Faced with environmental challenges and the demand for sustainable electronic products, various industries around the world are seeking solutions to optimize operations and minimize carbon footprints. Regardless of the industry, it is necessary to control processes to reduce energy consumption, minimize waste, and achieve maximum output.

Motion and control products work together to control the motion, speed, and position of mechanical components in electronic applications. These products are designed to provide precise, efficient, and reliable control over all aspects of motion, enabling machines and equipment to achieve optimal performance and minimal error while performing their functions.

DigiKey is a global electronic component distributor that offers a variety of motion and control products from multiple suppliers, enabling customers to improve the sustainability and efficiency of their automation systems.

Core components of motion and control systems
Electric motors are the core of motion and control solutions, and the main way to convert electrical energy into mechanical energy. There are several types of motors commonly used in applications, each with unique characteristics and advantages. For example, AC motors are known for their durability, efficiency, and high-speed operation capabilities, making them suitable for industrial machinery, HVAC systems, and other applications that require long-term reliable performance. On the other hand, DC motors have excellent torque and speed control capabilities, making them very suitable for applications such as robots and automotive systems that require precise motion. Stepper motors provide high-precision positioning and can be used for 3D printers, CNC machines, and other devices that require precise incremental motion. Servo motors have the characteristics of fast response and high torque output, and are used in applications that require fast and precise motion, such as aerospace systems.

In order to effectively control and regulate the operation of motors, motion and control solutions rely on various drivers and controllers. Variable frequency drives (VFDs) are used to control the speed and torque of AC motors, achieving smooth, efficient operation and energy savings. The servo drive is designed specifically for servo motors and can provide closed-loop control to achieve high-precision positioning and motion. The motion controller can simultaneously handle multiple motion axes, used to coordinate and synchronize the movements of various components in complex applications, achieving smooth and accurate operation.

Actors also play a crucial role in motion and control systems, as they are responsible for converting energy into motion and providing the force to move mechanical components. The advantages of hydraulic actuators are high output force and the ability to handle heavy loads, making them suitable for applications such as construction equipment and industrial machinery that require raw power. Pneumatic actuators rely on compressed air to generate motion and provide rapid response, making them suitable for applications involving rapid repetitive motion, such as packaging and assembly lines. Electric actuators include linear and rotary types, providing precise control in applications such as medical, automotive, and aerospace devices and equipment.

Images of Robot Vision Sensor Camera System in Smart Factory
Figure 2: Robot vision sensor camera system in smart factory. (Image source: Shutterstock)

Sensors, feedback devices, and control systems
To ensure the highest precision and reliability of the motion and control system, sensors and feedback devices are used to monitor and measure various aspects of motion. Position sensors, such as linear and rotary potentiometers, can provide real-time data on the exact position of mechanical components, enabling precise positioning and tracking. Encoders, such as incremental encoders and absolute encoders, are used to determine the angular position and velocity of the rotating shaft, thereby achieving precise speed and position control. Rotary transformers are similar to encoders, but are specifically designed for harsh environments and can also provide high precision and reliability in sensitive applications.

The control system combines all these components to coordinate and manage the overall operation of motion and control solutions. Programmable Logic Controller (PLC) is a robust and durable industrial computer designed specifically for control and automation, capable of processing multiple input and output signals simultaneously in factory automation, process control, and other applications. Compared with PLC, industrial PC has stronger flexibility and processing capability, and is usually used in conjunction with advanced motion control software to simulate motion control algorithms in complex multi axis systems.

Motion and control components in industrial applications
Motion and control solutions are crucial for improving the efficiency, precision, and productivity of various industrial processes. For example, they manage equipment such as robotic arms and machine tools to enhance industrial operations and minimize errors to the greatest extent possible. In automobile production factories and warehouses, motion and control systems coordinate the movements of industrial robots, collaborative robots (cobots), and autonomous mobile robots (AMRs) to perform tasks such as handling, assembly, and inspection. Similarly, in industrial packaging applications, motion and control solutions pick up and transport items such as cardboard boxes and pallets through conveyor systems, sorting machines, and automated storage systems (AS/RS).

In the medical field, motion and control systems have changed the way medical services are provided and research is conducted. They can achieve precise positioning, measurement, and automation of medical devices and equipment such as surgical robots, diagnostic imaging systems, and laboratory instruments. For example, surgical robots equipped with motion and control components can accurately perform minimally invasive surgeries, shorten patient recovery time, and improve overall efficacy. The automated liquid handling system in pharmaceutical research laboratories also uses motion and control systems to accurately distribute and mix reagents, simplifying the drug development process and accelerating the development of new therapies.

In mission critical applications such as satellite positioning, aircraft control systems, and missile guidance, the aerospace and defense industries also rely on precision motion and control solutions. In these fields, even the slightest deviation in expected motion or position can have catastrophic effects. Motion and control technology ensure that the operation of these systems has extremely high accuracy and reliability, enabling satellites to maintain orbit, aircraft to fly safely, and missiles to hit targets. In addition, these solutions also contribute to the development and testing of new aerospace and defense technologies, enabling engineers to simulate and validate complex systems before they are deployed on site.

Understand DigiKey's Multi Supplier Strategy
By collaborating with multiple suppliers, DigiKey ensures a wide range of product choices for engineers and system designers. This strategy not only increases the variety of products, but also improves the supply situation, enhances pricing competitiveness, and provides opportunities to acquire rich technical expertise. One obvious advantage of DigiKey's multi vendor approach is its ability to meet a large number of industry demands. Whether it's compact stepper motors for precision instruments or high torque servo drives for heavy-duty automation, DigiKey's inventory can provide solutions for all applications. This diversity enables engineers to find the most suitable product that meets their specific needs, thereby optimizing the performance and efficiency of the entire system. In addition, by sourcing from multiple suppliers, DigiKey minimizes the risk of supply chain disruptions - when a manufacturer experiences production issues or delays, alternative products can be purchased from other suppliers to ensure reliable and stable supply for customers. This elasticity will make everything completely different, as even the shortest downtime in industrial facilities can have a significant impact on resources, budgets, and operations.

Advanced motion and control products from industry-leading enterprises
DigiKey's partnerships with leading manufacturers such as Schneider Electric, Siemens, and Omron demonstrate its commitment to quality and innovation. These industry giants are renowned for their cutting-edge motion and control solutions that utilize advanced features and technologies to improve efficiency and sustainability.

Schneider Electric's Altivar ™ On the basis of the start/stop performance of previous iterative products, the soft starter ATS480 (Figure 3) further extends the service life of the equipment and maximizes the application availability in harsh environments. Altivar 212 VSD provides maximum usability and safety for HVAC system integrators and end-users, saving energy and improving building comfort and management levels. Similarly, the ATV320 VFD has the characteristics of safety, reliability, and simplicity, with a compact appearance that is easy to install and efficiently utilizes space.