Discover how motion control brings motors, gearheads, sensors, electronics, and software together to create precise, safe, and reliable drive solutions for demanding real-world applications.
Motion Control
A motor provides the power. Motion control ensures that it is applied at the right time, in the right place, and with the right dynamics.
maxon insights #1 maxon insights is a series of themed publications on drive technology. Each issue focuses on a specific field and provides insights into technologies, new develop- ments, and real-world applications. Contributors include specialists from maxon as well as external experts from research and industry.
2
maxon insights # 1
EDITORIAL
Motion control as a core capability
In 1994, we began building the Corporate Center Motion Control at maxon as a small team. We had already gained initial experience with controllers in the preceding years and our task was clear: not only to provide our customers with the right drive, but also to make motion in their applications easier to control. At first, we developed, sold and supported analog servo controllers. It soon became obvious that the future would be digital. maxon invested early in digital servo con trollers, embedded software, and graphical commissioning tools. This step brought us closer to our customers’ applications and opened up new possibilities in control engineering, parameteri zation, diagnostics, and software. We continued to learn – from successes, mistakes, and many conversations with customers. Over the years, this success gave rise to a center of expertise at maxon’s headquarters in Sachseln, closely linking electronics development, firmware, software, control engineering, and customer support. Questions from the market thus feed directly into development. The strategic importance of motion control continued to grow. Where individual components often took center stage in the past, the quality of the overall system is what matters today. Customers expect reliable solutions that are easy to integrate and remain avail able over the long term. Motion control brings the motor, gearhead, sensors, electronics, software, and application expertise together in a compelling drive solution. For maxon, the decisive strength increasingly lies in matching individual technologies to specific requirements. Motion control bridges the gap between products and our customers’ applications. It helps us assess technological developments at an early stage, apply innovations selectively and develop solutions that will also meet future requirements. This importance will continue to grow. Conventional micro controller miniaturization is reaching its limits. At the same time, multi-core architectures, specialized processors, connected systems, and artificial intelligence are opening up new possibilities. Taking advantage of them requires a deep understanding of systems and the ability to translate technology into tangible customer value. The journey continues – our ambition remains the same: to make motion more precise, safer, and easier for our customers to use. This publication shows how we are doing that in practice today.
Patrik Gnos, Director R&D Motion Control and Head of the Corporate Center Motion Control at maxon’s headquarters in Sachseln
3
Motion Control
CONTENTS
6 Interview Stefan Müller “Customer-specific
solutions are in our DNA”
10 Fundamentals The six most
important questions about motion control
12 Expertise
Experience that shortens the path to a solution
16 Control electronics Product overview
18 Servo controllers 28 Motion controllers 34 Platforms and customization When standard products are no longer enough 36 maxon MIND The motor as a sensor 38 Application story Tool measurement at the micrometer scale 42 Application story A proven tool, reimagined 46 Expertise
How does a transport robot get from A to B?
CTO Stefan Müller talks about the future of motion control, close customer collaboration, and how experience leads to new solutions. Page 6
48 Functional Safety Safety in motion 50 Application story
Assistance that adapts to every step
52 Customer Support
From question to solution
54 About maxon
Servo controllers: Precise control of torque, speed and position – tailored to the drive and application. Page 18
4
maxon insights # 1
Motion controllers: When several axes work together, the higher-level controller coordinates their motion sequences. Page 28
IMPRINT Publisher: maxon Group, Brünigstrasse 220,
6072 Sachseln, Switzerland; media@maxongroup.com Editorial team: maxon newsroom, Urs-Ueli Schorno (Lead Editor), Sven Gallinelli, Andrew Bamford Design: Bodara AG, Büro für Gebrauchsgrafik, Zurich Printing: Druckerei Odermatt AG
The goal is clear, but the path is complex: For a transport robot to reach its destination accurately, navigation, control, and drives must work closely together. Page 46
© 2026 maxon. All rights reserved.
5
Motion Control
6
maxon insights # 1
INTERVIEW
“Customer-specific solutions are in our DNA” Stefan Müller is responsible for maxon’s technological direction. In this interview, he explains why systems thinking, close customer collaboration, and technological depth are inseparable – and why motion control is increasingly becoming a core capability.
Text Urs-Ueli Schorno Photos Philipp Schmidli
7
Motion Control
Stefan Müller, if you were introduc- ing maxon today to someone who does not yet know the company, how would you describe the essence of what we do? At our core, we develop drive solutions comprising compact, highly efficient motors and gearheads, generally for highly demanding applications. Our solutions are used in medical technology, robotics, automation and aerospace. The easiest way to explain this is through ap- plications. In laboratory automation, we move samples. In intralogistics, our drive solutions enable mobile robots to store and retrieve goods precisely and safely. In medical technology, we ensure the re- liable delivery of insulin. Examples like these help most people understand what we actually do. Ultimately, all these ap- plications are about motion control: adapting movement precisely to the task at hand and meeting the customer’s re- quirements as effectively as possible. How has maxon’s approach changed in recent years? What has not changed is the way we work. We are at our best when we col- laborate very closely with our customers and develop solutions together. That has been part of maxon’s DNA for many years. What has changed most is the ap- plications – and, with them, our prod- ucts. They have become more powerful and more complex. Today, we deliver far more highly integrated mechatronic solutions in which the motor, gearhead, encoder, electronics, and software work together. We are clearly moving toward integrated systems that include control electronics – solutions in which mechan- ics, electronics and software are consid- ered as a single unit. We are increasingly taking responsibility for the integration ourselves. This brings maxon closer to the customer’s actual application, mak- ing close collaboration with the cus- tomer even more important.
“Applications are becoming more connected and more complex. Motion control is becoming a key technology.”
Stefan Müller, CTO maxon Group
8
maxon insights # 1
What role do platforms and custo mization play in this combination? Platforms provide the foundation for im- plementing customer-specific solutions efficiently and with manageable risk. Once the core technology and produc- tion processes have been established, we can respond more quickly and make targeted adaptations. Not every project can be based entirely on existing plat- forms. In such cases, it is important to communicate development risks openly – particularly with highly inte- grated systems. How do you balance innovation and stability in development? It is a classic trade-off. That is why we have dedicated advanced development teams that focus on new technologies while working closely with customers, universities, and partners. For us, inno- vation does not mean immediately pur- suing every new idea. It means deliber- ately deciding which technologies offer genuine added value and are mature enough to be integrated into products and platforms for the long term. Many current trends revolve around AI, robotics and automation. What role does motion control play here? These topics are closely connected. AI is fundamentally changing robotics. Ro- bots are leaving protected areas and moving into unstructured environments. They are also interacting increasingly with people, for example in logistics or industrial applications. In these appli- cations, motion control becomes a key technology because systems are becom- ing more complex, more connected, and more dependent on context. This re- quires functional safety, as humans and machines work in increasingly close proximity. This development is not a short-term hype. It will remain with us for many years. Alongside these visible
What personally excites you about technology and development at maxon? My background is in electrical engineer- ing, and I have worked with electric drives for many years. What particularly fascinates me is the interaction between the motor, electronics, gearhead and control system. Truly optimal solutions can only be created when these disci- plines are considered together – and that is something we place great importance on at maxon. maxon has a very broad portfolio. From a developer’s perspective, what is the real strength of that breadth? The strength lies in our strong technol- ogy base. Depending on the application, we can select precisely the right technol- ogy – from different motor concepts and gearheads to electronics. This breadth allows us to think freely and choose the solution that makes the most sense, both technically and commercially. It also en- ables us to develop system solutions without being constrained by a particu- lar technology from the outset. Where does a component end and motion control begin? That depends very much on the customer and the application. Some customers de- liberately want components only, while others are looking for integrated solu- tions. Both approaches have their place. The important point is that systems only perform well when the underlying com- ponents are first-class. Motion control becomes the central element precisely at this interface – where individual com- ponents become a functioning system. That is why we continue to invest heav- ily in the development of key technolo- gies and develop systems wherever they provide clear added value for the cus- tomer. It is not an either-or choice, but a deliberate balance.
trends, there are also topics that may seem less exciting, such as new regula- tory requirements and ensuring robust production processes and supply chains. However, these are crucial if innovative technologies are to be used reliably in practice. What advice would you give young engineers starting at maxon today? Find what genuinely interests you and become good at it – without allowing yourself to be guided too much by short- term trends. I have seen for myself how hypes change. Ultimately, what matters is doing something that continues to give you satisfaction over the long term. What distinguishes a good technical solution from a truly compelling one? A truly compelling solution does not only work under ideal conditions. It is well thought out, stable, and reliable in everyday use. That is where genuine technological depth and systems under- standing become apparent.
Profile Dr Stefan Müller has been Chief Technology Officer of the maxon Group since 2022 and is responsible for the company’s techno- logical strategy. He joined maxon in 2017 and holds a doctorate in electrical engineering from the Uni- versity of Stuttgart.
9
Motion Control
MOTION CONTROL Q&A
The six key questions about motion control Motion control ensures that movements are executed precisely, efficiently, and reliably. Today, it is no longer just about the motor, but about the interaction between mechanics, sensors, electronics and software. The following questions provide a concise introduction to the key principles.
1 What does motion control mean? Motion control means tailoring motion to the requirements of a specific application. A motor in a robot joint must meet different requirements from a drive in a laboratory instrument or packag- ing machine. What matters, therefore, is not the motor alone, but how the motor, sensors, electron- ics, software, and mechanics work together.
3 What sets maxon apart from other motion control providers?
Many providers specialize in individual com ponents. maxon can provide motors, gearheads, sensors, electronics, and software from a single source, allowing the system as a whole to be optimized. The aim is not to maximize the per- formance of every individual component, but to achieve the best possible interaction between them. This creates added value that is greater than the sum of its parts.
2 What distinguishes motion control from conventional drive technology? A motor provides the power. Motion control ensures that it is applied at precisely the right time, in the right place, and with the right dynamics. Beyond closed-loop control itself, this includes aspects such as dynamics, energy efficiency, the synchronization of multiple axes, and behavior under changing loads.
10
maxon insights # 1
4 Why must motion control systems be predictable? In robotics, medical technology, and industrial automation in particular, motion systems must behave predictably and repeatably at all times. Only then can safety, quality, and trust be ensured. New technologies such as data-driven analysis or artificial intelligence do not alter this basic principle: the motion itself must remain under control at all times.
6 Which develop- ment will have the greatest impact on motion control in the future? Motion systems will become even more inter- connected and take more information from their surroundings into account. At the same time, demands on software, usability, and functional safety will increase. The challenge is to add intelligence to the system without compromising its stability and predictability.
5 What role does software play in today’s motion control systems? Software is often where the decisive added value is created. Modern control algorithms, diagnostic functions, and the synchronization of multiple axes significantly expand the capabilities of a drive system. At the same time, straightforward commissioning and operation are becoming increasingly important. Engineers should be able to focus on their application – not on the funda- mentals of drive control.
11
Motion Control
A mobile robot uses a robotic arm to retrieve a package from a shelf – a complex motion task in intralogistics.
12
maxon insights # 1
EXPERTISE
Experience that shortens the path to a solution New motion control approaches do not start from scratch. Proven platforms make expertise built up over many years available from the outset.
Text Daniel Hug
Developing a servo drive or motion controller may not seem particularly complicated at first glance. Many microcontroller manufacturers offer exten- sive software development kits (SDKs) and libraries for controlling brushed and brushless DC motors. Today, a wide range of highly integrated compo- nents is also available to handle various motor con- trol functions. A skilled engineer can use these resources to develop functional control solutions in a relatively short time, even without in-depth expertise in con- trol engineering and power electronics. This may be entirely sufficient for simple applications. As requirements become more complex, however, this approach soon reaches its limits. The demanding requirements of highly dy- namic ironless motors, uncompromising minia- turization, and stringent efficiency targets com- bined with sophisticated thermal design require specialist expertise and experience. The same ap- plies to clock synchronization across a wide range of communication interfaces and modern sensor systems. If high production volumes and availabil- ity over several decades are also required, it be- comes clear why maxon decided to develop its own electronics as well. The crucial point, however, lies elsewhere: a drive system reaches its full potential only when
13
Motion Control
all its components are optimally matched – from the gearhead and motor to the sensors and control- ler. This is essential, particularly in highly inte- grated solutions. Getting the most out of a system requires a holistic approach to system optimization and an in-depth understanding of every component. Development starts with the customer A new platform starts not with the technology, but with the application. The central question is how to create genuine value for customers that gives them a competitive advantage. This may sound simple, but the enormous variety of applications makes it a challenging task. maxon’s activities span medical technology, robotics, and industrial auto- mation as well as mobility applications. The re- quirements vary accordingly. Time is another factor. The typical life cycle of a servo drive or motion control platform is seven to ten years. A platform therefore cannot be devel- oped solely for today’s requirements. The more important question is how customers, applications, and markets will change over the coming years. The real skill lies in identifying the broadest common denominator across these sometimes very different requirements – one that makes sense both technically and commercially. Only then does the actual evaluation of possible technical solutions begin. Many perspectives, one goal A platform is not created within a single develop- ment department. “Wisdom of the crowd” is not just a catchphrase here, but a guiding principle. We are convinced that an interdisciplinary approach leads to better solutions. Product Management takes the lead. It sets the direction and drives the product’s continued devel- opment together with the specialist departments involved. Global Sales specialists maintain close contact with customers and help to understand us- ers’ actual needs and pain points. Business Development teams know the applica- tions and markets, identify synergies, and recog- nize opportunities for new products. R&D, in turn, develops the appropriate technical solutions – from electronics hardware and embedded application software to control algorithms. Actual development begins only when these perspectives come together. Proven foundation, customized solution Platforms provide the basis for customer-specific solutions. Not every application can be optimally served by a standard product. At the same time, developing every solution from scratch would make sense neither technically nor economically. This is precisely where the strength of a platform lies. It provides a proven basis on which custom- er-specific adaptations can be implemented effi- ciently. Customers benefit from shorter develop-
ment times, predictable risks, and technology that has already been proven in numerous applications. At the same time, sufficient flexibility remains to meet specific requirements and create genuine points of differentiation. Innovation without disruption The development of a platform does not end with its market launch. It is continuously enhanced throughout its life cycle. The motion control world evolves through incremental innovation. Custom- ers expect stable products and long-term availabil- ity. At the same time, requirements continue to grow – in areas such as miniaturization, connec- tivity, safety, and software functionality. The challenge is to combine innovation with stability. New functions and technologies must be incorporated into the platform, while customers expect transitions between product generations to be as seamless as possible and their investments to remain protected over the long term. maxon therefore relies on regular firmware and software updates. These make it possible to intro- duce new functions and improvements without jeop- ardizing the stability of existing applications. This keeps a platform relevant for many years and allows it to evolve with the requirements of its users.
About Daniel Hug Daniel Hug heads Motion Control Services at maxon. In this role, he is responsible for the develop- ment of motion control platforms such as ESCON2 and EPOS4.
14
maxon insights # 1
EXPERTENBLICK
Motion control enables precise, controlled movements in the confined space of a surgical robot.
15
Motion Control
CONTROL ELECTRONICS
Control electronics perform different functions within a drive system. Servo controllers regulate individual drives, while motion controllers coordinate multiple axes at the higher system level. The solution used depends on the control task, system architecture, and level of inte gration. The available platforms, form factors, and power ratings provide the basis for customer-specific adaptations and developments. On the following pages, we introduce the ESCON2, EPOS4 and MACS plat forms – from typical applications to selected products.
Our products
Servo controllers
From page 18
ESCON2
EPOS4 Easy to use Positioning System
Easy Speed Controller
From page 20
From page 24
16
maxon insights # 1
Motion controllers
From page 28
MACS Multi-Axis Controller System
From page 30
17
Motion Control
CONTROL ELECTRONICS
Servo controllers Servo controllers are the key link between the drive and the application control system in modern motion solutions. They combine power electronics, a wide range of interfaces, and intelligent control algorithms within a compact footprint. This enables optimal control of torque, speed, and position across a wide variety of applications. With ESCON2 and EPOS4, maxon offers two powerful platforms that cover the full spectrum of modern motion control applications.
■ Servo controllers and Motion Studio engineering software
+ Sensors
+ Motor
18
maxon insights # 1
Drive systems, for example for:
Industrial robotics Humanoid robotics Mobile robotics Medical technology
Semiconductor manufacturing Power tools
+ Gearhead
19
Motion Control
CONTROL ELECTRONICS > SERVO CONTROLLERS
ESCON2 The ESCON2 servo controllers in the Value Line are designed for a broad range of applications and flexible system integration. Field-oriented control (FOC) is possible using only the motor’s Hall sensors; commands can be issued via CANopen as well as digital and analog I/Os. The ESCON2 platform thus provides an easy entry point into modern motion control – now also for positioning tasks.
+ Sensors
+ Motor
+ Gearhead
20
maxon insights # 1
Drive systems, for example for:
Packaging
In compact handheld tools for the pack aging industry, every minute of battery life counts. The ESCON2 platform allows application logic and motor control to be integrated within a compact footprint. Field-oriented control (FOC) helps to use the available energy efficiently.
Mobile robotics
In mobile robots, drive and steering axes are controlled individually or in combination. ESCON2 can, for example, control individual drives and be integrated compactly and easily into the higher-level control system via CANopen.
Drones
For drones, weight and available instal lation space are key considerations. Thanks to their high power density and speed control up to 120,000 rpm, compact ESCON2 modules are particu larly well suited to such applications.
21
Motion Control
CONTROL ELECTRONICS > SERVO CONTROLLERS > ESCON2
Three examples. Many possibilities.
ESCON2 Nano 24/2
ESCON2 Compact 60/30
The OEM module can be integrated directly into customer-specific electronics and requires very little installation space.
The ready-to-connect servo controller is designed for 60 V and 30 A, making it suitable for drive applications with higher power requirements. Technical Highlights ■ 60 V / 30 A ■ Ready-to-connect design ■ For drives with higher current requirements
Technical Highlights ■ 24 V / 2 A ■ OEM module ■ For space-constrained integration
22
maxon insights # 1
ESCON2 60/12
The complete ESCON2 portfolio: find all products, variants, and technical data online.
The enclosed servo controller is designed for 60 V and 12 A and intended for integration into industrial machinery and systems.
Discover all ESCON2 products.
Technical Highlights ■ 60 V / 12 A ■ Enclosed design ■ Ready-to-connect integration
New: Positioning with ESCON2 ESCON2 is being expanded to include positioning functions. In addition to current/torque and speed control, ESCON2 will also support position- ing tasks in the future.
For information on availability and supported variants, please contact us.
23
Motion Control
CONTROL ELECTRONICS > SERVO CONTROLLERS
The EPOS4 servo controllers in the Performance Line are designed for demanding positioning and motion tasks. A variety of control, feedback, and communication options allows them to be integrated into different drive and automation architectures – whether the application calls for dual-loop control or Functional Safety.
EPOS4
+ Sensors
+ Motor
+ Gearhead
24
maxon insights # 1
Drive systems, for example for:
Industrial robotics
Robot axes continuously execute changing motion profiles. EPOS4 dynamically controls the individual drives, implementing the setpoints received from the robot or machine controller via EtherCAT or CANopen.
Humanoid robotics
Humanoid robots combine numerous joint axes. A higher-level motion controller coordinates their trajectories, while EPOS4 controls the individual drives close to the motors and sensors – regardless of the chosen control structure or whether Functional Safety is required.
Semiconductor manufacturing
In semiconductor manufacturing, positioning axes must execute movements precisely and repeatably. EPOS4 supports a wide range of sensor interfaces and various control algorithms for this purpose.
25
Motion Control
CONTROL ELECTRONICS > SERVO CONTROLLERS > EPOS4
Three examples. Many possibilities.
EPOS4 Compact 60/20 CAN STO
EPOS4 Micro 24/1.5 CAN
The ready-to-connect servo controller features an integrated STO function, making it suitable for machinery and automation solutions with corre- sponding functional safety requirements.
The compact form factor allows EPOS4 control to be integrated where installation space is limited.
Technical Highlights ■ 24 V / 1.5 A ■ OEM module ■ CANopen interface
Technical Highlights ■ 60 V / 20 A ■ Integrated STO function ■ CANopen interface
26
maxon insights # 1
EPOS4 Disk 60/12 EtherCAT SSC
The complete EPOS4 portfolio: find all products, variants, and technical data online.
The disk-shaped design allows the control electronics to be integrated close to the motor.
Discover all EPOS4 products.
Technical Highlights ■ 60 V / 12 A ■ EtherCAT interface ■ Near-drive integration
27
Motion Control
CONTROL ELECTRONICS
Motion controllers Motion controllers provide higher-level coordination of multiple drive axes. While servo controllers regulate the individual drives, motion controllers synchronize their movements and execute programmed sequences. This allows the movements of multiple axes to be coordinated in terms of timing and function.
■ Motion controller and Motion Studio engineering software
+ Axis 1*
+ Axis 2
* Axis = drive system consisting of servo controller + sensors + motor + gearhead
28
maxon insights # 1
Coordinated movements, for example for:
Gantry systems Pick-and-place Machine tools Printing and processing machines Robotics
+ Additional axes
29
Motion Control
CONTROL ELECTRONICS > MOTION CONTROLLERS
The MACS motion controllers in the Performance Line are freely programmable and coordinate multiple axes, including kinematic groups. Depending on the version, the platform ranges from compact six-axis solutions to the MasterMACS with up to 32 axes.
MACS
+ Axis 1*
+ Axis 2
+ Additional axes
* Axis = drive system consisting of servo controller + sensors + motor + gearhead
30
maxon insights # 1
Drive systems, for example for:
Pick-and-place
Pick-and-place systems require synchro nized movement across multiple axes. MACS combines them into a kinematic group and controls the required motion sequences.
Metrology
Measurement systems may require several moving axes whose positions must be aligned throughout a measure ment sequence. MACS synchronizes these axes within the process.
Door automation
In automatic door systems, multiple drives work together within a shared motion sequence. MACS controls how these axes interact.
31
Motion Control
CONTROL ELECTRONICS > MOTION CONTROLLERS > MACS
Three examples. Many possibilities.
MicroMACS6 Module
MicroMACS6 The freely programmable motion controller can control up to six external power stages via Ethernet and two independent CANopen interfaces. Four PWM outputs are also available for controlling servo controllers.
The programmable module can be integrated directly into customer-specific motherboards. Combined with ESCON2 or EPOS4 modules, it enables compact multi-axis solutions.
Technical Highlights ■ Control of up to 6 axes
Technical Highlights ■ Up to 6 axes ■ Ethernet and 2× CANopen ■ 4× PWM outputs
■ Freely programmable OEM module ■ Can be combined with ESCON2 and EPOS4 modules
32
maxon insights # 1
MiniMACS6 AMP-4/50/4-IF1
The complete MACS portfolio: find all products, variants, and technical data online.
The motion controller features four integrated power stages, each providing 211 W of continuous power and 370 W of peak power. The current measurement circuitry is optimized for controlling smaller motors.
Discover all MACS products.
Technical Highlights ■ 4 integrated power stages ■ 211 W continuous / 370 W peak power per power stage ■ Current measurement optimized for smaller motors
33
Motion Control
PLATFORMS AND CUSTOMIZATION
When standard isn’t enough
An off-the-shelf product is not always sufficient. Requirements change, new ideas emerge, and products evolve. This is where existing platforms prove their flexibility: they can be adapted and developed into a customer-specific solution.
As told to Urs-Ueli Schorno
34
maxon insights # 1
Compact integration: The EPOS4 controller and EC 45 flat motor form a customer-specific drive unit on a single circuit board.
The new architecture also changed the require- ments for the technical implementation. Compo- nents, interfaces, and form factors had to be re- aligned. However, there was no suitable off-the-shelf solution combining a compact design, integrated motion control and CAN-based communication. Two platforms become one solution There was no need to develop a solution entirely from scratch. Instead, proven platforms from the maxon portfolio could be combined in a targeted way. This reduced development time and built on processes that had already been validated. The customer-specific solution was based on an EC 45 flat motor and an EPOS4 positioning con- troller. Both are already available as standalone products in the maxon portfolio. The customer-spe- cific adaptation consisted of integrating them on a single hardware platform. To achieve this, maxon’s EPOS4 controller was integrated directly into the motor’s electronics plat- form. At the same time, the form factor was adapted to the available installation space – or, as Roman Berger puts it, the solution was “designed into the available space.” The aim was not maximum miniaturization for its own sake. What mattered was bringing the elec- tronics and motor together in a well-engineered package. “One PCB costs less than two,” says Roman Berger. At the same time, integration reduces the effort required for cabling and interfaces. Depending on the application, a decentralized approach can offer advantages in terms of integra- tion, modularity, or cabling. Other applications con- tinue to rely deliberately on centralized control ar- chitectures. In this project, the decisive factor was therefore not choosing the “right” approach, but the ability to implement a demanding customer-specific solution quickly and in a technically sound way. More than a one-off project The result is a versatile unit suitable for applica- tions such as compact conveyor modules, diverter drives, and small autonomous logistics vehicles. The solution is already being evaluated for further applications. Each new application will, of course, require further adaptations – such as different form factors, motor sizes, or interfaces. This is precisely the strength of the platform approach: existing tech- nologies can be adapted quickly to new require- ments and provide the basis for further customer- specific developments.
A typical day at maxon – and an example of how customer-specific solutions are created: a customer selects a new motion control architecture for the project. This changes the requirements for the drive solution. “The drive intelligence was originally located centrally in one place,” explains Roman Berger, Business Development Manager at maxon. “Later, the customer wanted to move motion con- trol directly into the individual units.” The new architecture offered advantages in service and maintenance while placing new demands on the integration of the drive electronics. The higher-level unit now primarily handles communication via CAN, while motion control it- self is performed locally on each individual axis.
35
Motion Control
maxon MIND
The motor as a sensor
The motor as a source for monitoring the condition of a machine: that is the goal of maxon MIND (Motion Insights and Diagnostics). The foundation is machine learning, physical expertise, and an open architecture.
Text Claude Jaquemet Photo Jeremias Wieland
In industrial drive technology, the motor has long been more than just an actuator. It provides valuable information about the condition of the entire system – pro- vided you know how to interpret the data correctly. This is exactly where maxon MIND comes in. The system uses motor signals to draw conclusions about the condition of the drive system and its en- vironment. This turns the motor into a sensor in the machine. maxon MIND analyzes data read from the controller during machine operation and detects patterns that indicate wear or malfunctions. It is not just about mon- itoring the motor itself, but the entire drive system and the associated mechan- ical components. This allows deviations to be detected early. The solution is particularly suitable for applications where potential failures must be detected early – for example, to increase personnel safety or minimize downtime. It also identifies problems
that remain hidden in conventional tests. In production lines with multiple ma- chines in sequence, maxon MIND detects even the smallest deviations before they affect downstream processes. The system also adds value in service operations when the actual condition of the equip- ment is critical for maintenance planning. Explainable, optimized AI Technologically, maxon MIND is based on explainable artificial intelligence. This makes diagnoses and predictions traceable – a key requirement for safety- critical and highly regulated applica- tions. The machine learning model de- veloped by maxon requires only small amounts of data and can run on simple hardware. This enables minimally in- vasive integration and reduces the ef- fort required for model training. As no computing infrastructure with graphics processing units (GPUs) is required,it can also offer significant cost advan-
tages. Existing applications can also be retrofitted. Data processing follows a clearly structured workflow. During machine operation, raw data is collected, prepro- cessed, and fed into the machine learning model. The model analyzes deviations from a healthy operating state. The re- sults are made available to customers via an Application Programming Interface (API). Glassbox instead of black box: every processing step remains traceable. High prediction quality A key feature of maxon MIND is the in- tegration of domain-specific expertise into the model. The physical relation- ships within a mechatronic system flow directly into the modeling process. This achieves high prediction quality with minimal data requirements. The system also learns from real- world applications. During commission- ing, an initial state is recorded that de-
36
maxon insights # 1
scribes the motor in the context of its environment. During operation, new data is regularly fed in and compared with the model – hourly, daily or as needed. Data quality plays a central role. To achieve valid results, the recorded signals must sufficiently represent the machine’s operating state. That is why maxon works closely with customers to define suitable measurement cycles. These may include standardized motion sequences that reflect typical load situations. This creates a robust model tailored to the specific application. An open platform By default, data processing takes place in the cloud. Customers can view and download their data. No personal data is required. All data can be anonymized by the customer, apart from the drive’s item and serial numbers. The platform has an open design and can be integrated into existing system
environments via an API. Motors, elec- tronic components, and controllers re- main unchanged. The only requirement is the installation of a software package on the master controller that transmits the data using the standardized MQTT communication protocol. If the machine is already connected to the internet and the controller can acquire data, the sys- tem can be operational within a few days. maxon MIND is positioned as a spe- cialized solution for demanding appli- cations. It focuses on an in-depth anal- ysis of the physical properties of the drive system. The combination of tech- nical focus, industrial robustness, and an open architecture delivers not just data, but tangible insights. This turns the motor into not only a drive, but also a central element of con- dition monitoring – and the key to greater efficiency, safety, and availability in con- nected production environments.
About the author Claude Jaquemet is Business Development Manager Digital Business at maxon Group. His work focuses on digital solutions that use drive data to generate insights into the condition of machines and systems.
37
Motion Control
APPLICATION STORY
Tool measurement with micrometer precision Whether a tool will machine accurately is often determined at the measurement stage. This requires axes, optics, and image processing to work together perfectly – with motion control providing the foundation.
Text Annalisa Isler
Laser markings serve as reference points for precise tool measurement.
38
maxon insights # 1
At the limits of human vision, high-accuracy me- trology takes over: the measuring head positions itself with a precision well below 1 μm, reliably cap- tures tool geometries, and transfers exact correction values to the CNC machine. The result is reproduc- ible manufacturing quality at the micrometer level. For 80 years, E. ZOLLER GmbH & Co. KG has been synonymous with measurable precision. To- day, the company manages a global network from the German town of Pleidelsheim, with its own subsidiaries and representatives at 85 locations in 62 countries. ZOLLER measures tools for CNC ma- chining at the micrometer scale. The long-standing collaboration between ZOLLER and maxon shows how this interaction works. “For us, precision at the micrometer level is what counts,” says Manuel Walter, Head of Purchasing at ZOLLER. This standard shapes the entire mea- surement architecture – from the mechanical design to motion control. The company began as a work- shop and is now an established name in the world of tool measurement. Industries including auto- motive, aerospace, medical technology, and me- chanical engineering rely on the company’s mea- suring machines. What often remains unseen is that optics, image processing, and motion must work together per- fectly to turn individual pieces of image informa- tion into usable data. This is where the real tech- nical challenge begins. In systems like these, motion control does far more than simply control a motor. It ensures that movements take place at the right moment, with the right dynamics, and in exactly the right posi- tion. Only the carefully coordinated interaction of closed-loop control, synchronization, and appli- cation logic turns motion into a precise measure- ment result. Precise axis positioning The systems use multi-axis controllers from maxon’s MACS platform. They coordinate the control of multiple axes, capture position data in real time, and provide the basis for synchronizing motion with image acquisition. Over the years, the con- trollers have been continuously developed together with ZOLLER. They have also been specifically tailored to the requirements of the measurement application. ZOLLER’s measuring and inspection equipment relies on a highly precise interaction between op- tics, image processing, and finely controlled mo- tion. At the heart of this process are powerful multi- axis motion controllers, which provide the timing for the entire measurement architecture. They con- trol the axes, synchronize image acquisition, and ensure that tool contours are captured at the micro meter level with maximum repeatability. For Georges Pappas, Head of Electrical Design at ZOLLER, this interaction is crucial: “Our systems
must be able to move quickly while also position- ing with high precision and holding positions with absolute stability.” The measuring devices move the tool, camera, and optical system along multiple axes. These axes must be positioned with micrometer accuracy, and their positions must be monitored continuously. The challenge is that positioning the measuring head along the X, Y and Z axes requires an accu- racy of better than 1 μm.
“We rely on accuracy down to the last micron.”
Manuel Walter, Head of Purchasing E. ZOLLER GmbH & Co. KG
The maxon multi-axis controller precisely posi- tions the axes and moves them to defined mea- suring points, coordinates dynamic acceleration and deceleration for different measurement meth- ods, and stabilizes the holding positions during image acquisition. This combination of functions is essential because even minimal vibrations or positioning errors would distort the measurement result. Georges Pappas sums up the requirement: “During image acquisition, the position must remain abso- lutely stable. Even the smallest movement or con- trol deviation would distort the measurement re- sult.” Particularly during the holding phase, this stability determines whether measurements remain highly accurate and repeatable. Synchronizing image acquisition and motion Another key technical element is interrupt-driven position latching. Each of the approximately 30 camera images per second triggers an interrupt in the controller. At the same time, the exact position
39
Motion Control
Precision in every detail: ZOLLER develops measuring and inspection systems for demanding manufacturing processes.
of the axes is latched – in other words, captured and linked to the corresponding image. Only by combining the pixel data with the pre- cise mechanical position can a usable measure- ment value be obtained. The motion controller therefore acts as the link between image process- ing and mechanics. Without this synchronization, measurements at the micrometer level would not be possible. Georges Pappas explains how this principle works in practice: “Every time the camera captures an image, a trigger signal is sent to the motion controller.” Because the camera operates continu- ously, the corresponding position values must be captured and buffered in real time so that the image and motion data can be correctly matched in the next step. Fabian Vogel, Managing Director of the Multi- Axis Controllers Competence Center at maxon, also sees this as the core of the application: “For us, it is essential to understand the application in detail – how the customer uses the measuring de- vices and what requirements arise during actual
operation. Only then can we tailor the control behavior and synchronization precisely to this specific application.” Capturing and temporarily storing the current axis position at exactly the right moment is crucial for reliable measurement results. Control behavior and dynamics for different measurement methods ZOLLER uses various measurement methods, in- cluding the measurement of contours, cutting edges and runout, as well as the determination of heights and angles. The multi-axis controllers must switch between rapid movements and highly stable stand- still phases. This combination of dynamics and stability places extreme demands on control tuning, drive performance, and real-time behavior. It is precisely this range – from rapid movement to an absolutely stable holding position – that makes the application so demanding. The challenge is not simply to set an axis in motion, but to ensure that it responds exactly as required by each mea- surement method.
40
maxon insights # 1
Working together for precise results
The high standard of quality is evident not only in the technology, but also in the collaboration. “Quality is non- negotiable for us,” emphasizes Manuel Walter, Head of Purchasing at E. ZOLLER GmbH & Co. KG. The application’s technical capabilities are the result of many years of collaboration. ZOLLER and maxon have worked closely together on development for around 15 years – not only integrating components, but also building a shared understanding of the application. “I have never experienced being unable to reach a development engineer at maxon or having a problem remain unresolved,” says Georges Pappas, Head of Electronics at ZOLLER. Particularly when requirements are complex, it is essential to analyze issues together and implement solutions efficiently. At maxon, understanding the application is equally im- portant: “For us, it is essential to understand exactly how the customer uses the application. Only then can we make the system behave exactly as the application requires,” explains Fabian Vogel, Managing Director of the Multi-Axis Controllers Competence Center at maxon. Reliability in day-to-day project work is just as important: “The best suppliers are those that work reliably, honor their commitments, and make processes noticeably eas- ier,” says Georges Pappas. Over the years, this creates more than a technical solution: it creates a shared understanding of the system – the foundation for stable, precise applications that can continue to evolve.
Integrated kinematics allow complex 3D measure- ment programs to be executed precisely. The po- sition values of the individual axes are synchro- nized with image acquisition via latching inputs. MACS controllers can generate trigger signals or respond to them, allowing image data to be cap- tured during every movement. This produces high-resolution three-dimensional images during scanning and inspection processes. To achieve maximum performance, the captured position values are buffered first. The measurement software then reads them continuously and assigns them to the corresponding camera images. By sep- arating acquisition from processing in this way, the system remains stable even at high speeds. The combination of dual encoder evaluation, real-time control, and synchronized image data acquisition makes maxon’s MACS controller an ideal solution for high-precision measurement and inspection applications. Applications that demand maximum accuracy and performance, even with complex motion sequences, require a solution that integrates seamlessly into sophisticated systems.
Discussing technical details: ZOLLER experts Georges Pappas (left), Head of Electrical Design, and Manuel Walter, Head of Purchasing.
41
Motion Control
APPLICATION STORY
A proven tool, reimagined
With the BXT4, Signode continues to advance its hand strapping tools. A new mechanical concept and the interplay between mechanics and motion control make the new generation more ergonomic, more powerful, and easier to use.
Text Urs-Ueli Schorno Photos Sven Gallinelli
42
maxon insights # 1
Andreas Keller managed the BXT4 project from the outset. Today, he is Head of Development at Signode Switzerland.
43
Motion Control
A compact overall system: Signode’s BXT4 hand strapping tool.
Hand strapping tools tension and seal plastic straps to secure packages for transport and storage. They are among the tools used thousands of times every day in industry and logistics – yet they rarely attract any attention. Insert the strap, pull the trigger and, a few seconds later, the strapping is secure. That is exactly how it should be. Signode is one of the world’s leading manufacturers of these tools. At its Swiss sites in Dietikon and Merenschwand, the company has been developing and producing hand strap- ping tools for industrial applications for decades. Around 200 people work at the two sites, 16 of them in Research & Devel- opment. The collaboration with maxon also has a long tradi- tion: maxon drive solutions have been used since the first generations of tools. With the BXT4, the partnership now extends to the latest motion control technology. The focus was not on reinventing a successful product. In- stead, the aim was to consistently develop a proven hand tool
Signode Signode is one of the world’s leading providers of packaging and transit protection solutions. At its Swiss site in Dietikon, the company develops and assembles hand strapping tools for industrial applications. It also op- erates a mechanical manufacturing facility in Merenschwand. Locations: Dietikon and Merenschwand, Switzerland Employees: Around 200, including 16 in Research & Development Focus: Development and production of battery-powered hand strapping tools for plastic and steel strapping
44
maxon insights # 1
Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 Page 17 Page 18 Page 19 Page 20 Page 21 Page 22 Page 23 Page 24 Page 25 Page 26 Page 27 Page 28 Page 29 Page 30 Page 31 Page 32 Page 33 Page 34 Page 35 Page 36 Page 37 Page 38 Page 39 Page 40 Page 41 Page 42 Page 43 Page 44 Page 45 Page 46 Page 47 Page 48 Page 49 Page 50 Page 51 Page 52 Page 53 Page 54 Page 55 Page 56Made with FlippingBook Publishing Software