The most crucial element in building a successful motion control project is a deep understanding of the machine requirements and technical specifications for your specific application. A common mistake engineers make is diving headfirst into the details of engineering configuration, focusing on precise motion trajectories or torque requirements. However, they often overlook other pressing factors that hinder effective engineering configuration, such as system integration, project management, and decision-making skills. To avoid errors in motion control, many engineering and management skills need to be applied to the application. A fundamental error stemming from a lack of thorough understanding of the machine's specific application and the absence of a comprehensive motion control plan is a serious problem. Without knowing the machine's motion characteristics and torque and communication requirements, the chosen hardware and software will be unsuitable. Rushing into implementation without a plan will only delay time and increase costs. When engineers discover they've installed a ball screw but need a linear motor to meet speed requirements, it's a disaster—requiring major redesign and restructuring. This echoes the old adage: "If you don't have time to do it right, how can you have time to do it well?" Ignoring Optimal Performance Integration Requirements Many engineers believe that system integration is too cumbersome and that it's better to simply install good components. Choosing good actuators as hardware is good, but what if the motor works well at high speeds while the actuator malfunctions? Each component must be carefully reviewed based on the machine's requirements to ensure that the combined components deliver the machine's specified performance and that the entire machine functions well. Generally, if engineers use products from a single manufacturer and work closely with them, the overall machine should be fine. However, with multiple suppliers, the engineers' task becomes more demanding. They must ensure the overall machine performs effectively in practical use. Ignoring Various Possible System Options Before Selecting a Solution This refers to directly selecting a solution without considering various possible options. This can lead to buying overly advanced equipment, such as purchasing a servo motor where a standard induction motor/drive system would suffice; or buying products that don't meet the equipment requirements, such as buying a stepper motor when a servo system is actually needed. Sometimes, the solution chosen by engineers limits the machine's capabilities because the chosen manufacturer cannot provide a comprehensive solution. For example, choosing a conventional motor to drive a mechanical actuator when a high-efficiency direct drive solution should be used. Therefore, each axis on the machine should be examined, and you should ask yourself what the requirements of each axis are and how to meet them to achieve optimal performance without exceeding limits. During the inquiry phase, consult multiple manufacturers to hear their different perspectives. Analyze each axis thoroughly to avoid blindly trusting only one company's solution or product. Unsure when to choose the optimal product or a single supplier for the entire system When there are only basic performance requirements and a lack of engineering resources to integrate a solution, choosing the "optimal product" approach can easily lead to potential compatibility issues. This method often involves buying the best motor from one company, and then buying the best amplifier, controller, and mechanical components from other manufacturers, etc. If you accurately know the performance requirements and are prepared to provide the corresponding resources to select and integrate these components, this can be a successful solution. If you only consider application performance and disregard cost, you can do this. However, on the other hand, if you expect a basic solution, you can also turn to a single supplier because you can confirm that their components are well-matched. Ultimately, it depends on what you expect to achieve and the results. Focusing only on price and ignoring performance The key is to follow the principles of engineering configuration processes. First, clarify the system specifications and requirements, select the best components, and then engage in rigorous price negotiations with the manufacturer. Do not pre-define a price range and select components sequentially. This latter approach is extremely risky; if the system fails to operate as required, significant time and money will be spent on repairs. In fact, when business is good, suppliers will usually try their best to cooperate and assist customers. However, if you first select the lowest-priced product and then tell the manufacturer, "It doesn't meet my performance requirements," the manufacturer might say, "Your product selection is incorrect. I can help you solve the problem, but we can't negotiate the price." Choose products with performance exceeding application requirements. The preceding sections discussed the error of focusing solely on price and the viewpoint of only buying the latest technology. For 30 years, there has been talk of phasing out DC drives; however, DC speed-regulating motors still have their uses. Over time, specific applications may abandon certain technologies in favor of others, but in reality, no one will adopt these advanced technologies unless they truly bring real benefits to equipment manufacturers and/or customers. Misunderstanding the role of mechanical dynamics in the application of control components. Selecting the best motion control components does not guarantee success. When various machines are connected to motion control components, their dynamic characteristics (friction, inertia, flexibility, electrical noise, etc.) change, which in turn affects and manifests as problems in the motion control system. A lack of understanding of these factors can lead to increasingly expensive and faulty systems, eventually causing them to malfunction. One crucial factor is flexibility. We have repeatedly encountered cases where people design machines, select expensive components, and purchase powerful and accurate servo systems. They then connect the motor with flexible couplings, completely disregarding transmission design principles. Finally, the user angrily complains, "No matter how we adjust it, this machine won't work!" We bring in relevant engineers to inspect and find something amiss. The motor's capacity exceeds design requirements, which shouldn't be the problem. Next, we check the coupling between the motor and the load. After readjusting the system's flexibility, the system speed still doesn't increase. These lessons force us to reflect: "Do we truly understand this machine? How are the various components integrated? Underestimating the importance of cables ." Some engineers consider cables an insignificant part of the control system, merely a few wires connecting components. Sometimes, engineers diligently study the machine, selecting controllers, drive units, and actuators, but forget about the cables. In fact, cables are an integral part of the motion control solution, and non-compliance with relevant standards (NEC, U, CE) is unacceptable. Cable bending exceeding material or design requirements, inappropriate materials, and poor shielding and insulation can all introduce hidden dangers to the system. Many motion control systems have cables installed by the user themselves (selecting and configuring shielding and insulation characteristics). If the moving cable carries a certain axial or torsional load, then the cable becomes crucial. Improper shielding can introduce electrical noise. System startup failures may indicate electrical noise problems. Abnormal system behavior and numerous strange occurrences ultimately necessitate seeking repair services. High-quality cables aren't necessarily expensive, but in small motor systems, the cable can sometimes be more expensive than the motor itself. This might seem strange, but it's often the case. Careful examination of the specific application reveals ways to reduce cable costs. Many users only start selecting and ordering cables at the last minute, forgetting that the cable is also an integral part of the overall machine design. Chris Radley, Senior Product Manager, Danaher Motion: Market Selection for Digital Motion Control Networks As a leading global manufacturer of motion control products, Danaher Motion is committed to helping customers build better machines faster, continuously improving the efficiency and productivity of complex manufacturing operations through technological innovation. The following analysis of the current market dynamics of motion control networks and a comparison of Sercos and SynqNet are provided for manufacturers' reference. Sercos (Serial Real-time Communications) SERCOS (an abbreviation for System) is a network communication protocol using fiber optics as the transmission medium and a speed of 16 Mbps. It is primarily designed for multi-axis motion control systems in automation systems. Since its application to the International Organization for Standardization (IEC) in 1989, it has evolved to its third generation (Sercos III). Currently, information from industry analysts indicates that Rockwell Automation's new product development is moving away from SERCOS and favoring Ethernet IP as the core protocol for future application development. This shift is also evidenced by the company's public strategy. Rockwell defines the Ethernet IP industry protocol and is a major manufacturer of Ethernet IP controllers, I/O products, HMI products, and drives. Ethernet IP is a relatively low-performance communication protocol with a loopback time of 10-100 ms and a synchronization time of approximately 10 μs. Rockwell is unlikely to develop products and services based on SERCOS III, but will continue to support platforms based on its proprietary SERCOS II. This makes Bosch Rexroth one of the last major manufacturers to support the SERCOS III protocol. The recent acquisition of Nyquist by Bosch Rexroth strongly suggests that SERCOS III will be a key focus of Nyquist's future 1394 "FireWire" implementation. Bosch Rexroth currently has two SERCOS III pilot products, a SERCOS II porting interface, and a development controller from Automate. No field installations have been performed to date. Meanwhile, SynqNet , since its initial launch at Semicon West 2001, has seen over 142,000 axes field-installed. It can be said to be the fastest-growing digital protocol in motion control. Based on the IEEE 802.3 standard and using industry-standard components, SynqNet is designed to meet the needs of numerous applications, including high-performance motion, drives, and I/O integration. Its architecture allows for flexible design and offers various customization options. Currently, it is supplied globally to large and medium-sized OEMs such as Danaher Motion, Yaskawa Electric, and seven other drive and I/O systems. Product vendors all support SynqNet solutions. SynqNet's future is based on integration with the standard Gigabit (500 Mbit/s x 500 Mbit/s) Ethernet physical layer to increase bandwidth while maintaining backward compatibility. Danaher Motion remains committed to collaborating with new and existing SynqNet vendors to provide complete motion control solutions. SynqNet is a key innovative technology in complete motion control solutions and will continue to penetrate various vertical markets and application areas. In summary, innovative programming and tuning software, global service support, ease of use, high performance, full customization, and flexible architecture all distinguish SynqNet from other Ethernet-based protocols. Furthermore, the number of SynqNet installations already completed demonstrates its success and future potential. Motion Control Network Comparison Table