The motion controller lives inside the driver · Path engine / coordinates / programmable IO / closed-loop control in one unit · Beyond cylinders & grippers · Standalone operation, bus-scheduled multi-axis
To make a machine "move", the conventional stack has three layers: PLC / motion controller → drive → motor. The controller computes trajectories, manages sequencing and reads IO; the drive simply converts pulses into rotation. That stack comes with four costs: purchase cost, cabinet space, bundles of wiring, and two separate development skill sets (PLC programming + drive tuning).
Integrated drive & control moves the controller into the drive: the path engine (motion segments / waits / loops), machine & workpiece coordinate system, programmable IO logic and closed-loop position control all execute inside the driver. Engineering is done with host PC software; the program is downloaded into the driver's EEPROM, survives power loss, and runs standalone at power-up. For single-axis machines there is no PLC and no motion controller — the drive IS the controller.
And it goes far beyond electric cylinders and grippers: whenever an action can be described as "trigger → reach position → wait → signal → loop" — feeding, press-fitting, dispensing, inspection, winding, lifting, valve positioning, metering — the drive can take direct responsibility for sensors and buttons.
Control and drive merge into one layer: signals land directly, actions fire immediately, the host PC appears only during engineering
Typical single-axis machines (feeding / press-fitting / lifting type), conventional vs integrated:
| Item | Conventional (PLC + drive) | Integrated drive & control |
|---|---|---|
| Control hardware | PLC / motion controller + drive + expansion modules | One integrated driver |
| Cabinet space | Two or more DIN devices + interposing relays | Single driver, footprint cut sharply |
| Wiring | Sensors → PLC, PLC → drive: two wiring layers | Sensors wire straight into driver IO |
| Skill set | PLC programming + motion tuning | Graphical path editing in host software |
| Response chain | IO → PLC scan → command issued: long chain | IO triggers motion control directly inside the driver |
| Changeover | Edit PLC program or re-tune parameters | Re-teach workpiece origin / switch stored path |
| Troubleshooting | Problem in the PLC or the drive? Check both | Driver status + monitoring software: one step |
Savings vary by machine — send us your cabinet BOM and we will compare line by line
Electric cylinders and grippers are simply two "productized" applications of this driver. At its core it fits any single-axis (or independent indexing axis) "trigger–position–wait–signal–loop" action: an IO signal says go, the drive executes the position profile, signals done, and loops. Typical scenarios:
Push parts into position at the end of a chute. A part-present sensor triggers the push, the path moves to target, an in-position signal releases the part to the next station.
Multi-segment press profiles: rapid approach → working feed → dwell → retract. Depth is position-controlled; repeatability is guaranteed by the closed loop.
Continuous paths with smooth blending between segments; wait segments control valve on/off timing at corners.
Step-and-repeat scanning for cameras or sensors: move one step, dwell one beat (wait segment for image capture), repeat.
Reciprocating traverse on winding machines: identical speed in both directions, smooth reversal, adjustable stroke per product.
Lift platforms and risers. Optional brake-control output: the brake engages automatically whenever the drive is disabled or stopped.
Multi-point openings for rotary or linear-stroke valves; several paths stored and switched per operating condition.
Positive-displacement dosing: revolutions precisely control dispensed volume, with multi-speed segments for process stability.
Doors, hatches and fixture clamps: a button triggers open/close, positions lock at the ends.
Timed cycling of exhibit platforms, light rigs and scenery: runs automatically at power-up, no operator needed.
Rule of thumb: if the action can be written as "a signal arrives → follow a curve to a position → stop/wait → give a signal → loop", it fits integrated drive & control.
Motion and wait segments in any combination; each segment has pre-wait time, target revolutions, absolute/relative mode, speed and acceleration/deceleration, with smooth blending to the previous segment; loops and block structures supported.
Machine coordinates are established automatically at power-up; a workpiece coordinate can be taught and paths written against it, with homing support.
Several path programs are stored in the driver and can be switched per product model or operating condition.
Inputs assignable to E-Stop / Stop / Run / Fault-Reset / Homing, with NO or NC polarity; outputs assignable to In-Position / Alarm / Brake / Running / Ready, with live status.
The built-in encoder feeds position back in real time for loss-free closed-loop motion; stall alarm time, speed ratio and error thresholds are configurable.
Position control during approach, automatic switch to torque hold on contact, adjustable clamping force, with a "torque-reached" signal — the basis of the gripper solution.
Standard RS485 / Modbus RTU port: parameter read/write, status monitoring, path switching, start and stop are all available over the bus.
Path table editing, coordinate teaching, parameter tuning, live status and curve monitoring; programs download to EEPROM for standalone operation with no power-loss loss.
Yes. Give each axis its own integrated driver; each completes its own motion independently. A PLC or industrial PC handles workflow scheduling over RS485 / Modbus RTU — issuing only "start, switch path, stop" commands and reading status. In other words the PLC's role shrinks from "motion computing + sequencing" to "process scheduling", which cuts program size dramatically. Integrated drive & control does not exclude the PLC — it re-divides the work.
High-speed interpolation and electronic cams demand synchronization bandwidth — keep a multi-axis motion controller or bus solution for those axes. Integrated drive & control simplifies the large population of single-axis / independent indexing machines; it is not a replacement for every controller. Using each product where it excels is the right way to cut cost.
Path programs and parameters live in EEPROM and survive power loss; at power-up the drive runs as configured. Changes are made in the host software and re-downloaded, with path editing, curve preview and live monitoring so edits are visible, not blind.
Yes — axis by axis: move that axis's IO signals from the PLC to the driver terminals, reproduce the original motion as a path inside the driver, then delete the corresponding PLC logic. Validate one axis at a time and roll out at controllable risk.
| Question | Answer |
|---|---|
| 1. Can the action be described as "trigger → follow path to position → wait → output → loop"? | Yes / No |
| 2. Are the axes independent (or only loosely sequenced)? | Yes / No |
| 3. Is the working speed within the practical range of a stepper system? | Yes / No |
| 4. Do you want to drop PLC programming and shorten development? | Yes / No |
| 5. Do programs need to survive power loss and auto-start? | Yes / No |
| 6. Any high-speed multi-axis interpolation / electronic cam needs? ("Yes" → prefer a multi-axis controller) | Yes / No |
All of 1–5 "Yes" and item 6 "No": this solution should apply directly. Send us your motion sequence for a free analysis when in doubt.
Engineering happens in the office; on site there is only wiring and verification