An innovator in autonomous mobile robots (AMRs) successfully launched a new platform by partnering with ADVANCED Motion Controls to resolve complex network integration challenges.
Through systematic diagnostics led by AMC applications engineers and targeted hardware modifications, the customer scaled production and accelerated their time-to-market.
The Challenge: High-Density Power for an Ambitious AMR Design
A developer of advanced AMRs was designing a new materials-handling vehicle. The design required synchronized, high-precision motion control within an extremely compact physical footprint.
To meet performance targets, each drive axis required high power density from the servo drives. Additionally, the system required integrated Safe Torque Off (STO) to ensure mission-critical safety compliance in a collaborative warehouse environment.
The Hurdle: Persistent Network Instability
The primary roadblock to the robot’s launch was persistent instability on the communication bus. During evaluations with incumbent drive technology, the engineering team encountered intermittent communication failures and transient errors that threatened the project’s timeline.
The intermittent nature of these errors made them difficult to trace. Standard drive solutions offered limited diagnostic visibility, leaving it unclear if the root cause lay within the network protocol, the drive hardware, or the system wiring.
The project stalled as the team struggled to pinpoint the source of the interference using off-the-shelf components.
The Solution: Deep-Dive Diagnostics and Collaborative Engineering
Introduced via a regional distributor, the ADVANCED Motion Controls team treated the project as a collaborative partnership. Recognizing the challenge was at the system level, AMC deployed intensive, hands-on support.
System-Level Troubleshooting
A lead AMC applications engineer conducted daily technical meetings to analyze the entire electrical environment.
Root Cause Identification
He determined the root cause was system-level noise and grounding loops, rather than a protocol limitation.
Structural Resolution
AMC provided specific wiring recommendations to structurally resolve the interference.
Application-Specific Modifications
While a standard FlexPro® drive was selected for its high power density, the ADVANCED Motion Controls design team provided a modified variant to streamline integration:
- I/O Alignment: AMC engineers changed the STO logic from 5V to 24V to match the existing system controller.
- Feature Optimization: AMC identified an unused internal relay driver that could be populated to provide a hardware-based braking solution, bridging a functional gap for the current robot generation.
The Results: From Prototype to Production
By partnering with ADVANCED Motion Controls to resolve core technical roadblocks, the manufacturer moved from beta testing into full-rate production.
The trust built during this project has positioned ADVANCED Motion Controls as the partner for the next-generation platform, migrating to future high-speed networks and integrated Functional
