Motion Controllers: The brains of Motion Controller Systems

Motion controllers are said to be the brains of any motion control system. If you see feedback-based systems, in these systems, motion controllers get input from the user, and then the input is compared with the feedback signal of the motor. The next step comprises performing the corrective action to bring the input (can be said the desired position) and output (or actual position) in line with one another. Hence, precision motion control is important.

Motion controllers create trajectories. Trajectories are followed by the motors with the purpose of meeting the desired commands. Its profiles are also referred to as motion profiles. What is a profile? A profile is a set of position commands versus time. Profiles are essential to inform the motor where to put the load and how quickly it must put the load. With the trajectories that are made by the motion, proper torque commands are produced. The torque commands are then sent to the drive, which powers the motor.

These actions are not easy and require a large amount of signal processing. To do the task easily and with perfection, digital signal processors (DSPs) come into play. The main function of digital signal processors or DSPs is to perform mathematical operations efficiently as well as quickly. In addition to that, digital signal processors or DSPs manage algorithmic processing much better than standard microcontrollers. It is difficult for standard microcontrollers to handle huge amounts of mathematical processing.

When we talk about basic profiles, there are so many of them, including triangular, ramp profiles, trapezoidal, complex polynomial, etc. These profiles come in handy when in particular situations and conditions, a particular type of motion is required. Let's take an example; a trapezoidal profile is defined by a graph of constant velocity and acceleration, and a graph of the velocity versus time profile is in the shape of a trapezoid.

Now talking about stand-alone controllers, stand-alone controllers are the whole systems that are frequently mounted in one physical enclosure. The enclosure should all of the necessary electronics, power supply, and external connections. Stand-alone controllers can be made into a machine, and they are responsible for one motion control application that involves controlling a single axis of motion as well as multiple axes.

We all know that Personal computer-based controllers are fixed onto the motherboard of a basic PC or an industrial PC. Typically these controllers are processing boards that prove helpful in generating and executing motion profiles. PC-based controllers are of great benefit as they provide a ready-made graphical user interface, which helps in making programming much easier.

Then there are individual microcontrollers. Individual microcontrollers are individual integrated circuits that are basically designed onto a printed circuit board, and these microcontrollers are equipped with feedback inputs and outputs to drivers for controlling a motor.

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