The Series 3564 BC from MicroMo Electronics includes a totally integrated brushless DC motor, amplifier, and full function motion control module.

Imagine an early 20th century engineer waking up in the year 2001 to find himself directing a team of automotive designers. If he survived the shock, he might instinctively begin by polling the group to learn which components they are most familiar with. After hearing many foreign terms like “oxygen sensor” and “engine knock signal processor,” he might, in frustration, ask if anyone knows anything about real components like carburetors, alternators, and distributor caps.

In a similar way, the motion system components we are now familiar with will be vastly different by the end of the 21st century; in some cases, unrecognizable. Functions that now sprawl over two or three components may end up residing in one; some elements may be gone entirely, dissolved into the fabric of the machine or taken up in software.

The path from here to there is not built so much on new technology, but new ways of implementing and combining it. The old way reflects traditional college engineering curriculum, which for practical purposes breaks machines down into disciplines, functions, and closely allied components. The partitions are artificial, however, and are becoming porous as technology and business practices transcend the abilities of individual engineers and the compartmentalized training they received.

The new approach to design, called system engineering, actually began in the late 1950s with large-scale military and aerospace projects. Since then, the method has been adopted by automakers as well as general manufacturers.

Examples of system engineering in motion are plentiful. No matter where you look, along rotary or linear motion axes, you’ll find component integration and function consolidation. Even engineering schools are getting into it, offering courses upon which the feats of 21st century engineering are likely to be built.

What is it

So what is system engineering? According to the International Council on Systems Engineering, it is “an interdisciplinary approach and means to enable the realization of successful systems.” In other words, it’s a way to design and build things that sell at a profit and do what they’re supposed to do for as long as they’re supposed to do it.

System engineering focuses on defining needs and functions early in the development cycle. It entails documenting all requirements at the start, then generating and validating the design with the entire product cycle in mind: operations, performance, testing, manufacturing, cost and scheduling, training and support, and disposal.

Although it involves additional work, the benefits of system engineering make it worthwhile. “Advantages include ease of integration and a shorter sales cycle for the supplier,” says Charles Schultz, vice president of sales for California Linear Devices Inc., Carlsbad, Calif. “It also promotes closer partnerships, letting machine builders focus on core strengths rather than ancillary tasks that used to require the additional expertise of a system integrator or control specialist.”

At its special devices facility, Litton Poly-Scientific combines several components to form complete closed-loop “integrated motion technology” (IMT) systems.

“We see the system approach as very much a trend,” says Don Labriola, president of QuickSilver Controls Inc., Covina, Calif. “Engineers are in short supply, with more firms willing to buy solutions instead of building them. Actually they save money that way,” Labriola explains. Electronics are cheaper than connectors and cables, so the more functions implemented in silicon and software, the better. Not too long ago, it was the other way around.

Complexity and certainty are also factors. “Projects are more complex than they were ten years ago, so it makes sense to purchase ‘function blocks’ rather than individual components,” Labriola explains. “This also simplifies certification because performance factors are known up front rather than arrived at later.”

Who’s doing it

One company that finds itself doing more and more system engineering is MicroMo Electronics Inc., Clearwater, Fla. The driving factor, as usual, is time and money. “It’s often less expensive to buy a complete system than to mix-andmatch components from several suppliers,” says Tod Grizzell, application engineer. “A turn-key system saves time as well, especially if you have a small staff, and there’s no guesswork in who to call for technical support.”

System engineering is more complicated than standard design, however, requiring both the supplier and designer to share a detailed knowledge of the application. Suppliers, therefore, must spend a lot of time gathering information. “It’s important for our engineers to understand not just the application, but budgets and time-tables as well,” explains Grizzell.

“We start by helping customers select the appropriate motor or gearmotor. We want to know how much torque is required; what are the motion needs; what are they moving; and what are the physical constraints — length, diameter, weight, thermal environment, and so on. The next step is to find out how the end user wants to control the motion,” Grizzell says.

The system approach, with everyone working as a team, follows a structured process from concept to production to operation. It considers both business and technical needs, with the goal of providing a quality product that meets all requirements.

To become more “system” oriented, MicroMo established a new product development process that’s both technology and customer-driven. Now, the motor maker’s design and fabrication process can be customized on an individual basis. “Our process lets us use custom lubes, for example, on gearheads slated for quiet or extreme cold applications,” says Grizzell. “We’ve even designed pieces for another manufacturer’s motor to drive an impeller system used in coronary interventions.”

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