Design & prototyping
Designing and prototyping drive and positioning solutions is a versatile process that requires a careful balance between mechanical design, control theory, electronics, and software engineering.
In today's rapidly changing technological landscape, drive and positioning solutions are crucial for industries such as robotics, manufacturing, automation, aerospace, intralogistics, and medical equipment. These solutions enable machines to perform tasks with high precision, reliability, and speed. However, designing and prototyping drive solutions is a complex process that requires a deep understanding of mechanical engineering, electronics, and software control.
Steps in designing drive solutions
The process of designing a drive or positioning solution typically involves several phases that require careful planning and analysis. Here is a general workflow:
1. Define the problem and requirements
An initial step is understanding the specific application and determining the requirements. Considerations include:
- Application type: what is the system designed for? Is it for robotic manipulation, automated production, or medical equipment?
- Precision and accuracy: what level of precision is required in the application? Different applications require different tolerances.
- Speed and acceleration: how fast does the system need to move, and how quickly does it need to accelerate or decelerate?
- Environmental factors: consider whether the solution needs to operate in specific environments, such as extreme temperatures, high humidity, or hazardous conditions.
2. Choosing the right motor and sensors
After identifying the problem and understanding the application requirements, the next step is selecting the right motors and sensors to meet those needs. Factors to consider include the required power, available supply voltage, form factor, and the required range of motion.
- Motors: The choice between stepper motors, servo motors, or DC motors depends on the need for precision and control. For example, servo motors offer high torque and precision in a compact housing, making them ideal for dynamic applications with precise control.
- Sensors: Position sensors and feedback devices ensure that the motion system operates as expected. Encoders provide accurate information about the position of a motor.
3. Select the control architecture
The control architecture involves determining how the motion control system will operate. This includes selecting controllers (e.g., PLCs, microcontrollers, motion control cards) and how they will communicate with other system components (actuators, sensors, human-machine interfaces).
An important decision at this stage is whether to use open-loop or closed-loop control:
- Open-loop control: This is typically used in systems where high precision is not crucial. The controller sends commands to the motor to adjust the motion without feedback.
- Closed-loop control: Closed-loop systems use sensors to provide feedback to the controller, allowing for (real-time) adjustments for precise motion control.
4. Simulation and modelling
Before the physical system is implemented, simulation and modeling play a crucial role in predicting how the system will perform. Our engineers use motion control simulation programs to model the motion behavior and optimize system parameters such as speed profiles, acceleration, and system stability. Simulations help customers identify potential issues early on and make necessary adjustments to the design.
5. Prototyping of the system
After the design phase and successful simulation, the next step is prototyping the drive solution. Prototyping allows the team to verify the theoretical design under real-world conditions. Prototypes can be built using off-the-shelf components or custom-made parts, depending on the complexity and requirements of the system.
- Hardware Prototyping: This involves assembling the selected motors, sensors, controllers, and power electronics. 3D printing, CNC machining, and other rapid prototyping methods are often used to create custom mechanical parts. Customer-specific electronics (PCBs) are designed using Altium Designer.
- Software Prototyping: The software that controls the system must also be developed and tested at this stage. This includes writing motion control algorithms, integra
6. Testing and iteration
Once the prototype is built, rigorous testing is essential to ensure that the drive solution performs as expected. Testing involves:
- Accuracy tests: Checking if the system meets the specifications for position, speed, and acceleration.
- Stress tests: Ensuring that the system can handle maximum loads, extreme temperatures, or other harsh operating conditions. We use our climate chamber for this.
- Reliability tests: Evaluating the system's long-term performance and fault tolerance.
Based on the test results, our engineers may need to iterate on the design and make adjustments to components, algorithms, or controllers.
Challenges in designing and prototyping motion control
Designing a drive or positioning solution is not without challenges:
- Complexity of control algorithms: Developing algorithms that control multiple axes or complex movements can be difficult and requires specialized knowledge of control engineering.
- Integration of components: Ensuring that motors, sensors, drives, and controllers communicate effectively is crucial for system performance.
- Time and cost constraints: Drive solutions are often complex and expensive to prototype. Finding the right balance between performance and cost can be challenging, especially for startups or small manufacturers.
Prototyping is a critical phase where designers can test concepts, refine systems, and move towards full production. From selecting the right motors and sensors to testing and iteration, each step plays a crucial role in ensuring that the final solution meets the specific needs of the application.
Feel free to contact us. You can reach us by phone at +31 (0)76 789 00 30 or +32 (0)3 328 07 60. You can also fill in the contact form. We will process your enquiry as soon as possible.
