Why Small Tweaks Matter in Motion Control
When most engineers think about improving machine performance, the first ideas are usually big ones: faster drives, upgraded PLCs, or a complete system overhaul. These projects matter, but they demand significant time, budget, and justification.
What often goes unnoticed are the small adjustments hiding in plain sight. In Beckhoff TwinCAT motion control, subtle changes in how motion is programmed can lead to smoother operation, less wear on equipment, and measurable improvements in throughput. Because motion is fully integrated into the TwinCAT environment, it’s easy to step from drive to PLC to HMI within the same project tree. That integration makes it straightforward to tune PLC commands to the drive’s capabilities—and match the drive back to the program—for the best results in the process.
It’s like fine-tuning an engine: you don’t replace the whole car, you tweak what’s already there. A jerk-limited profile here, a blended move there, or smarter conveyor logic—and suddenly the same hardware feels like it’s been upgraded.
In this post, we’ll look at three motion control adjustments you can implement directly in TwinCAT. They don’t require extensive reprogramming, but they do require knowing where to find them.
Smooth the Ride with S-Curves
Acceleration curves are easy to ignore. If the axis moves from point A to point B, most default settings feel “good enough.” But the shape of that curve determines how much stress you’re putting on the mechanics—and how long they’ll last.
Older systems—and even many current drives—use trapezoidal profiles by default. These rely on acceleration and deceleration ramps to keep motors from pulling too much current at startup. It’s a proven method, but it still creates abrupt transitions. The result is motion that gets the job done, but with more vibration, product shifts, and long-term wear on belts, gears, and bearings.
How to adjust it in TwinCAT:
- Open the axis in Motion → Dynamics settings.
- Enable jerk-limited (S-curve) profiles for acceleration and deceleration.
- Or, in PLC code, add the Jerk parameter to the MC_MoveAbsolute block.
Why it matters: smoother moves, quieter machines, and longer component life. A minor configuration change with an outsized impact on reliability.
Keep Robots Moving with Blended Sequences
In high-speed tasks like robotics or pick-and-place, every fraction of a second matters. Accurate motion is great—but if the system stops and starts constantly, cycle times creep up and wear adds up.
Traditionally, commands are executed one by one: move, stop, then move again. It works, but it’s like driving through a city and hitting every red light. You’ll still reach your destination, just more slowly and with more wear on the brakes.
Try this in TwinCAT motion control:
- In PLC code, use motion blocks such as MC_MoveAbsolute or MC_MoveRelative.
- Adjust the BufferMode parameter to MC_Buffered or MC_BlendingLow/High.
- This allows the next move to begin before the previous one has fully finished.
The result: shorter cycle times, smoother transitions, and less stress on tools and mechanics. Robots glide instead of jerking, packaging lines move faster without jams, and conveyors keep material flowing.
Smarter Conveyor Logic
Conveyors don’t always grab attention, but they quietly determine how smoothly a facility runs. When they’re inefficient, you feel it in higher energy costs, premature bearing failures, and frustrating downtime.
Most conveyors still run like light switches: on, off, repeat. Product moves, but at the cost of energy spikes and mechanical strain.
Options to explore in TwinCAT:
- Add zone conditions in PLC logic.
For most setups, this means writing simple PLC code such as IF sensor detects product THEN Axis.Run ELSE Axis.Stop. No product means no wasted motion. If you’re using Beckhoff hardware like the EP7402 MDR controller, you can also enable its built-in ZPA functions, reducing the need for custom code.
- Use velocity ramps.
In the axis Dynamics settings or motion commands, configure ramps for acceleration/deceleration to reduce torque spikes. The programmer typically sets these, but Beckhoff drives can also apply current and torque limits, so the system adapts if loads change at takeoff—helping prevent overload trips.
- Coordinate handoffs. Sequence zones so upstream conveyors slow down if product backs up, preventing pileups and belt strain.
The payoff: quieter operation, lower energy bills, and conveyors that keep pace without the constant lurch of hard starts and stops.
Closing Thoughts
Motion control isn’t just about reaching the next position; it’s about how you get there. Small changes in profiles, sequencing, and logic can turn a system that feels rough and wasteful into one that runs smoothly and reliably. The best part is that these aren’t major rebuilds; they’re simple adjustments you can make directly in Beckhoff’s TwinCAT software. For engineers, that means quick wins. For plants, it means equipment that lasts longer and provides more value shift after shift.
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