and medical-device makers ... and based on massive data gleaned over years to shape recommend adjustments.

First consider servotuning. Most vendors of servo controls offer motioncontrol autotuning software. Usually, the servodrive and controller move the system at multiple frequencies and then tuning parameters are autoset for optimal response.

Even now, autotuning can’t always produce the most optimized motion — especially in dynamic systems. In these situations, manual gains and filters tuning is typically required — and done by highly experienced integrators, consulting engineers, or in-house engineering with

Standardizing on a given ecosystem unifies design-engineering workflows.

lots of institutional knowledge. Such manual tuning is common.

But in a few high-end (demanding and dynamic) applications, AI-equipped servotuning can now run prewritten algorithms that proceduralize, formalize, and thereby replicate the so-called “black

magic” of tuning experts.

For example, one AI-driven software called EasyTune can autotune servosystems with approaches honed by machine learning. The software is targeted to semiconductor, photonics, aerospace, and medical-device makers and based on massive amounts of data gleaned over years to shape recommend adjustments. From our webinar sponsor Aerotech, this software lets engineers fine-tune their systems without needing indepth knowledge of servomechanic tuning.

Panasonic Industry is another supplier. They sell a servodrive that runs an AI-equipped servotuner (called precAIse Tuning) to cut position settling times to better than those of possible with manually tuned systems. That lets end users take full advantage of a Minas A7 servo drive-motor-control system having 27-bit encoder resolution and response frequencies to 4 kHz.

Other suppliers that offer AI-equipped servotuning software include Fanuc and Mitsubishi Electric with their Compact AI software.

In fact, Compact AI also executes certain predictive-maintenance functions — the second motion-related use we mentioned. Here, the trend is towards real-world uses of AI to leverage all the data that’s now easy to collect from automated installations. For example,

the programmed versus actual move profiles of machine axes can be noted during commissioning and then tracked over time for deviations or performance drifts as well as more dramatic changes such as payload. Some suppliers’ tools include AI that can also inform parameter servotuning to adjust for a machine reassigned to new tasks or showing wear over time.

AI aside, many of today’s software tools can also detect when servomotor temperature (proportional to current draw) rises over time — typically because of wear of the mechanical assembly. Preventative maintenance with AI can track these trends to best time relubrication or replacement.

Vibration detection with accelerometers (in some cases on encoders) can also be paired with controllers … those that run Fast Fourier Transforms can allow the visual display of frequencies normally present when a machine runs … and when those frequencies change.

When informed with sensor feedback, software can also monitor multi-axis synchronization, energy consumption, advanced tuning settings, and the reliability of system communication and controls.

To be clear, the most advanced versions of these functions are typically

FOR POSITION FEED BACK

associated with dedicated motion controllers … and hardware does have a bearing on what software is employed. Of course, software associated with PLCs and industrial PCs handle motion ... and so-called software ecosystems have really blurred the differentiation between motion and the rest of the automation space.

PLC and industrial PC systems offer tight I/O integration, automation synchronization, vision, RFID, and SCADA and MES applications for digitaltransformation (DX) functions.

TRENDS IN DESIGNENGINEERING SOFTWARE CONSOLIDATION

Regarding software for electrohydraulic and servo-pneumatic systems, leading options offer realtime tuning and advanced condition-monitoring functions once systems are in operation. For example, some offerings from Danfoss allow programming and commissioning as well as valve configuration.

For electromechanical systems destined for discrete automation, it’s now pretty standard for motion to seamlessly meld with machine functions — confusingly called process control in a lot of contexts. For example, Aerotech’s Automation1 is billed as a software-based controller. It can run on PC or drive

Position, angle and speed measurement

Contactless, no wear and maintenance-free

High positioning accuracy and mounting tolerances

hardware, and lets engineers program single axis moves or build complete machines. The suite’s Motion Development Kit is configuration, control-device setup, and programming … including that EasyTune (which we covered earlier), and live build checking.

For automation employing PLCs, Siemens and Rockwell dominate; these include TIA Portal and FactoryTalk along with the SIMOTION, Studio 5000, and other pieces for motion and drive functions.

Standardizing on a given ecosystem unifies design-engineering workflows. A potential drawback to using such suites is vendor lock-in. It’s also true if an engineer picks B&R Automation Studio or Beckhoff TwinCAT or Bosch Rexroth ctrlX or Omron Sysmac or Schneider EcoStruxure because these also define entire machine architectures. Of course, machine builders can’t always pick the platform. Once a company is locked into a vendor, it may be impossible to switch. Software compatibilities can also evolve over time — and that can also necessitate the need to manage legacy versions.

NEW TRENDS IN SIZING, SELECTING, AND COMMISSIONING TOOLS

In 2025 we take for granted all the online sizing and selecting portals (and

downloadable software) ... especially when those tools are for configuring and procuring mechanical components. Tools abound from all kinds of linear-motion, gear, encoder, and coupling suppliers. But even electric motors are configurable now.

Examples abound, but one industrytypical example is the Leroy-Somer Configurator from Nidec to let machine builders select motors, gearmotors, electronic drives, and brakes (if applicable) to obtain CAD files and technical specifications.

With some motors, it’s also become possible to import component parameters into control software.

For example, ECM PCB Stator Tech lets engineers specify motors with stators that are printed according to the engineer’s requirements. At the core of this technology is software that takes engineers from simulation to prototyping to fully functional motors in a go.

Generated by the design tool is the aforementioned hardware as well as tightly integrated firmware for realtime control.

A new company called Alva Industries now offers a similar software tool for procuring custom motors. Called TorqStudio, this online platform was first shown at Smart Production Solutions or SPS 2025 show. The software combines motor simulation and design — from the exploration of concepts to detailed

performance verification before machine builders have to commit to hardware.

For motor creation, the engineer just defines their required motor size. The platform then automatically generates an optimized motor variants with different tradeoffs in motor mass, motor constants (Km), torque capabilities, and efficiency.

It’s entirely analytical so results come in milliseconds instead of minutes or hours. Every generated motor is mathematically accurate, physically realistic, and manufacturable.

Users can also analyze any motor created within the software or from a stock catalog of torque motors and frameless motors.

We’ve already touched on AI for servotuning … and expect to see more in coming years. Software with these tools and other commissioning tools often come from companies traditionally known for their drives. For example, Yaskawa’s free SigmaWin+ is the de-facto setup and tuning suite for Sigma SERVOPACK amplifiers for mechanical analysis, simulation, and autotuning. Kollmorgen, Elmo Motion Control, ACS Motion Control, Galil … these companies also lead with drives and the software follows.

EDGE COMPUTING AND CLOUD COMPUTING

Ever-more tools are built into today’s software and yet many need vendor addons. Base software packages are often free. However, motion add-ons, safety editors, and visualization and simulation modules usually require purchase … so there can cumulative licensing costs tiered into base software packages. Or the opposite can also be true (as with Siemens products, for example) … so purchase of the base package allows access to a library of modules. Either way, hardware comes with free customer experience or CX software just to get the user going out of the box.

Cloud computing for system setup and configuration aren’t especially common yet — unless there’s reuse of some configuration for projects being scaled perhaps. But what is common are operations that leverage offsite

computational capabilities to aggregate, manage, filter, and analyze data. That usually offers more computational power than local platforms.

For edge computing in discrete

automation, typical edge devices include actuators, sensors, and connectivity components. These can also include gateways (for cross-system communications) and in fact, smart

motors can also be considered edge devices if they include onboard drive and control electronics. These eliminate data bandwidth and latency issues.

Essentially, these filter and analyze data before it’s sent onward to central controls or the design’s cloud presence. Here, AI (in the form of machine learning) is already leveraging edge-generated data to monitor and improve individual component and overall machine performance and life.

Code generation in engineering software is nothing new … it generates models and executable PLC or motioncontroller code so machine builders don’t have to write it by hand. Commonly supplied motion blocks (prewritten) are axis control, camming, gearing, and diagnostics. Oftentimes, this is Structured Text or Function Blocks that can run deterministically on the target hardware — and in IEC 61131-3 programming formats. IEC 62443-4-2 is increasingly important as well for cybersecurity of discrete automation.

A nice-to-have is an ecosystem function that gives engineer access to the entire stack including lower-level code — even that generated by autotuning, sampling, and interpolation modes. Where there’s a bit of code transparency, there’s the possibility of debugging control logic, drive parameters, fieldbus issues, and various machine-safety states. •

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MOTION CONTROL TRENDS IN MATERIAL HANDLING

Material handling, as it is generally called, involves the manipulation and transport of material for a number of reasons, from storage to manufacturing processes to lab uses in medical and research fields to semiconductor manufacturing, and more. The technology involved in material handling applications are the same as many other uses, including motion control components such as motors, drives, controllers, as well as actuators and mechanical transmission elements, as anytime the transport of discrete items are involved there will be motion control.

Creative Motion Control features high-force electric actuators, with the company’s CPD-800 series capable of maximum continuous dynamic force of 125,000 ft-lb.

The best material-handling systems ensure seamless operations in manufacturing, such as taking products from raw materials to finished products, and a whole host of other operations. Machine end users can leverage efficient material handling to maintain high-quality standards for their precision products. Innovations in material-handling are having an impact on manufacturing, production, and automated warehousing. These include advancements in conveyors, ac motor and drive systems, linear and robotic-based automated warehousing and retrieval systems, linear and rotary actuators, encoders, and other feedback

technologies. From high-speed sorting and accurate positioning to seamless robotic collaboration, these modern systems are reshaping industries such as e-commerce, logistics, and manufacturing.

ACTUATORS IN ROBOTIC SYSTEMS FOR MATERIAL HANDLING

There are plenty of robotic systems being used by manufacturers designed specifically for material handling uses. Among those robotic systems, there are a range of different types of linear actuators employed.

There are several major types of linear actuators, which include pneumatic cylinders (rod or carriage style), hydraulic cylinders (rod style), screw-driven actuators (rod or carriage style), beltdriven actuators (carriage style), and linear

motors (carriage or rod style).

Which actuator is best suited for a particular application will depend on a number of factors. For robotic material handling, the choice of actuator depends on the specific application requirements, such as speed, load capacity, precision, and the type of movement needed (linear, rotary, or vertical lift). Each actuator type offers unique benefits to optimize performance and efficiency in these systems.

For example, payload specifications are key; from a few kilograms to upwards of several hundred kilograms or more. Another critical specification is reach, often given in millimeters or meters. Also, the required torque as well as the motion profile.

To take just one example, consider linear motor actuators. These directdrive actuators eliminate mechanical

transmission elements, connecting the load directly to the carriage. Linear motors are compact, efficient, and capable of high speeds and accelerations. They’re especially well-suited for multiaxis cartesian or gantry systems where precision and fast move and settle times are important. Linear motor actuators are also environmentally friendly due to reduced energy consumption and the elimination of hydraulic fluids. What’s more, actuators for robotics are being integrated with other components such as sensors and controls to save space, simplifying design and installation.

Recently, Creative Motion Control, a manufacturer of roller screws and roller-screw-based actuators, announced their extra-large and high-force electric actuators, some capable of maximum dynamic continuous forces of up to 125,000 and 250,000 ft-lb.

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TRANSITION FROM HYDRAULICS TO ELECTRIC ACTUATION

For applications requiring high forces for handling large payloads, the traditional go-to for actuation has been hydraulic systems. However, there is also the seemingly age-old “hydraulic vs. electric” debate, where the thinking is that hydraulics were going away, eventually to be replaced by electric actuators.

The consensus today appears to be that there is a place for both kinds of actuators in a wide industrial landscape. However, increasingly, electric actuators, as they’ve evolved to offer more power density, are replacing hydraulic actuators in some applications. For material handling, this may apply to some common kinds of applications such as pallet handling, lift tables, coil & roll handling

(heavy industrial loads), and others.

The main advantage of hydraulics is the high force density and controllability of hydraulic actuators, making them ideal for performing tasks such as lifting, pushing, pulling, and rotating heavy objects with ease. Nevertheless, there has been an ongoing transition to electric actuation for some applications. The truth is that there are a number of applications or use cases where such a transition is possible, and so the change is being made.

Converting hydraulic systems to electric actuators can yield significant efficiency, safety, environmental, maintenance and economic benefits, but realizing these benefits requires careful decision making throughout the conversion process. To help facilitate the electrification of a linear motion application, ensuring optimal performance and long-term success, it’s recommended

to consistently follow a proven set of steps. Some applications where the shift from hydraulic actuators to electric actuators has taken place include selfdriving forklifts used in industrial warehouses, highlighting the shift to more intelligent material handling equipment.

MOTORS AND DRIVES

The motors and drives used in material handling applications are also seeing changes geared towards specific application requirements and aligning with general trends towards more intelligent machinery.

It’s important to have the right drive system for material handling equipment in place to increase efficiency and reliability. This goes for any piece of equipment from motor-assisted tow trucks to forklifts, to robotic vehicles and more. On the motor

The CMMT-ST servo drive starter kit from Festo comes with a CMMT-ST 300 W servo drive, EMMT-ST stepper motor with battery-free multi-turn absolute encoder, motor cable and connectors, and QR codes linking to essential software tools.

end, this can include ac as well as dc motors, both brushed and brushless, and the appropriate drives.

One area in particular that has seen development is smaller servo drives, especially for mobile robotics applications or smaller robotics. Here, the idea is that drives with higher current output can power applications such as traction motor applications in autonomous mobile robots (AMR), automated guided vehicles (AGV), and other space-limited mobile robotics that require higher-power.

For example, a drive from Festo helps achieve these goals while at the same time helping to simplify design and development. The company’s CMMT-ST servo drive starter kit provides control engineers and programmers with a costeffective way to learn commissioning and sizing for Festo’s multiprotocol servo drives, which range from 300 W dc to 12 kW ac.

The Festo CMMT-ST servo drive and corresponding EMMT-ST stepper motor are packaged in a pre-application starter kit for developers. Each of these developer’s kits contains a CMMT-ST 300 W servo drive, EMMT-ST stepper motor with battery-free multi-turn absolute encoder, motor cable, and connectors.

The CMMT-ST servo drives have a number of features including integrated safety functions such as Safe Torque Off (STO), data monitoring, dynamic, pointto-point, and interpolating movement, and control of a number of different motor types including BLDC, stepper, and EC motors. Fast and easy commissioning is available with Festo Automation Suite, and there is direct and secure cloud connectivity.

The Festo CMMT-ST DC and CMMTAS AC servo drives are compatible with EtherNet/IP, EtherCAT, PROFINET, and Modbus TCP protocols. Users log onto the drive and select the protocol from a dropdown menu, which reduces inventory and engineering effort. •

Conveyor tending by robots is supremely demanding. Pairing robotics with pallet-fixture conveyors (as depicted here) is one increasingly common approach — especially in automotivecomponent, medical-device, and electronics manufacturing … as well as automated product testing and inspection.

NEW AUTOMATION IN ROBOTICS AND PACKAGING APPLICATIONS

MILES BUDIMIR | SENIOR EDITOR

Motion control is central to robotics, and robotics are now central to a wide range of industrial operations — from their traditional use in manufacturing to mobile robotics and warehouse automation. Take the case of warehouse automation, which is continuing to evolve. Here, fleets of mobile robots have grown and robot

deployments are still accelerating, even though the market has been soft for the past few years. The variety of robots is expanding as well; from picking and collaborative robots to robots loading and unloading trucks and robots for palletizing. There’s also a lot of talk about humanoid robots, with most of the trials for humanoid robots actually taking place in warehouse applications. At the end of the day, what’s driving all of this are labor shortages around the world, and people are really looking to augment their existing staff and deal with all the supply chain shocks that

companies have been dealing with over the past few years.

DESIGN CHALLENGES

Along with these new uses are changing expectations, impacting design parameters. For instance, whether it’s sensing or manipulation or even safe navigation and mobility, these new robotic systems are requiring new thresholds of accuracy and precision. Another big challenge for people designing motion control systems is that they’re not operating in isolation

anymore. Quite often one has to integrate among systems, and that might call for having a mobile robot that’s picking up something from a stationary arm that’s picking pieces. Or there might be an instance where a fork truck has to operate around human workers. So, there’s a real issue about getting all these systems to play well together. Then there’s also the issue of how are they connecting. Is it EtherCAT, Profinet, Ethernet-IP? The good news is that there is a software layer that’s emerging that can help coordinate all of this complex motion.

Another major concern is safety. Many of the warehouses where these systems are being implemented are not standardized, so there are still human workers in them. This makes avoiding collisions between humans and robots, and between robots themselves, a critical issue. For instance, there are situations where two robot arms may not be talking properly and they collide. But there are also cases where there are “traffic jams” with robots, or misplaced items. For example, a robot may be unloading a box from the back of a truck and drop it.

So, the question then becomes is the robot able to then safely recover, pick up the item that was dropped, and put it back on a conveyor, for instance, or is some other solution more feasible? How to manage it all?

A lot of these safety concerns go back to technical parameters such as precision and repeatability. However, designers are also under pressure to implement lighter actuation and smaller form factors. Sensors are continuing to improve, but they have to be constantly integrated.

There are also technologies such as regenerative drives or wireless charging that can maximize energy efficiency. Because many warehouses are massive facilities, there’s also the push to improve cycle times as well as endurance.

MOTION CONTROL SOLUTIONS

The motion control components and their design and feature sets are evolving to meet these needs. Take one of the functions in warehousing applications that meld with packaging and material handling; part handling.

Consider an ejection system. In contrast to heavy payloads such as product-filled boxes or other heavy objects, some applications involve small or delicate parts, which call for different handling techniques. For such use cases, there are soft eject systems that are designed to handle lighter or more fragile payloads.

Or consider applications in the beverage industry. Here, the items may be glass bottles or cans. The bottles move at extremely fast speeds, upwards of 1,000 bottles per minute or more. At such speeds, anomaly detection requires a motion system to remove any defective bottles, which could be that one bottle isn’t filled all the way or there’s a chip on the glass rim or a missing cap, or some other anomaly.

Such an application requires a lot of different functions from a motion system. For starters, it must have a detection system, with sensors and software to identify anomalies accurately. In addition, there needs to be high-speed connectivity or networking to enable fast removal

of the anomaly from the line without disrupting the rest of the process. This includes responding without damaging the bottle (or product) itself, which would create additional problems and disrupt operations further.

In this type of application, with the speeds that these applications demand, manual inspection is simply not feasible. Which is what makes them ideal for an automated inspection system. However, here precision (and speed) is key. That’s why these systems rely on precise motion

control systems that communicate between the sensors, the software, and making sure that these systems receive accurate signals in a time-sensitive way. After proper detection, the next step is how to remove the anomaly from the line. Here the challenge becomes how to eject the anomaly without too much force that causes it to fly off the conveyor or break the bottle. So, this leads to other considerations besides the detection itself — namely, that the specified actuators excel in these types of applications.

SAFETY IS JOB ONE WITH ROBOTICS

THERE’S BEEN A BLURRING OF LINES between traditional industrial robotics and collaborative robots. Robotic safety features are just one aspect of this convergence. Newer systems aim to reduce reliance on gates, fences, and other physical isolation — as well as inappropriate overreliance on emergency-stop buttons than can cause various production issues. Personnel-detecting equipment such as light curtains remains increasingly relevant here.

The latest news in robotics safety is that the Association for Advancing Automation (A3) just published in late 2025 the American National Standard for industrial robot safety requirements — to govern robots’ safe manufacture, integration, and use.

ANSI/A3 R15.06 dates to 1986 … ISO 10218 (upon which the current iteration is based) dates to 2006. Basically, to unify U.S. approaches, the Robotic Industries Association (RIA) combined the ISO standard into their ANSI/RIA standard.

In 2021, A3 absorbed RIA and the management of its standards. This and the fact that the standard now comes from A3 underscores the inextricable link between motion and robotics.

So, the new 2025 ANSI/A3 R15.06-2025 and .06-3-2025 includes Parts 1 and 2 — basically, the U.S. adoption of ISO 10218-1:2025 and 2:2025. Then a Part 3 (with U.S. and Canadian input) addresses requirements not covered by ISO. The standard emphasizes risk assessments, personnel safety protocols, and technical directives for system integrators, manufacturers, and end users to maintain industrial-environment safety.

This is why manufacturers are developing systems using special kinds of linear motors instead of other common actuation technologies such as pneumatic actuators, for instance, which may be a bit too aggressive in the case of removing bottles from lines. Here, a series of linear actuators can fire off sequentially to remove bottles from the line within milliseconds. They can do this while keeping the bottle upright and without disturbing the rest of the line.

NETWORKING, COMMUNICATION, AND BEYOND

Beyond some of the basic motion components already discussed, networking and communications are also vital to motion control and automation. Technologies include sensors, software, and AI tools that are improving predictive maintenance functions in automation systems as well.

Data connectivity and interoperability are central here, with sophisticated sensors that can detect vibration, heat, and other parameters and deliver realtime data. Now with the use of AI or machine learning algorithms, such systems can also decode large continuous data streams. Then based on all of their past learnings, such systems can predict when a component might fail or how much useful life the component has left before needing to be replaced or serviced.

These newer capabilities require more upfront effort and engineering resources, such as the need to connect and collect large amounts of data for a long time in order to train the AI algorithm. Here engineers must know how to work with such systems and put an effective AI tool to use — a different skill set than the typical motion system engineer may possess.

In the end, the benefits can be well worth the investment. With predictive maintenance, one no longer has to rely on manually created or calculated maintenance schedules, which could include conservative estimates such that recommendations may include replacing parts prematurely, and therefore not optimizing the life of that part. •

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POSTMASTER:

wire windings — all with threefold less heat waste.

The motors excel in motorized surgical tools, active prostheses, drones, aerospace designs, precision industrial equipment, and robotics.

The performance of traditional motors depends on their copper windings — in turn quite long and challenging to wind … so during prototyping many are in fact assembled by hand. Then full production runs are done on oft-expensive and inflexible machines dedicated to a particular coil.

In contrast, Mirmex Motor winding patterns are created using AI algorithms and printed on strips of flexible circuit board that are then put flat into axial flux architectures or

closed into tube for radial architectures. The manufacturing and validation are automated. By varying the winding’s conductor sizes, thicknesses, interconnections, and even the pattern itself, the winding can be optimized for different applications, environments, and constraints. •