Integrated Servo Motor

Jkongmotor integrated drive+motors combine stepper or bldc motor and drive components into one compact unit. These integrated servo motors provide a space-saving design that minimizes wiring and reduces costs compared to separate motor and drive components. Available in NEMA 8, 11, 17, 23, 24 and 34 frame size.

• pulse type
• RS485-Modbus-RTU network type
• CANopen network type

Protection level:

• Waterproof type: IP30 IP54 IP65 optional

How Do Integrated Servo Motors Work?

Integrated servo motors are advanced motion control devices that combine a servo motor and a drive/controller into a single, compact unit. Unlike conventional servo systems, which require separate motor and controller components, integrated servo motors streamline the setup while offering high precision, fast response, and simplified installation.

Basic Structure of an Integrated Servo Motor

An integrated servo motor combines multiple components into one system:

1. Motor

• The motor component is typically a brushless DC (BLDC) or AC synchronous motor.
• It generates rotational motion with high torque, precise speed, and controllable position.
• The rotor may include permanent magnets, and the stator contains electromagnetic windings.

2. Feedback Device

• A built-in encoder or resolver continuously monitors the rotor position.
• Feedback allows the system to adjust motor operation in real-time, achieving precise positioning and speed control.
• Common types include incremental encoders, absolute encoders, and resolvers.

3. Integrated Drive/Controller

• The drive or servo amplifier is embedded within the motor housing.
• It converts electrical input signals into controlled current for the motor windings.
• The controller also processes feedback from the encoder and applies closed-loop control to maintain desired speed or position.

Working Principle of Integrated Servo Motors

The operation of an integrated servo motor relies on closed-loop feedback control and electromagnetic actuation. The process can be broken down into several steps:

Step 1: Command Signal Input

• A control signal from a PLC, motion controller, or microcontroller specifies the desired position, speed, or torque.

Step 2: Position and Speed Detection

• The built-in encoder monitors the rotor’s current position and speed.
• This data is continuously sent to the internal controller.

Step 3: Error Calculation

• The controller compares the actual position/speed with the commanded input.
• Any difference between the actual and desired values is called the position or speed error.

Step 4: Control Signal Adjustment

• The controller generates a corrective electrical signal to the motor windings.
• This adjusts the rotor’s rotation to reduce the error, maintaining precise motion.

Step 5: Continuous Feedback Loop

• The feedback loop operates continuously, ensuring accurate response to changes in load, speed, or position.
• This allows the motor to maintain high precision, smooth motion, and dynamic responsiveness.

Electronic Commutation in Integrated Servo Motors

Most integrated servo motors use brushless designs with electronic commutation:

• Sensors (Hall effect or encoder signals) detect rotor position.
• The controller switches current in the stator windings based on rotor position.
• This generates rotating magnetic fields that interact with the rotor magnets to produce motion.

Electronic commutation allows smooth acceleration, precise speed control, and minimal mechanical wear, improving motor performance and lifespan.

Advantages of Integration

In the modern era of industrial automation and precision engineering, integrated servo motors have emerged as one of the most versatile and efficient solutions for motion control applications. These motors combine the power of high-performance servo systems with compact, all-in-one designs that streamline installation, reduce wiring complexity, and enhance overall operational efficiency.

1. Compact Design and Space Efficiency

One of the most compelling advantages of integrated servo motors is their compact design. Traditional servo systems typically require separate servo drives, controllers, and encoders, which increases the physical footprint of the system. By integrating these components into a single motor unit, manufacturers can significantly reduce space requirements.

This space efficiency is crucial in applications where floor space is limited, such as in robotic arms, CNC machinery, or packaging equipment. Moreover, the reduced system volume leads to simpler mechanical layouts, allowing engineers to design more ergonomic and streamlined equipment.

2. Simplified Installation and Reduced Wiring

Integrated servo motors drastically simplify the installation process. Since the servo drive, encoder, and motor are built into a single unit, the need for complex external wiring is minimized. This not only reduces installation time but also lowers the risk of wiring errors, which are a common source of downtime and maintenance issues.

The integrated design also enables plug-and-play functionality in many systems, allowing rapid deployment and easier integration with PLCs or motion controllers. For production environments, this translates into faster machine setup and reduced labor costs, which are critical for high-volume manufacturing operations.

3. Enhanced Precision and Performance

Integrated servo motors are renowned for their high precision and excellent dynamic performance. With the encoder and drive embedded in the motor housing, feedback loops operate at higher speeds and with greater accuracy. This tight integration ensures smooth motion control, precise positioning, and rapid acceleration/deceleration profiles.

Applications such as robotics, CNC machining, and semiconductor manufacturing benefit from this enhanced precision. The motor’s ability to maintain consistent torque under varying loads ensures repeatable performance, which is vital in industries where micrometer-level accuracy is required.

4. Improved Energy Efficiency

Energy efficiency is a critical consideration in modern industrial systems, and integrated servo motors excel in this domain. By combining the motor and drive into a single optimized unit, manufacturers can minimize energy losses commonly associated with long cable runs and mismatched components.

Integrated servo systems also feature advanced energy-saving algorithms, including regenerative braking and adaptive torque control. These technologies reduce energy consumption and lower operating costs, making them ideal for companies aiming to achieve sustainability goals while maintaining high productivity.

5. Reduced Maintenance Requirements

Maintenance demands are significantly lower with integrated servo motors due to fewer external components and simplified system architecture. Traditional setups often require periodic inspection of multiple discrete elements, including wiring harnesses, separate drives, and encoders. In contrast, integrated systems consolidate these elements, reducing the number of potential failure points.

This translates into higher system uptime, less frequent downtime, and lower total maintenance costs over the equipment’s lifespan. Additionally, modern integrated servo motors often feature diagnostic capabilities built into the drive, enabling predictive maintenance and proactive fault detection.

6. High Reliability and Robustness

Reliability is a key advantage of integrated servo motors. With fewer connections, external components, and cabling, the overall system becomes inherently more robust. Many integrated units are designed to withstand harsh industrial environments, including high temperatures, vibration, and dust exposure.

The robust construction ensures that integrated servo motors maintain consistent performance over long operational periods, reducing unexpected breakdowns and minimizing production losses. For industries such as automotive manufacturing and heavy machinery, this reliability is essential to maintain stringent production schedules.

7. Cost-Effectiveness Over the Long Term

While integrated servo motors may initially appear more expensive than conventional setups, the total cost of ownership is often lower. Savings come from multiple factors:

• Reduced installation labor and time
• Lower maintenance costs
• Energy efficiency and reduced electricity bills
• Fewer replacement parts and lower downtime

By considering these factors, companies can achieve long-term economic benefits while simultaneously improving system performance and reliability.

8. Flexibility in Application

Integrated servo motors are incredibly versatile and suitable for a wide range of industrial and commercial applications. They are used in robotic systems, CNC machines, conveyors, packaging equipment, medical devices, and semiconductor manufacturing.

The combination of compactness, precision, and reliability allows engineers to deploy integrated servo motors in applications that require tight spaces and high-accuracy motion control, while also scaling easily to larger systems without adding significant complexity.

9. Enhanced Safety Features

Modern integrated servo motors often come equipped with built-in safety features, such as overcurrent protection, thermal monitoring, and automatic fault detection. These features help prevent catastrophic failures, protect personnel, and comply with industrial safety regulations.

By embedding these safety mechanisms directly into the motor unit, manufacturers can reduce the need for external safety circuits, simplifying compliance with ISO and IEC standards.

10. Streamlined Communication and Smart Integration

Many integrated servo motors support advanced communication protocols, including EtherCAT, CANopen, Modbus, and PROFINET. This enables seamless integration with modern industrial networks and Industry 4.0 architectures, allowing real-time monitoring, data collection, and remote control.

The integration of smart features and network connectivity empowers engineers to analyze performance metrics, optimize motion control, and implement predictive maintenance strategies more effectively.

Conclusion

The advantages of integrated servo motors are clear and far-reaching. From compact design, simplified installation, and enhanced precision to energy efficiency, reliability, and cost-effectiveness, these motors provide a comprehensive solution for modern motion control needs. Their versatility across multiple industries, combined with built-in safety features and smart connectivity, makes them a cornerstone of advanced automation systems.

For any organization aiming to improve efficiency, reduce maintenance, and optimize performance, integrated servo motors represent a strategic investment that delivers both immediate and long-term benefits.

Applications of Integrated Servo Motors

Integrated servo motors are compact, high-performance motion control systems that combine the motor, encoder, and drive/controller into a single unit. This integration simplifies installation, reduces wiring, and enhances precision and responsiveness. Their high efficiency, accurate positioning, and compact design make them ideal for a wide range of applications across industrial automation, robotics, medical devices, and precision machinery.

1. Industrial Automation and Assembly Lines

Integrated servo motors are widely used in industrial automation due to their precise motion control, fast response, and repeatability.

Applications Include:

• Robotic Assembly: Accurate joint and end-effector positioning for assembling electronics, automotive parts, and appliances.
• Conveyor Systems: Smooth, controlled movement of materials, reducing jams and improving throughput.
• Automated Packaging Machines: Precise control of filling, sealing, and labeling processes.
• Pick-and-Place Operations: High-speed and accurate placement of components in manufacturing environments.

Benefits: Their compact design and integrated controller minimize wiring and setup complexity, while ensuring high-speed, precise motion across the production line.

2. CNC Machines and Precision Machining

Integrated servo motors are essential in CNC machinery where accuracy and repeatability are critical.

Applications Include:

• Milling Machines: Controlling spindle and table movements with micron-level precision.
• Lathes and Turning Centers: Ensuring smooth, precise rotation and linear motion.
• Laser and Waterjet Cutters: Accurate toolhead positioning for complex cuts.
• 3D Printers: Precise layer deposition for high-quality additive manufacturing.

Benefits: Closed-loop control and built-in encoders provide high precision, reducing errors and improving production quality.

3. Robotics

Integrated servo motors are integral to industrial and collaborative robots due to their compactness, high torque, and precise control.

Applications Include:

• Articulated Robotic Arms: Smooth, accurate motion for assembly, welding, and material handling.
• SCARA and Delta Robots: Fast, repeatable movements for packaging and electronics assembly.
• Humanoid Robots: Precision joint actuation for dexterity and coordinated movement.

Benefits: The combination of fast response, high torque, and positional accuracy allows robots to perform complex tasks reliably and efficiently.

4. Medical Devices and Laboratory Automation

The precision, smooth motion, and compact design of integrated servo motors make them ideal for medical and laboratory equipment.

Applications Include:

• Surgical Robots: Controlling robotic arms with sub-millimeter accuracy.
• Diagnostic Instruments: Precise movement of imaging components, slides, or sensors.
• Infusion Pumps: Accurate dosing and fluid control.
• Automated Laboratory Systems: Sample handling, pipetting, and robotic experimentation.

Benefits: Their quiet operation and high reliability enhance patient safety and improve laboratory workflow.

5. Packaging and Material Handling Systems

Integrated servo motors are widely adopted in packaging and logistics applications, where timing, speed, and positioning are crucial.

Applications Include:

• Labeling Machines: Precise label placement at high speed.
• Filling and Capping Machines: Accurate dispensing and assembly in food, beverage, and pharmaceutical industries.
• Sorting Systems: High-speed item recognition and routing on conveyor lines.
• Automated Storage and Retrieval Systems: Precise linear and rotary motion for warehouse automation.

Benefits: Their integrated control and compact footprint reduce installation complexity while increasing throughput and reliability.

6. Aerospace and Defense Applications

Integrated servo motors are utilized in aerospace and defense systems where high precision, reliability, and compact size are mandatory.

Applications Include:

• Flight Control Systems: Positioning of ailerons, flaps, and stabilizers.
• Satellite Mechanisms: Antenna or solar panel deployment with precise alignment.
• Defense Robotics: Actuation for unmanned vehicles and remote weapon systems.
• Simulation Equipment: High-fidelity motion platforms for pilot training.

Benefits: They provide robust performance under dynamic loads and harsh conditions, making them essential for mission-critical operations.

7. Automation in Printing and Textile Machinery

Integrated servo motors are widely used in printing presses and textile machines for accurate positioning, tension control, and synchronization.

Applications Include:

• Printing Press Rollers: Ensuring consistent image alignment and high-speed operation.
• Textile Looms: Accurate control of yarn tension and shuttle movements.
• Label and Packaging Printers: High-resolution printing with precise material feed.

Benefits: High accuracy, repeatability, and smooth motion improve product quality and operational efficiency.

8. Semiconductor and Electronics Manufacturing

Integrated servo motors enable precise and reliable motion in electronics assembly and semiconductor production.

Applications Include:

• Wafer Handling Systems: Precise placement and movement of silicon wafers.
• PCB Assembly Machines: High-speed pick-and-place operations.
• Testing and Inspection Equipment: Controlled movement of probes and sensors.
• Microelectronics Fabrication: Nano-level positioning in photolithography and deposition processes.

Benefits: Their compact design and high accuracy are crucial for miniaturized, high-precision manufacturing environments.

Conclusion

Integrated servo motors offer a complete, compact, and highly efficient motion control solution by combining the motor, encoder, and controller into one unit. Their applications span industrial automation, robotics, CNC machinery, medical devices, aerospace, packaging, and semiconductor manufacturing.

By providing high precision, fast response, simplified installation, and reduced maintenance, integrated servo motors enhance performance and reliability across diverse industries. They are the preferred choice for engineers and designers seeking compact, intelligent, and precise motion solutions in modern automation and control systems.

Integrated servo motors work by combining a brushless motor, built-in encoder, and internal controller into a single unit. Using closed-loop feedback control, the system continuously monitors rotor position and adjusts electrical input to ensure precise speed, torque, and positioning.

This integration offers high precision, compactness, simplified installation, and improved reliability, making integrated servo motors ideal for a wide range of applications in industrial automation, robotics, medical devices, and precision machinery.

By streamlining motion control into a single, intelligent unit, integrated servo motors enhance performance, reduce system complexity, and provide cost-effective precision solutions for modern engineering challenges.