Integrated Motors Are Simplifying Automation — What It Means for Motion Systems

Industrial machines have traditionally separated the motor, drive, feedback device and control system.

That architecture works well, but it can also mean more cables, more components and more space inside the machine cabinet.

A new direction is becoming more visible in motion control: integrating more functions closer to the motor.

Recent industry developments are combining motor technology with drive functions, communications and diagnostics. On October 2, Drives & Controls reported on an integrated motor platform using IO-Link to bring communication and diagnostic information directly to the point of motion. The approach is intended to simplify machine architecture and provide control systems with more device-level information.

For OEM machine builders, this trend raises an interesting question.

If the motor becomes more intelligent, what happens to the gearbox and the rest of the mechanical transmission?

From Separate Components to Integrated Motion

A traditional servo or stepper axis may include several separate elements.

There is the motor.

There may be a separate drive.

Feedback can come from an encoder.

The control system manages the axis.

A gearbox may reduce speed and increase torque.

Additional sensors can monitor operating conditions.

Each component has its own wiring and installation requirements.

Integrated motor technologies are trying to reduce some of this complexity by bringing more functions into the motor or actuator assembly.

This can reduce the number of separate components that machine builders need to install.

It can also make commissioning and diagnostics more straightforward.

IO-Link Brings More Information to the Machine

One of the interesting parts of the latest integrated motor developments is communication.

An ordinary motor primarily provides mechanical output.

A connected motor can provide information about itself as well.

According to the recent Drives & Controls report, the new IO-Link motor approach provides access to information such as configuration, identification, diagnostics and operating data.

This matters for OEMs because machine maintenance is increasingly becoming a data problem as well as a mechanical problem.

If a device can identify itself and report useful operating information, technicians may spend less time checking wiring, searching for device parameters or troubleshooting an unknown component.

Smaller Control Cabinets Can Change Machine Design

Reducing the number of separate devices can have a physical effect on the machine.

A machine with fewer drive components and shorter wiring paths may require less cabinet space.

For compact automation equipment, this can be valuable.

Packaging machines, inspection equipment, electronic assembly systems and other compact production machines often have limited space available for electrical and mechanical components.

Moving functions closer to the point of motion can therefore help machine builders rethink the layout.

But the mechanical transmission still needs to fit that architecture.

The Gearbox Does Not Disappear

Integrated motor technology does not eliminate the need for a gearbox.

A motor and a gearbox solve different problems.

The motor generates mechanical power.

The gearbox changes speed and torque and can provide the mechanical characteristics required by the driven axis.

For example, a high-speed servo motor may need a planetary gearbox to deliver suitable output torque and speed.

A robotic joint may use a harmonic reducer where compact size and low backlash are important.

An RV reducer may be selected for an axis requiring high rigidity and torque capacity.

A right-angle gearbox can change the transmission direction where machine space is restricted.

The control architecture may become more integrated, but the mechanical requirements remain.

More Data Does Not Automatically Mean Better Motion

There is also a practical limit to what connected motion components can solve.

A motor can report its operating condition.

A controller can monitor data.

A sensor can detect abnormal behavior.

But none of these functions can compensate for an incorrectly selected gearbox.

If the transmission ratio is wrong, the motor may not operate at the desired working point.

If the gearbox has excessive backlash, software cannot completely remove the mechanical play.

If the output bearing is overloaded, additional communication will not solve the mechanical problem.

The basic engineering process therefore remains important.

The motor, gearbox, load and control system need to be considered together.

Motor and Gearbox Matching Becomes More Important

As motion systems become more integrated, component compatibility becomes increasingly important.

OEM engineers may need to evaluate:

• Motor power

• Rated torque

• Motor speed

• Gearbox ratio

• Output torque

• Backlash

• Torsional rigidity

• Mounting dimensions

• Communication requirements

• Duty cycle

• Installation space

The objective is to create an axis that performs as a complete system rather than a collection of independent components.

This is particularly relevant for machines using multiple servo axes.

One axis may need high speed.

Another may need high torque.

Another may need compact dimensions.

The transmission requirements can therefore be different even when the control architecture is standardized.

Why This Matters for Industrial Automation

The latest integrated motor developments reflect a wider change in machine design.

Automation equipment is becoming more connected.

Controllers need more information from field devices.

Maintenance teams want better diagnostics.

OEMs want simpler wiring and faster commissioning.

Machine builders also need to reduce cabinet size and installation time where possible.

These requirements are pushing intelligence closer to the actual point of motion.

At the same time, the mechanical transmission still needs to deliver the required torque, speed and positioning performance.

This creates a combined design challenge for electrical and mechanical engineers.

Precision Transmission Remains Part of the Equation

Fenghua Transmission Technology (Jiangsu) Co., Ltd. provides planetary gearboxes, harmonic reducers, RV reducers, right-angle gearboxes and motors for industrial automation and precision machinery.

Its product portfolio also includes precision gears and racks and other motion components. The company states that its servo-specific precision gearbox series is compatible with servo and stepper motors from mainstream global manufacturers.

For OEM applications, motor matching can involve the flange, shaft diameter, pilot diameter, bolt pattern and other interface dimensions.

These details may seem mechanical compared with the latest developments in connected motors and industrial communication.

In practice, they determine whether the motion system can actually be assembled and operated reliably.

The Next Generation of Motion Systems Will Combine Both Sides

The development of integrated motors and IO-Link does not mean that mechanical engineering is becoming less important.

The opposite may be true.

As electrical and software functions become more integrated, the mechanical transmission needs to fit more naturally into the complete system.

The motor needs to communicate.

The controller needs to understand the axis.

The gearbox needs to provide the right mechanical ratio and torque.

The machine needs to move accurately and repeatably.

For OEMs, the goal is not simply to make one component smarter.

It is to make the complete motion system easier to design, commission, operate and maintain.

That is where integrated motors, connected controls and precision transmission are beginning to meet.