Motion control is generally understood to mean the use of servo and/or stepper systems as the "muscle" to move a given load. Motor and drive systems, such as variable frequency drives (VFDs) with AC motors, can be controlled by a PLC. These systems are typically used for providing speed control, while motion control systems are capable of extremely precise position control as well as velocity and torque control. Applications which require positioning of product, synchronization of separate elements, or rapid start/stop motion are all perfect candidates for the use of motion control. PLCs are very capable of providing the signals required to command these servo and stepper systems in a cost-effective and digital (noise-free) manner.
One beneficial technology for modern motion control is the permanent-magnet brushless motor. The old brush-type motors were less efficient, and required brush replacements at regular intervals. Advancements in magnet technology have enabled the design of compact, powerful motors, whose rotors require no electrical connections (or brushes). Virtually all modern motion control systems, both servo and stepper-based, now employ brushless motor technology.
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