An innovator in specialized collaborative robotics overcame a critical prototype-to-production bottleneck by transitioning from standard servo drives to a custom multi-axis architecture. This consolidation significantly reduced motion control hardware costs and physical footprint while maintaining the high-bandwidth impedance control required for safe, human-centric interaction.
The Challenge: High Precision Within Tight Spatial Constraints
A developer was engineering a highly specialized collaborative robot (cobot) designed for direct human interaction. To operate safely and effectively, the application required multi-arm synchronization capable of advanced impedance control (force feedback).
The control electronics had to fit within a heavily constrained, sound-dampened consumer enclosure, ruling out traditional industrial cabinets. Furthermore, the system demanded highly reliable Safe Torque Off (STO) integration to ensure strict compliance with collaborative safety standards.
The Hurdle: The Performance vs. Packaging Trade-Off
During R&D, standard FlexPro® drives successfully proved the technical concept, delivering the required torque density and EtherCAT communication precision.
However, as the project moved toward volume production, the physical packaging overhead and per-axis unit economics of the prototype configuration presented a major barrier.
The engineering team faced a common hardware dilemma: find a way to maintain premium, haptic-level performance without exceeding strict production cost targets or expanding the physical footprint.
The Solution: Architectural Consolidation
Recognizing that the barriers lay in redundant packaging and duplicated components rather than the core motion technology, ADVANCED Motion Controls proposed a structural redesign. Because the robot’s axes operated interdependently, AMC developed a custom dual-axis drive solution that consolidated two axes of control onto a single Printed Circuit Board (PCB).
- Eliminated Redundancy: By sharing logic circuits, power inputs, and communication interfaces, the design removed the need for duplicate connectors, housings, and processors.
- Simplified Integration: The consolidated design drastically reduced internal cabling, improving airflow within the compact chassis and reducing overall assembly time.
- Unified Communications: The custom board presented a single, streamlined EtherCAT node, simplifying the master controller’s network map.
The Results: Achieving Production Unit Economics
The architectural pivot allowed the developer to successfully bridge the gap between prototype performance and production targets.
- Cost Efficiency: The multi-axis approach significantly lowered the per-axis cost, achieving the required unit economics without sacrificing performance.
- Production Launch: Meeting strict Bill of Materials (BOM) targets allowed the company to move out of the prototyping phase and into full-rate manufacturing.
- Continuous Improvement: The success of the initial consolidation has evolved into an ongoing engineering partnership focused on the continuous optimization of the system’s motion control architecture.
