Feature: Embedded design
To build or buy in a motion controller? By Gerard Bush, Sales Manager, Intelligent Motion Control (INMOCO)
T
hree-axis embedded printed circuit board motion controllers are integral in applications such as test equipment, mobile robots and various
machines. Whilst high volume and specific development needs might drive toward in-house build, minimising development time and lowering cost for smaller volumes is an advantage of buying in a controller, with a hybrid option offering the best of both worlds. Typically controlling three axes of
brushless DC and/or stepper motors up to around 350W, an increasing trend is to embed a microchip-based controller within the machine itself. Te close proximity this provides enables faster response time, less noise pick-up and a compact footprint, as well as reduced cabling.
Building a controller Te advantages of developing a motion controller in-house are two-fold: Since it’s a tailored approach, the controller can be given dedicated functionality, specific to
22 May 2023
www.electronicsworld.co.uk
Typically controlling three axes of brushless DC and/or stepper
motors up to around 350W, the increasing trend is to embed a microchip-type controller
within the machine itself
the application, with specific connectors and form factor. Te second advantage is cost: when producing volumes of thousands of units, a custom-designed controller can be cost-effective. However, in-house design requires
expertise and time. Selecting connectors and the wiring scheme is the first step, a
stage that can take up to three months. Next is design of the motor amplifier. If done from the ground up, an amplifier can be made flexible in specification and control. Its design will also include considerations such as electromagnetic interference and current control, a process that can take at least another three months. Instead, an off-the-shelf PCB-mounted amplifier can be integrated, still providing advanced features such as safety controls, whilst saving on development time. Ten there’s the motion-control chip
itself. Using a separate microprocessor gives the freedom to write customised motion engine code, but this stage can add at least 12 months to the project. To enable communication with the host network and coordinate motion sequences, the microprocessor will need soſtware development, which can take up to six months. As with the amplifier, an off-the- shelf motion-control chip can be integrated into a custom-designed PCB controller to save time, yet retain control over its form factor, profile generation and application- specific control.
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