Top 5 Machine Design articles of 2025
Key Highlights
- Optimize system architecture by distinguishing between the cost-effective reliability of PLCs for discrete tasks and the high-speed, data-heavy processing power of PACs for complex smart factory environments.
- Adopting hybrid motion control—combining hydraulic force with electric precision—and treating feedback as a core design parameter allows for the creation of high-load machines capable of sub-micrometer accuracy.
- Digital servo drives and standardized, PC-based HMIs simplify the commissioning process while enabling machines to function as sophisticated IIoT data gateways for predictive maintenance and cloud analytics.
Choosing the right control architecture and motion technology is critical for machine builders and system integrators who must balance cost, performance and future-proofing. These five articles from partner publication Machine Design help to make those choices more informed.
Understanding the distinction between programmable logic controllers (PLCs) and programmable automation controllers (PACs) allows integrators to select the most efficient brain for a system; while PLCs offer a reliable, cost-effective solution for discrete machine tasks, PACs provide the PC-style processing power and tag-based programming necessary for the complex, data-heavy environments of smart factories. By matching the controller to the specific requirements of the application—whether it’s simple motor control or multi-axis robotic coordination—builders can avoid the pitfalls of over-specification while ensuring the system can scale as end-user needs evolve.
In the realm of physical movement, the shift toward hybrid motion control and advanced feedback systems represents a significant leap in machine capability. Hybrid systems combine the high force of hydraulics with the precision and maintenance-friendly nature of electric actuators, allowing builders to create machines that handle high-load tasks without the messy infrastructure of traditional fluid power. Simultaneously, treating feedback as a core design parameter ensures that these movements are not just powerful, but intelligent. For an integrator, this means building more resilient machines that use real-time data loops to compensate for external disturbances and component variations, resulting in higher throughput and sub-micrometer positioning accuracy.
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Operational efficiency is further enhanced by advancements in digital servo drives, which act as the critical link between the digital controller and the physical motor. Digital drives offer high power density and rapid update rates, making them indispensable for space-constrained applications like aerospace and mobile robotics. For a system integrator, these drives simplify the commissioning process through AI-assisted tuning and real-time diagnostics. Their ability to synchronize multiple axes across diverse digital platforms allows for the creation of more flexible, modular machine architectures that can be easily integrated into broader Industrial IoT (IIoT) ecosystems for predictive maintenance.
Finally, the human element of automation is being streamlined through standardized human-machine interfaces (HMIs), which reduce the complexity inherent in custom equipment design. By adopting a unified family of touchscreen interfaces, machine builders can provide a consistent user experience regardless of the underlying control hardware. This standardization is a massive win for system integrators, as it drastically reduces the time spent on custom screen development and operator training. With PC-based HMIs now offering high-resolution multi-touch capabilities and seamless connectivity to 5G and cloud analytics, builders can deliver equipment that is not only easier to operate but also serves as a sophisticated data gateway for the end user’s digital transformation.
Top 5 Machine Design articles for machine builders and system integrators
