Servo motors are crucial in enabling high-speed, accurate motion control in complex applications. Their use enhances productivity, ensures repeatability, and supports operations that require precision and rapid dynamic response.
As core components of advanced drive systems, these high-performance servo motors allow complex tasks to be executed with greater efficiency. Their integration not only streamlines production but also elevates standards for precision and control—both essential for meeting the demands of modern industrial operations.
Continue reading to discover the importance of servo motors in industrial automation, highlighting how they contribute to more efficient and reliable drive systems. Enjoy the read!
What is a servo motor?
Servo motors, also known as servo systems or actuators, are electromechanical components essential for advanced motion control in industrial automation processes. Designed to accurately regulate position, speed, and torque, servo actuators ensure stable performance and fast responses, even in operations requiring high precision and dynamic adjustments.
In increasingly demanding industrial environments, the servo motor stands out as a key piece in automated control, enabling safe, stable, and highly reliable operations, even under variable load conditions and continuous production cycles.
Types of servo motors
In industrial automation engineering, understanding the types of servo motors available is essential for designing high-performance motion control systems capable of delivering precision, stability, and operational efficiency.
Each type of servo motor has specific features suited for different application requirements, from light, repetitive tasks to complex operations requiring high mechanical robustness. Selecting the right servo actuator directly impacts the reliability and productivity of the entire system.
DC servo motor (direct current)
Powered by direct current, DC servo motors offer quick response and effective position and speed control. They are ideal for low-power applications such as lightweight robots, lab equipment, and simple positioning mechanisms.
AC servo motor (alternating current)
Designed for industrial environments, AC servo motors support high loads and continuous cycles while providing excellent torque control. They are widely used in CNC machines, robotic arms, and automated assembly lines, where performance and reliability are critical.
Closed-loop stepper motor
It’s ideal for automation and systems requiring precision—without the higher cost of traditional servo motors.
What are the advantages of servo motors over AC induction motors?
Precision
Servo motors stand out significantly for their ability to achieve extraordinary precision in movements and positioning.
Unlike AC motors, which typically operate at a constant speed without position feedback, servo motors use encoders or sensors to constantly monitor the exact position of the shaft.
This real-time feedback allows for adjustments that enable movements accurate to fractions of a degree. This level of precision is essential for industrial applications such as CNC machines, robotics, and automation systems.
Control
In terms of control, servo motors offer an unmatched advantage over AC motors. They allow precise control of speed, position, and torque, thanks to their sophisticated construction and the use of advanced algorithms in the controller.
While conventional motors are limited to on/off operations or basic speed control, servo motors can be programmed to perform complex tasks that require fine variations in speed and positioning. This makes them ideal for applications that demand high flexibility and refined control.
Dynamic response
The dynamic response of servo motors is another area where they outperform AC motors. Due to their real-time feedback system and the ability to make instant adjustments to control commands, servo motors can quickly respond to changes in load or operating conditions.
This makes them highly effective in dynamic environments where operating conditions change rapidly, such as in automated handling systems and adaptive production lines.
The ability to respond promptly to precise commands and instantly adjust operations is key to maintaining efficiency and quality in automated processes.
What are the components of servo motors?
Motor
The heart of a servo motor is the motor itself, which can be either direct current (DC) or alternating current (AC), depending on the specific application. DC motors are commonly used in applications requiring fine control of speed and torque at low speeds, while AC motors are preferred in high-power and high-speed applications.
The motor is responsible for converting electrical energy into mechanical motion, and its construction is optimized for rapid response and efficiency in variable operation cycles and precision demands.
Encoder
The encoder is a crucial component that sets servo motors apart from AC motors. It measures the exact position of the motor shaft in real-time, providing constant feedback to the controller.
There are two main types of encoders: incremental and absolute. Incremental encoders provide information on the movement of the shaft, while absolute encoders provide the exact position of the shaft at any given moment.
This feedback is essential for advanced motion control, allowing instant adjustments to keep operations within desired parameters.
Controller
The controller is the intelligence behind the servo motor, interpreting input commands from the control system (such as a PLC or computer) and adjusting the motor’s operation based on feedback received from the encoder.
It executes complex control algorithms, such as PID (Proportional, Integral, Derivative), to regulate the motor’s speed, position, and torque with precision. The controller can also dynamically adjust the motor’s operation to handle load variations and other operational conditions, ensuring optimized performance.
How to select the right servo motor for your application
Load analysis
Evaluate the characteristics of the load the servo motor will move. This includes weight, inertia, and the required speed. The load's inertia, in particular, should match the motor’s inertia to ensure effective dynamic response and prevent oversizing.
Torque requirements
Calculate the torque needed to move the load under the expected operational conditions. This involves considering static torque to overcome inertia at the start of movement and dynamic torque to maintain the load in motion. The chosen servo motor should provide the necessary torque with an adequate safety margin.
Speed and precision
Identify the maximum speed required and the positioning precision. The servo motor’s speed should meet or exceed the maximum speed required for the application. Additionally, the precision of the internal encoder in the servo motor should be sufficient to meet the system’s precision requirements.
For applications that require both high-speed performance and accurate positioning, consider Festo’s CMMT-AS servo drive and EMMT-AS servo motor. This combination offers dynamic motion control, seamless integration, and optimized space-saving design—ideal for modern automation needs.
Control interface
Consider the compatibility of the servo motor with the existing control system. The servo motor’s controller should be able to communicate effectively with the main controller or PLC (Programmable Logic Controller), using the appropriate communication protocols.
Operating environment
Consider the environmental conditions where the servo motor will be installed. Factors such as temperature, humidity, dust or liquid presence, and potential electromagnetic interference can affect the choice of servo motor. Ensure the selected motor is designed to withstand the specific conditions of the operating environment.
Cost-effectiveness
Analyze the cost-effectiveness of the servo motor option. While servo motors with higher capacities and precision may have a higher initial cost, they can offer better performance and efficiency, resulting in long-term savings.
Also read: Automation in Intralogistics
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Servo motors, also known as servo systems or precision actuators, are electromechanical devices that are fundamental for motion control in industrial automation processes. Developed to precisely regulate position, speed, and torque, servo motors offer stable performance and fast responses, ensuring that even operations with high demands on dynamic adjustments and extreme precision run amazingly efficiently.
In increasingly challenging industrial environments, the servo motor is a key component in automated control; it facilitates safe, stable, and highly reliable operations, even under variable load conditions and continuous production cycles.
What Is a Servo Drive System?
A servo drive system consists of a servo drive, a servo motor, and an encoder. The servo drive controls the servo motor by comparing the target values with actual feedback from the encoder and adjusting the motor accordingly. The encoder continuously provides position and speed data for precise motion control.
Types of Servo Motors
In industrial automation engineering, understanding the types of servo motors available in the market is essential for designing high-performance motion control systems that can deliver precision, stability, and operational efficiency. Each type of servo motor has specific characteristics that meet different application requirements, from light and repetitive processes to highly complex operations with tough mechanical demands. The appropriate choice of servo actuator directly influences the reliability and productivity of the overall system.
AC Servo Motor (Alternating Current)
The AC servo motor is a brushless, permanently magnetized synchronous motor designed for low-voltage operation. Engineered for industrial environments, it supports high loads and continuous operation cycles while providing excellent torque control. These motors are commonly used in CNC machines, robotic arms, and automated assembly lines, where high performance and reliability are essential, e.g. EMMT-AS.
DC Servo Motor (Direct Current)
The DC servo motor is a brushless, permanently magnetized synchronous motor designed for extra-low voltage operation (24…48V). As a type of brushless DC (BLDC or EC) motor, it requires an electronic servo drive to manage the switching of DC currents. It offers a rapid response with good position and speed control, making it ideal for low-power applications such as light robotics, laboratory instruments, and simple positioning systems, e.g. EMMT-EC.
Closed-Loop Stepper Motor
Combines the design of a stepper motor with real-time feedback, thus eliminating step losses. Ideal for light automation and systems requiring precision without the high price tag of a traditional servo motor, e.g. EMMT-ST and EMMB-ST.
Linear Servo Motor
Instead of rotary motion, this type generates linear motion and does so extremely precisely. It is perfect for inspection equipment, medical applications, and industrial processes requiring controlled straight-line displacement.
Advantages
Servo motors offer several advantages over conventional motors, making them essential in modern industrial automation:
Precision
It is the ability of servo motors to achieve extraordinary precision in movements and positioning that makes them unique. Unlike conventional motors, which operate at a constant speed without position feedback, servo motors use encoders or sensors to continuously monitor the exact position of the shaft. This feedback allows real-time adjustments, and ensures that the motor creates movements with a precision that can reach fractions of a degree. This characteristic is essential in industrial applications where precision is critical, such as in CNC machines, robotics, and automation equipment.
Control
The control offered by servo motors is another unmatched advantage over conventional motors. They can precisely control speed, position, and torque thanks to their sophisticated construction and the use of advanced algorithms in the controller. While conventional motors are limited to on/off operations or basic speed control, servo motors can be programmed to perform complex tasks that require subtle variations in speed and positioning. This makes them ideal for applications that need a high level of flexibility and refined control.
Dynamic Response
The dynamic response of servo motors is another area where they surpass conventional motors. Thanks to their real-time feedback system and the ability to instantly adjust to control commands, servo motors can quickly respond to changes in load or operating conditions. This makes them extremely effective in dynamic environments with rapidly changing operating conditions, such as in automated handling systems and adaptive production lines. Being able to promptly respond to precise commands and adjust operation instantly is crucial for maintaining efficiency and quality in automated processes.
What Are the Components of Servo Motors?
A servo motor system comprises several key components that work together to provide precise motion control:
Motor
The core of a servo motor is the motor itself, which can be either direct current (DC) or alternating current (AC), depending on the specific application. DC motors are commonly used in applications requiring precise control of speed and torque at low speeds, while AC motors are preferred in high-power and high-speed applications. The motor converts electrical energy into mechanical movement, and its design is optimized for rapid response and efficiency in variable operating cycles.
Encoder
The encoder, or position sensor, is a crucial component that differentiates servo motors from conventional motors. It measures the exact position of the motor shaft in real time, providing continuous feedback to the controller. There are two main types of encoders: incremental and absolute. Incremental encoders provide information about the movement of the shaft, while absolute encoders indicate the exact position of the shaft at any given moment. This feedback is essential for precise motion control, allowing real-time adjustments to be made so operation is maintained within the required parameters.
Servo drive
The servo drive is the intelligence behind the servo motor, interpreting input commands from the control system (such as a PLC or computer) and adjusting the motor's operation based on feedback received from the encoder. It executes complex control algorithms, such as PID (Proportional, Integral, Derivative), to precisely regulate the motor's speed, position, and torque. The servo drive can also dynamically adjust the motor's operation to manage load variations and other operating conditions, ensuring optimized performance, e.g. CMMT-AS or CMMT-ST.
Choosing the Right Servo Motor for Your Application
Choosing the right servo motor for your application is critical to ensure a system operates efficiently and reliably. Each application has specific requirements, and the motor must be selected based on the characteristics of the movement, load, and environment in which it will operate.
Analyze the Load
Understand the type of movement required: is it linear or rotary? Is the load heavy or light? Constant or variable? These answers are essential to determine the power, torque, and precision needed for the application.
Evaluate the Desired Precision and Speed
Applications that require high speeds or highly precise positioning may need motors with high-resolution encoders and controllers capable of making real-time adjustments. Speed and precision must be balanced to meet operational requirements without compromising system stability.
Check System Compatibility
Ensure the servo motor is compatible with your controller, communication protocol (such as EtherCAT, PROFINET, etc.), and power supply. Compatibility guarantees easier integration and stable operation.
Consider the Operating Environment
The motor must be suitable for the environmental conditions in which it will operate, such as exposure to dust, moisture, vibration, or extreme temperatures. Choosing a model with an appropriate protection rating (e.g., IP rating) is vital to avoid failures and extend its lifespan.
Cost-Benefit Analysis
More robust and precise motors often come at a higher initial cost, but they may offer a better return in the long term through increased productivity, energy savings, and reduced downtime. Always consider long-term operational costs in your evaluation.
Use our configurator Electric Motion Sizing and size your electric or electromechanical drive system quickly, easily and precisely.
Final Thoughts
As automation becomes more intelligent and adaptive, the servo motor stands out as a key enabler of that evolution. The combination of precision, speed, and flexibility makes it indispensable across a wide range of industries.
For engineers, system integrators, and manufacturers seeking smarter motion control solutions, understanding the role of the servo motor is not just helpful—it’s essential.
