DRIVES, CONTROLS & MOTORS FEATURE


varying in real-time, which directly impacts motor performance, longevity and operational efficiency. Failing to account for these factors can result in inefficiencies, system downtime and increased operational costs. Choosing the wrong motor can cause a multitude of problems, including overheating, excessive wear and system breakdowns, which can lead to costly downtime. On the other hand, an over specified motor can lead to greater energy consumption, further raising operating costs and diminishing system performance. Selecting the right motor is not just about meeting immediate needs but also about ensuring long-term reliability and scalability. Without considering futureproofing, manufacturers risk relying on outdated systems that cannot integrate with technologies like AI, machine learning (ML), or IoT, which can limit a manufacturer’s ability to stay competitive in a rapidly evolving industrial landscape. With this in mind, design engineers, OEMs and machine builders must select the right motor type to deliver efficient, reliable solutions. But how?


ADVICE ON CHOOSING MOTORS FOR INDUSTRY 4.0 There are several considerations to make when selecting motors to ensure seamless integration into modern, automated production systems. Aligning the motor’s torque, speed and


power requirements with the application’s needs is critical. For instance, high-torque applications such as CNC machines require motors with sufficient power for consistent operation. Where precision is required, such as in robotic arms in automated assembly lines, stepper motors are ideal. Stepper motors move in precise increments without drift, making them ideal for applications requiring fine control. Furthermore, they can be integrated with sensors and controllers to enable real-time adjustments based on production demands, enhancing automation efficiency and minimising errors. Reducing carbon footprints and operational


costs is a key focus in modern manufacturing. Brushless DC motors support these goals by offering high reliability and requiring minimal maintenance. Brushless motors deliver superior


performance per watt compared to brushed DC motors, thanks to the elimination of brushes. This reduces friction and heat generation, resulting in lower energy consumption. As a result, these motors are ideal for applications


like automated assembly lines and HVAC systems, where reducing energy consumption


FAULHABER BHx brushless


ironless motor


and maintenance downtime is crucial. In addition, brushless motors generate


less electromagnetic interference (EMI) and operate more quietly. This makes them an excellent choice for potentially noise-sensitive environments, such as clean rooms in semiconductor manufacturing or precision medical device assembly.


“Selecting the right


motor is not just about meeting immediate needs but also about ensuring long-term reliability and scalability”


They also provide precise control over power input, higher torque density and longer lifespans with less maintenance. Their robust design and reliability help ensure operational continuity, even in environments where uptime is critical. This allows companies to lower their total cost of ownership while improving productivity. Connectivity is another important factor.


Motors equipped with built-in sensors and communication protocols like Modbus, EtherCAT or PROFINET enable real-time data collection, predictive maintenance and remote diagnostics. This functionality is vital in creating smarter,


more responsive systems capable of adapting to changes in production demands and preventing unplanned downtime. Data-driven insights allow for early detection of potential issues, enabling proactive maintenance and reducing the risk of costly operational disruptions. Linear servomotors, for example, can be integrated with external sensors that track real-time conditions including temperature, vibration and load. These sensors provide valuable insights into motor health, allowing manufacturers


to monitor system performance and prevent Stepper motors


failures before they disrupt operations. In dynamic environments where conditions fluctuate,


such as in high-speed production or robotics applications, these integrated systems ensure smooth operation and enhance the system’s overall efficiency. Lastly, reliability is paramount in environments


operating 24 hours a day. Due to their brushless designs, stepper and BLDC motors are known for their long service life and low maintenance. These motors can run for thousands of hours without significant maintenance, making them ideal for critical systems that cannot afford downtime. With fewer moving parts, these motors are less susceptible to wear and tear, ensuring greater longevity and consistent performance.


ADAPTABLE SOLUTIONS As Industry 4.0 evolves, motors must be adaptable to accommodate new technologies and scalable production systems, and should be chosen with the flexibility to integrate seamlessly with future advancements in robotics, AI, IoT and ML. For instance, motors with built-in wireless


communication capabilities can integrate with IoT systems to enable remote monitoring and optimisation of performance, energy consumption and maintenance schedules. Without this adaptability, companies risk being locked into systems that cannot evolve with changing market demands or technological developments. Engineers and manufacturers must carefully


consider the specific requirements of their applications and select motors that can perform efficiently while accommodating future technologies. Custom drive designs that align with production needs – whether for robotic precision control or low-maintenance performance in automated systems – can help optimise energy use, reduce downtime and support continued adaptability.


ESSENTIAL ENABLERS In industry 4.0, motors are more than just components – they are essential enablers of precision, efficiency and adaptability in modern manufacturing. Selecting the right motor ensures seamless integration with automation, optimises performance and supports future scalability. As manufacturing continues to evolve, prioritising energy efficiency, connectivity and durability will be crucial in developing smarter production systems that meet the demands of an ever-changing industrial landscape.


EMS


T: 0118 981 7391 www.ems-limited.co.uk


MARCH 2025 DESIGN SOLUTIONS 33


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