Industry 4.0 is the term for the fourth industrial revolution, which involves the integration of digital technologies, automation, and data exchange in manufacturing systems. One of the key aspects of Industry 4.0 is real-time monitoring, which allows manufacturers to track production status, optimize performance, and prevent errors. SANMOTION motion controllers are essential devices for real-time monitoring, as they provide precise control and feedback of motion-related processes in production lines. In this post, we will explain how SANMOTION motion controllers enable real-time monitoring for Industry 4.0.

Motion Controllers monitor production status in real-time


Feedback Sensors for Precision

SANMOTION motion controllers use feedback sensors such as batteryless encoders, resolvers, or linear scales to measure the position, velocity, and acceleration of moving components. These sensors send real-time feedback to the motion controller, which adjusts the control signals accordingly. This ensures accurate and consistent motion profiles for the production process.

Communication Protocols for Data Exchange

diagram of Ethercat motion controller by sanyo denki

SANMOTION motion controllers also support communication protocols like EtherCAT and Modbus TCP/IP, which allow them to exchange data with other components of the production system. This enables coordinated operation and real-time sharing of production status information.

Diagnostic Signals for Status Updates

Additionally, SANMOTION motion controllers generate diagnostic signals and status flags that indicate the operational status of the system. These signals are communicated to supervisory systems or operators through HMI interfaces, which enable real-time monitoring and troubleshooting.

Automatic Motion Profiles and Trajectory Planning for Execution

G-code (DIN 66025 compliant) enables control of various robot mechanisms such as cartesian, SCARA, and delta robots.


SANMOTION motion controllers include a CNC function that generates and executes motion profiles and trajectory plans for actuators and robots. This function reads the desired motion trajectory from a CAD (DXF file) drawing and moves the components along predefined paths. This program-less system can significantly reduce development times and provide real-time insights into the production progress and status.

Integration with SCADA/MES Systems for Visibility

Moreover, SANMOTION motion controllers integrate with SCADA or MES software, which provide real-time production monitoring, reporting, and analysis capabilities. These software collect data from motion controllers and other production equipment and visualize production status, track performance metrics, and identify inefficiencies. (Learn more about ISA-95 systems integration.)


Alarm and Event Handling for Anomalies

SANYO DENKI Motion Controller S200 Networking diagram

SANMOTION motion controllers generate alarms and events based on predefined conditions. Real-time monitoring of these alarms allows operators to promptly respond to abnormal conditions and minimize downtime.

Remote Access and Monitoring for Accessibility

web-browser-monitoring capability by SANMOTION C motion controller SANYO DENKI

In conclusion, SANMOTION motion controllers actively contribute to customers’ manufacturing operations in the Industry 4.0 landscape. By providing remote monitoring capabilities, SANMOTION enables proactive maintenance, troubleshooting, and optimization of production processes, ensuring agility and innovation in manufacturing.

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