When machine builders are specifying motion systems, it is easy to focus on the numbers. Torque, speed, power density and price are clear; measurable factors that provide a straightforward way to compare components. In modern machine design, however, these figures rarely tell the full story. Many of the biggest challenges in automation arise not from component performance, but from how systems are assembled. Integration, commissioning and troubleshooting often determine whether a machine is delivered on time and performs as intended.
The hidden cost of engineering time
One of the most overlooked factors in motion system design is engineering time. When comparing components, it is common to focus on upfront cost, which can make a lower-cost drive or controller appear attractive in isolation. This approach can lead to unintended consequences if it increases the time required to integrate and commission the system. Every additional hour spent configuring communication, writing custom code or diagnosing unexpected behaviour delays machine startup, which in turn, delays production and increases overall project cost. The cost of lost time can significantly outweigh any savings made on hardware.
Time-to-commission should therefore be considered alongside traditional performance metrics. Systems that are easier to configure, faster to debug, and more intuitive to operate can deliver significant value, even when their initial purchase price is higher.
Integration over individual components
Modern motion systems are rarely built from a single device. A typical machine may include controllers, drives, motors, I/O and human-machine interfaces, all of which must communicate reliably. When these components are sourced from different vendors, integration can become a significant task. Differences in communication protocols, configuration methods and software environments often require additional engineering effort to resolve. Even with increasing standardisation, such as the adoption of protocols like OPC UA, achieving seamless interoperability is not always straightforward.
System-level thinking is becoming more important as a result. Rather than selecting components purely on individual specifications, engineers must consider how easily they can be combined into a functioning whole. Reducing the effort required to make devices communicate and behave as expected has a direct impact on development time and long-term reliability.
The role of software and tools
As motion systems become more capable, software plays an increasingly central role in their performance. The engineering environment used to configure and program a system can be as significant as the hardware itself.
Three areas are particularly relevant:
• Configuration: devices should be quick to connect and simple to set up with minimal manual intervention.
• Programming flexibility: support for widely used standards, such as IEC 61131 languages, allows engineers to work in a way that suits their application.
• Diagnostics: effective troubleshooting tools make it easier to identify and resolve issues during commissioning and operation.
These tools also help limit the impact of shortfalls in access to skilled personnel. Many facilities no longer have large teams of experienced engineers on hand to support complex systems, so there is growing value in specifying solutions that are easier to understand and maintain, and that are well-supported by their supplier.
A broader view
Integrated platforms, where controllers, drives and software tools are designed to work together, can help reduce complexity and shorten development cycles. Suppliers such as Kollmorgen, part of Regal Rexnord, have responded to this shift by developing motion solutions that emphasise ease of integration and usability alongside performance.
For machine builders, the challenge is to look beyond the spec sheet and consider how design choices will affect the time, effort and expertise required to deliver a working system. In modern automation, the most effective solutions are not always the most powerful on paper, but those that enable machines to be built, commissioned and maintained with confidence.
For more information contact Kollmorgen,
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