Author: Ken Cheng

The Basics on AC Drives

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AC drives, also known as variable frequency drives (VFDs) or adjustable speed drives (ASDs), are essential components in modern industrial and commercial applications. They control the speed and torque of AC motors by varying the frequency and voltage of the power supplied to the motor. This capability enhances energy efficiency, reduces mechanical stress, and improves process control.

In this article, we will explore what AC drives are, their key components, how they work, and their benefits in various applications.

Read more: The Basics on AC Drives

What is an AC Drive?

In short, an AC drive is an electronic device that regulates the speed and performance of an alternating current (AC) motor. Unlike traditional fixed-speed motors, AC drives allow for precise control over motor speed, acceleration, and deceleration, making them ideal for applications where varying speeds are necessary.

To better understand an AC Drive, we need to think about it in terms of “what makes up an AC Drive” and “How it works”.

The key components of an AC Drive consist of a Rectifier, that converts AC supply to DC voltage. Capacitors that filter and stabilize DC voltage. An inverter that uses pulse-width modulation (PWM) to recreate an AC waveform. Adjustable output controls like a variable switch. This controls AC output and motor speeds.

Example of AC drive.

You can read ore detailed information about AC drives here.

What are the Benefits of AC Drives?

While the upfront cost of installing an AC drive seems high, benefit of long terms savings make investing in an AC drive, a no brainer. Long term savings stands as the biggest benefit of having an AC drive. AC drives manage power consumption of your overall operation making sure your machines are using only the base load requirements. This improved regulation of energy also means less mechanical and electronic stress on your equipment resulting in increased longevity of your machine. The diminished stress also means less maintenance needed which translates to more savings!

Common Applications

AC drives do a lot of behind-the-scenes task that many do not really recognize. However, when you realize how many industries rely on automation, the importance that AC drives have becomes very apparent. Some obvious ones like manufacturing and energy where AC drives get used to run machines like conveyor belts or wind turbines. Some lesser known applications could include water treatment where AC drives an be used to control pumps. AC drives are also used in HVAC systems to control fans, pumps, and compressors for better energy efficiency.

Conclusion

AC drives play a crucial role in modern motor control systems, offering energy efficiency, precise speed regulation, and improved operational performance. By understanding how they work and their benefits, industries can optimize their processes, reduce costs, and enhance equipment longevity.

Whether in manufacturing, HVAC, or renewable energy, AC drives continue to revolutionize motor control, making them indispensable in today’s automated world.

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Servo Amplifier Innovations in 2025

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In 2025, the landscape of industrial automation and precision motion control is being redefined by innovations in servo amplifier technology. As smart manufacturing, servo amplifiers have undergone a significant transformation to meet the rising demands for speed, efficiency, and intelligence.

Read more: Servo Amplifier Innovations in 2025

How Servo Amplifiers Have Changed

Past Servo Amplifiers

Older servo amplifiers, commonly used in mid-to-late 20th century industrial and military applications, were primarily analog devices. These devices relied on operational amplifiers (op-amps), transistors, and thyristors (SCRs) to control motor position, speed, or torque. These amplifiers used feedback signals from resolvers, tachometers, or potentiometers to compare the actual motor performance with the commanded input. The error signal was amplified and used to adjust the motor’s power supply. This was done typically via pulse-width modulation (PWM) or linear amplification in high-precision systems.

Power regulation in these systems was often achieved using linear amplifiers for low-power applications or phase-controlled rectifiers (SCR-based) for higher-power motors. Linear amplifiers provided smooth, low-noise output but were inefficient due to significant heat dissipation. SCR-based amplifiers improved efficiency by switching high currents at precise phases of the AC input waveform, though they introduced more electrical noise and required careful tuning to avoid instability in the servo loop.

No Digitalization

Older servo amplifiers lacked modern digital processing, meaning tuning and compensation (such as PID control) had to be manually adjusted using potentiometers and RC networks. This made them sensitive to temperature drift and component aging. Despite their limitations, these systems were robust and provided sufficient performance for many early CNC machines, radar systems, and industrial automation tasks before digital signal processors (DSPs) and microcontrollers revolutionized servo control in the 1980s and beyond.

Servo Amplifiers of 2025

Today’s servo amplifiers have come a long way since their 20th century counterparts. These new servo amplifiers leave smaller environment footprints and built more energy efficient.


Smaller Footprints

One of the most notable trends in 2025 is the drastic reduction in the size of servo amplifiers without compromising performance. Thanks to advancements in power electronics, including the widespread adoption of silicon carbide (SiC) and gallium nitride (GaN) semiconductors, modern servo amplifiers offer higher switching frequencies, reduced heat generation, and more compact form factors. This makes them ideal for tight spaces in collaborative robots (cobots), mobile platforms, and micro-automation environments.

AI

Servo amplifiers have grown smarter. Many new models now feature embedded AI and machine learning algorithms that allow for auto-tuning, adaptive control, and predictive maintenance. These amplifiers can analyze motor performance in real time, detect anomalies, and even predict component failure before it happens. This leads to lower downtime, longer equipment life, and significantly improved OEE (Overall Equipment Effectiveness).


Cloud and Edge Connectivity

Modern servo amplifiers are increasingly designed with native Ethernet-based protocols (like EtherCAT, PROFINET, and Ethernet/IP) and support for edge computing. Some amplifiers even feature built-in web servers for remote access, configuration, and monitoring. This level of connectivity enables seamless integration into industrial IoT (IIoT) ecosystems and real-time data sharing with MES and ERP systems.


Energy Efficiency and Regenerative Capabilities

As sustainability continues to drive industrial innovation, energy-efficient servo amplifiers have become a priority. New-generation amplifiers support dynamic energy regeneration, capturing kinetic energy during deceleration and feeding it back into the power supply or shared bus systems. Coupled with high-efficiency motor control algorithms, these amplifiers contribute to reduced energy costs and a smaller carbon footprint.

Universal Compatibility and Modular Designs

Many new models are motor-agnostic, capable of driving brushless DC (BLDC), stepper, and synchronous/asynchronous AC motors from a single unit. Modular designs allow engineers to scale systems up or down with minimal reconfiguration, speeding up development time and reducing inventory complexity for OEMs.

Integrated Cybersecurity

With increasing connectivity comes greater vulnerability. Recognizing this, manufacturers now embed cybersecurity features directly into servo amplifiers, including secure boot, encrypted firmware updates, and real-time network monitoring to guard against cyber threats. This is especially critical in sectors like aerospace, defense, and medical automation.

Conclusion

The evolution of servo amplifiers in 2025 is emblematic of the broader shift toward smarter, more connected, and sustainable automation technologies. As these amplifiers become more compact, intelligent, and energy-conscious, they will play an even greater role in shaping the next generation of high-performance machinery and robotics.

Whether you’re an automation engineer, OEM, or system integrator, staying abreast of these innovations will be key to building future-ready solutions.

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Servo Amplifiers: Diagnosing and Fixing Ground Faults

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Ground faults in a servo amplifier system can lead to erratic behavior, unexpected shutdowns, or even permanent damage to equipment. A ground fault occurs when an unintended electrical connection exists between a live conductor and ground, causing leakage currents that disrupt normal operation. Diagnosing and fixing these faults promptly is essential for maintaining system reliability and safety.

This article provides a step-by-step guide to identifying and resolving ground faults in servo amplifier systems.

Read more: Servo Amplifiers: Diagnosing and Fixing Ground Faults

Recognizing the Symptoms of a Ground Fault

The quintessential step to repairing a ground fault is being able to recognize and identify symptoms. After all, you can’t fix a problem if you don’t know what the problem looks like. When looking for symptoms of a ground fault keep an eye out for:

Unexpected shutdowns or fault alarms (e.g., “Ground Fault” error on the drive)

Erratic motor behavior (jittering, unexpected movements, or loss of torque)

Burning smells or overheating components

Electrical noise affecting feedback devices (encoders/resolvers)

Tripped circuit breakers or ground fault protection devices

Safety Precautions

Once you’ve recognized the symptoms of a ground fault, you may have that impulse of wanting to go straight into poking around and tinkering with the drive. However, before you do that, you need to take precautionary steps to ensure your safety. Exercising the following precautions will prevent the chances of a hazard occurring, increasing your safety.

  1. Make sure the power is disconnected and verify with a multi-meter.
  2. Ensure the capacitors are discharged.
  3. Use insulated tools and wear personal protective equipment (PPE)
    – Companies like RefrigiWear offer a selection of insulated foot wear that protects against high voltage.
  4. Follow lockout/tagout procedures if working in an industrial environment.

Isolating the Fault

Once you are confident that all safety precautions have been taken and that the system is completely off and all power fully dispersed, then you can proceed forwards with isolating the fault. Here are a few ways you can isolate a fault.

Checking the Power Supply

Using a multi-meter, you can check the power supply to see if you get a low resistance rating that would indicate a short in the ground.

Checking the Motor Windings

You can test the motor windings by disconnecting the motor cables from the power supply. Next, measure the resistance between each motor phase and the ground. There should be high resistance (>1MΩ). A low resistance is an indicator of a short in the motor frame.

Check Encoders and Resolver Connections

Another way is to check encoders and resolvers for any exposed or damaged wires. You can check do this by checking for continuity between signal lines and ground. There should be no direct connection.

Inspecting the Servo Amplifier

If you need to check the servo amplifier, look for obvious visual signs like burnt components, blown fuses, or discolored PCBs. Using a multi-meter test the DC bus capacitors for leakage or short circuits. Double check proper grounding of the amplifier chassis.

Repairing the Ground Fault

While diagnosing and isolating faults are lightly challenging but doable for most people, it is advised that if you are not most versed in servo amplifiers then reach out to a professional for repairs.

Repair/Replace Damaged Wiring

If the issue is with the cables then replace any damaged or frayed cables. Also, check for strain relief on connection points to the devices. Good strain relief prevents future wear of cables. Make sure you use shielded cables for motor and feedback connections.

Address Motor Issues

Check your motor bearings as mechanical wear can cause internal shorts. If your motor windings are shorted, replace the motor.

Replacing Components

Replace blown out PCB and capacitors. Double check the amplifier is properly grounded. Be sure to check the specs before doing so.

Verify Grounding Scheme

When verifying the grounding scheme, make sure the system has a single-point ground to avoid ground loops. Also, make sure wires are properly sized and securely connected

After Repair Testing

After repairs are done, before you restore power, make sure to give another test. Use a multimeter to test resistance on motor windings and cables. After that, gradually power up the system and monitor for fault messages. Finally, run the servo motor at low speed and check for any odd sounds or for overheating.

Conclusion

Ground faults in servo amplifier systems can cause significant downtime if not addressed properly. By following a structured diagnostic approach—checking power supplies, motor windings, feedback cables, and amplifier components—you can efficiently locate and resolve the issue. Always prioritize safety, use proper testing equipment, and ensure correct grounding practices to prevent future faults.

Regular preventive maintenance, including insulation resistance checks and visual inspections, can help detect ground faults early and extend the lifespan of your servo system.

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The Impact of Tariffs on Industrial Automation

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The Impact of Tariffs on Industrial Automation


Industrial automation has become a cornerstone of modern manufacturing, driving efficiency, productivity, and competitiveness. However, the increasing use of tariffs—taxes imposed on imported goods—has introduced new complexities for businesses relying on automation technologies. While tariffs aim to protect domestic industries, they can also disrupt supply chains, increase costs, and slow innovation in industrial automation. This article explores the effects they have on the automation sector.

Read more: The Impact of Tariffs on Industrial Automation

What Are Tariffs?

There exists the misconception that tariffs are a tax on exporters. However, that simply isn’t true. A tariff is an import tax that gets put upon the importing company not the exporting company. Typically the importing party pays the tariff then in turn passes the cost of the onto their customers by marking up the price of the goods imported in.




How Tariffs Affect Industrial Automation

1. Increased Costs for Automation Components

Many industrial automation systems rely on imported components, such as robotic arms, sensors, controllers, and motors. When tariffs are imposed on these goods, manufacturers face higher procurement costs. For example, U.S. tariffs on Chinese-made automation parts have forced companies to either absorb the extra expenses or pass them on to customers, leading to higher prices for automated systems.

2. Supply Chain Disruptions

Tariffs can disrupt global supply chains by making certain suppliers less competitive. Companies that depend on just-in-time manufacturing may struggle with delays and shortages if they must switch suppliers due to tariff-related cost increases. This can slow down automation adoption as businesses face uncertainty in sourcing critical components.

3. Slowdown in Automation Adoption

Small and medium-sized enterprises (SMEs) that are considering automation may delay investments due to higher costs from tariffs. This could slow overall productivity growth in manufacturing, as automation is a key driver of efficiency.

4. Encouragement of Domestic Production

On the positive side, tariffs may incentivize companies to produce automation components locally. Countries imposing tariffs often aim to boost domestic manufacturing, which could lead to increased investment in homegrown automation technologies. However, building a competitive local supply chain takes time and may not immediately offset the negative effects of tariffs.

5. Trade Wars and Long-Term Uncertainty

Ongoing trade tensions, such as those between the U.S. and China, create uncertainty for automation suppliers and manufacturers. Companies may hesitate to make long-term investments in automation if trade policies remain unpredictable.

Are There Advantages to Tariffs?

While tariffs are generally looked down upon for their disruption to the flow in the global economy. When used responsibly and with proper domestic infrastructure in place, tariffs do have certain advantages.

Reshoring of Manufacturing

Companies may bring production back to domestic markets, increasing demand for localized automation solutions.

Innovation in Alternative Technologies

Higher costs for imported components could accelerate the development of new automation technologies that rely less on tariff-affected parts.

Strategic Sourcing Diversification

Businesses may seek suppliers in countries not subject to tariffs, leading to a more resilient supply chain.

Conclusion

Tariffs can present obstacles and potential opportunities for industrial automation. While they raise costs and disrupt supply chains, they may also encourage domestic production and innovation. Companies in the automation sector must adapt by diversifying suppliers, investing in local manufacturing, and exploring new technologies to mitigate risks. Policymakers should also consider their long-term impacts on industrial competitiveness, ensuring that trade policies support—rather than hinder—technological advancement.

As automation continues to transform manufacturing, navigating trade-related challenges will be crucial for sustaining growth and maintaining a competitive edge in the global market.

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Three-Phase Power

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Three-phase power remains a widely used method for generating, transmitting, and distributing electricity. It is more efficient than single-phase and is the backbone of industrial and commercial electrical systems. This article explores the history of three-phase and its most common applications today.

Read more: Three-Phase Power

How Three-Phase Power Works

Three-phase power consists of three alternating currents (phases) spaced 120 degrees apart. This
arrangement ensures a constant energy delivery, unlike single-phase systems, which have energy
fluctuations. Key advantages include:

  • Higher Efficiency
    • Requires less conductor material compared to single-phase for the same power output.
  • Smoother Power Delivery
    • Ideal for running large motors without interruptions.
  • Flexibility
    • Can power both industrial equipment and residential areas by splitting phases.

History

Before three-phase power, electrical systems primarily used direct current (DC) or single-phase alternating current (AC). Thomas Edison promoted DC power, while Nikola Tesla and George Westinghouse advocated for AC due to its ability to transmit electricity over long distances. In 1887 Tesla developed the first AC induction motor. This motor was capable of both two and three phase. Tesla’s work demonstrated that three-phase systems were more efficient for energy transmission and motor operation.

In 1891, the first long-distance three-phase power transmission became demonstrated at the International Electrotechnical Exhibition in Frankfurt, Germany. Engineers Dolivo-Dobrovolsky, Mikhail Osipovich, and Charles Eugene Lancelot Brown successfully transmitted 175 kW of power over 175 km with minimal losses, proving the superiority of three-phase AC. The success of this demonstration paved the way for modern three-phase and by the early 20th century, three-phase power became the standard for industrial and commercial power distribution. This was primarily due to its efficiency, reliability, and ability to power large motors.

Example of first three-phase motor by Tesla.
The Tesla Polyphase was the first example of a three phase motor.

Most Common Uses for Three-Phase Power

Since its inception in the 1800’s, three-phase power has seen itself used in a wide variety of industries and applications. It sees the most use in the industrial sector. Factories use three-phase to run heavy equipment such as pumps and conveyor systems without voltage drop. You can read more information about three-phase and AC Motors in the industrial sector here.

In the commercial sector, like shopping centers, hospitals, and office, three-phase power gets used in HVAC systems to keep the buildings habitable all year long. The renewable energy sector sees three-phase being generated and fed back into the energy grid.

Three-phase power also finds a more direct to consumer use as well. It gets used to power data centers all over the world. The computational power of these server require stable high capacity voltage which three-phase excels in providing. As of late, three-phase has found their use in the electric vehicle industry being used at charging stations for people to charge their vehicles.

Conclusion

Three-phase power revolutionized electrical engineering with its efficiency and reliability. From its origins in Tesla’s innovations to its widespread use in industry and infrastructure, three-phase systems remain the standard for high-energy applications. As technology advances, three-phase will continue to play a crucial role in modern energy systems.

Average Lifespan of a PLC

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Programmable Logic Controllers (PLCs) are integral components in industrial automation, serving as the backbone for controlling machinery and processes. Understanding their lifespan is crucial for maintenance planning and system upgrades. While exact lifespans can vary based on factors such as operating conditions and technological advancements, industry observations provide valuable insights.

Read more: Average Lifespan of a PLC

General Lifespan Estimates

Discussions among industry professionals suggest that PLCs can operate effectively for approximately 10- 20 years. For instance, some facilities have reported PLCs functioning reliably for over 30 years before replacement. However, it’s essential to recognize that these figures are anecdotal and can vary based on several factors, including the specific model, operating environment, and maintenance practices.

Schneider PLC

Factors Influencing PLC Lifespan

Several elements can impact the operational life of a PLC:

  • Operating Environment: Units in a clean, temperature-controlled settings typically outlast those in harsh environments with extreme temperatures, dust, or moisture.
  • Maintenance Practices: Regular maintenance and timely updates can extend lifespan by preventing issues that could lead to premature failure.
  • Technological Advancements: As technology evolves, newer models with enhanced features become available, which might prompt upgrades even if existing units are still functional.

Prolonging PLC Lifespan

To optimize the lifespan and performance of PLCs, consider the following strategies:

  • Standardization: Implementing standardized systems across facilities can simplify maintenance and training, leading to more efficient operations.
  • Vendor Support: Engage with manufacturers to understand their support policies, ensuring access to necessary components and technical assistance throughout the lifecycle.
  • Proactive Upgrades: Regularly assess the benefits of upgrading to newer PLC models, balancing the advantages of advanced features against the costs and potential disruptions of replacement.

Conclusion

While PLCs are designed for durability and can function effectively for decades, their actual lifespan depends on various factors. By considering operating conditions, maintenance practices, and technological developments, industries can make informed decisions to ensure the reliability and efficiency of their automation systems.

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Three Basic Types of Servo Motors

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Servo motors are a crucial component in automation, robotics, and various control systems. They are designed for precision control of angular or linear position, velocity, and acceleration. There are three basic types of servo motors: positional rotation motors, continuous rotation motors, and linear motors. Each type has unique characteristics, advantages, and specific applications.

Read more: Three Basic Types of Servo Motors

Positional Rotation Servo Motors

Specifically designed for limited-angle rotation; positional rotation motors usually rotate between 0 and 180 degrees. They contain built-in feedback mechanisms, typically using a potentiometer, to control precise positioning.

Characteristics & Applications

  • Less than 180 degree rotational movement.
  • Used for precise angle adjustments
  • Compact and cost effective
  • Commonly used in camera gimbals, robotic arms, and small automated systems.
servo motors

Continuous Rotation Servo Motors

Continuous rotation motors are designed to rotate continuously in either direction, similar to a DC motor but with controllable speed and direction. These do not have position feedback but instead rely on pulse width modulation (PWM) signals to control their speed and direction.

Characteristics & Applications

  • Has full 360 degree rotational movement in either direction.
  • Speed and direction controlled via PWM signals.
  • No built-in position feedback
  • Used in processes that require continuous movement such as conveyor belts and motorized platforms.
This video explains the difference between positional and continuous servo motors.

Linear Servo Motors

Linear motors convert rotational motion into linear motion, providing precise control over movement in a straight line. These motors are commonly used in applications that require accurate positioning along a linear path.

Characteristics & Applications

  • Can convert rotational motion into linear motion
  • Very precise and accurate
  • Incorporates lead screws, belt drives, and directional actuators
  • Used in operations that require linear movement such as CNC machines and 3D printers.
servo motors

Conclusion

Each type of motor serves different applications based on its characteristics and advantages. Positional rotation motors offer precise control for limited-angle movements. Continuous rotation motors provide controllable speed and direction for continuous movement. Finally, linear motors enable precise linear motion control. Understanding these differences helps in selecting the right servo motor for any given application, ensuring efficiency and accuracy in motion control systems.

If you have found what you have read helpful then check out our article on extending your servo motor life. Feel free to also check out our article about the warning signs of a failing servo motor.

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