Although motion control and robotic systems may be used to achieve the same goal, they do so in different ways. So, what exactly are the differences between them?
In the industrial sector, automated factories are a growing trend. This is not difficult to understand, as these applications help improve efficiency and productivity. To create an automated factory, engineers can implement a motion control system or introduce a robotic system. Both methods can be used to accomplish the same tasks. However, each method has its own unique setup, programming options, motion flexibility, and cost-effectiveness.
Fundamentals of Motion Systems and Robots
A motion control system is a simple concept: initiating and controlling the movement of a load to perform work. They offer precise speed, position, and torque control capabilities. Examples of using motion control include: product positioning required by applications, synchronization of independent elements, or rapid start and stop of motion.
These systems typically consist of three basic components: a controller, a driver (or amplifier), and a motor. The controller plans the path or calculates the trajectory, sends low-voltage command signals to the driver, and applies the necessary voltage and current to the motor to produce the desired motion.
Programmable logic controllers ( PLCs ) offer a cost-effective and noiseless method for motion control. Ladder logic programming has long been a core aspect of PLCs, with newer models represented by human-machine interface (HMI) panels, which provide a visual representation of the programming code. PLCs can be used for the logic control of various motion control devices and machinery.
In a traditional PLC-based motion control system, a high-speed pulse output card is used in PLCs to generate pulse sequences for each servo or stepper drive. The driver receives the pulses, and each pulse has a preset value. A separate signal is used to determine the direction of transmission. This method is called "step and direction".
This diagram illustrates a conventional motion control system, which includes a servo controller , a motor, and sensors .
Commonly used terms in motion control vocabulary include:
• Velocity: The rate of change of position with respect to time; a vector consisting of magnitude and direction.
• Speed: The magnitude of speed.
• Acceleration/Deceleration: The rate of change of speed with respect to time.
• Load: The driving element of a servo system. This includes all machine components and moving parts.
Servo amplifier: A device that controls the power of the servo motor.
• Servo controller: also known as a position controller, this device provides programming or instructions to the servo amplifier, usually in the form of an analog DC voltage signal.
• Servo motor: A device that moves the load. This is the main moving element, and it may include a series of main actuators, such as actuators and induction motors.
• Stepper controller: A device that provides pulses to stimulate the windings of a stepper motor, producing mechanical rotation. It is also known as a speed controller. The frequency or pulses determine the motor speed, and the number of pulses determines the motor position.
• Analyzer: A device that monitors the position of a servo motor and load. Also known as a position sensor.
• Speed sensor: also known as a speed generator, it monitors the speed of the servo monitor.
Baxter, a company that rethinks robotics, is a perfect example of a ready-made collaborative robot solution.
According to the Robotics Institute, "A robot is a reprogrammable, multi-functional robotic arm that can move objects, parts, tools, or specialized equipment through a wide variety of movements."
"Although some components found in the motion control system were located inside the robot, they are fixed inside the robot. The speed of the motors, the actuation force, and the mechanical connections are all components of the robot."
The components that make up a robot system are similar to those of a motion control system. This is a controller that allows parts of the robot to work collaboratively and connects it to other systems. Program code is installed into the controller. Furthermore, many modern robots use HMIs based on computer operating systems (such as Windows PCs).
The robot itself can be an articulated robotic arm, a Cartesian, cylindrical, spherical, scalar, or a parallel selector robot.
These are considered the most typical industrial robots.
For a complete list of robots, refer to our "Differences Between Industrial Robots".
Robot systems also have actuators (i.e.:
The engine or motor moves the linkage to the designated position.
Connections are the parts between joints.
Robots use hydraulic, electric, or pneumatic drives to achieve movement.
Sensors are used to provide feedback on the robot's environment, offering visual and auditory input for operational control and safety.
They collect information and send it to the robot controller.
Sensors can enable robots to work collaboratively—resistive or tactile feedback allows robots to operate around human workers.
The end effector is connected to the robot's arm and functions;
They have direct contact with the products being manipulated.
Examples of end effectors include clamps, suction cups, magnets, and welding torches.
The difference between a musculoskeletal system and a robot
One of the main differences between the two systems is time and money.
Modern robots are marketed as ready-made, turnkey solutions.
For example, a robotic arm has already been constructed and is very easy to install.
General Robotics provides examples of common "devices" and "robots".
They can be programmed through the HMI control panel, or their movement can be recorded by recording positional motion.
The end effector can be replaced with whatever you need, and engineers don't have to worry about the individual programming of the robot's moving parts.
General-purpose robots offer simple location recording programming to assist end users.
The final effector can be swapped for specific applications.
The downside of robots is their cost.
On the other hand, the components that make up motion control applications are modular, and the ability to modularly control motion systems provides greater cost control.
However, for users, there is a greater knowledge requirement to operate the motion control system correctly.
Its components require separate programming from the end user.
If engineers require multiple settings, module configuration availability, and cost constraints, then a motion control system can provide the benefits they seek.
An experienced engineer can spend time planning, installing, and commissioning a motion control system.
You can mix and match old and new hardware and create solutions for your system.
Rockwell Automation’s FactoryTalk is a modern software controller that can operate simultaneously in motion control and robotic systems.
The next major difference between the two systems is the software.
In the past, hardware drove purchasing decisions, but now the differences in product hardware are slightly different.
Motion control systems that rely heavily on hardware, especially legacy systems, require more maintenance to ensure proper operation.
Closed systems or modern plug-and-play components rely more on software operation.
The functionality of the software is crucial, as many users expect modern controllers to be able to perform all the necessary tasks.
This means that money will be spent on individual components, while more money will be used for monitoring operations, such as PCs and advanced HMIs.
Users also expect the software controller to be easy to use.
The simpler the interface and operation controller, the more likely users are to choose its application.
This saves time and money on training and setup.
Modern controllers that can be used in motion systems and robots have software options that can provide several automated processes.
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