Evolving Motor Controller Design for Modern Robotics and Complex Automation Tasks

Pharmaceutical manufacturing is becoming increasingly reliant on robotics and automation. From precise dispensing and high-speed sorting to kit assembly and sterile packaging, today’s automation tasks demand advanced motor and drive technology to keep pace with complex, high-reliability environments. 

Brushless DC (BLDC) motors are emerging as a key solution across industrial automation, offering the precision, efficiency, and durability required by these robotic systems. Modern motors are expected to both deliver high performance and maintain functionality through repeated steam sterilization cycles in clean manufacturing zones.

Here, we look at key trends shaping modern motor controllers in advanced automation and explore how capacitor technologies are evolving to meet new demands.

Key Trends Shaping Motor Controllers in Complex Automation Tasks 

The rising complexity of automated systems is redefining what's required from modern motor controllers.

Two motor types are taking center stage: Brushless DC (BLDC) motors and Permanent Magnet Synchronous Motors (PMSMs). These motors offer superior energy efficiency, lower maintenance, and smoother operation compared to traditional brushed motors. In tandem, there’s rising demand for compact, high-power-density motor controllers to reduce system footprint. Sensorless control techniques, which eliminate the need for traditional position sensors, are also growing in popularity, as they reduce system complexity and cost while improving reliability.

While these trends promise higher performance, they also bring new engineering challenges. To enable finer speed and torque control in BLDC and PMSM motors, motor controllers must operate at higher switching frequencies. This places greater thermal demands on the system, requiring advanced heat dissipation strategies in those compact enclosures.

Further, accurate rotor position estimation becomes essential in sensorless systems, which requires sophisticated control algorithms and high-quality components that can maintain precision under variable loads and environmental conditions. While sensorless control reduces hardware complexity, it can be difficult to manage at low speeds where signal quality is poor. 

The Role of Capacitors in Advanced Motor Drives 

Capacitors are critical to the performance and reliability of motor controllers, and evolving application demands are reshaping capacitor requirements too. As motor drives shift to higher DC bus voltages and increased power density, capacitors must deliver improved electrical and thermal performance within tighter physical constraints.

Key performance criteria for modern industrial capacitors include:

• High voltage ratings that exceed the operating voltage of the motor controller with higher DC bus levels.
• Low ESR and ESL to minimize energy losses and heat generation during high-speed switching.
• High ripple current ratings to handle variable AC currents in dynamic load conditions.
• Compact form factors that support the miniaturization of motor controllers.
• Enhanced reliability and lifespan to reduce downtime and maintenance in mission-critical applications. 

To meet the rigorous demands of modern automation, Knowles offers capacitors engineered for durable, high-performance motor controller designs. This includes ceramic safety capacitors (Class X and Y), high-temperature rated MLCCs, film safety capacitors, traditional motor-run capacitors, and supercapacitors for high-load support in robotics.