Sports cars are fun to drive, but that extra performance is probably unnecessary if the main job is the school run. Machine builders face a similar challenge when specifying automation. While some applications demand advanced motion control and high-performance hardware, many do not. Karl Walker, business development manager at Beckhoff Automation UK, explains why right-sizing automation can reduce costs while providing a foundation for future growth.
With nearly half of manufacturers ranking process automation among their top investment priorities over the next two years, according to Deloitte’s 2025 Smart Manufacturing Survey, machine builders must balance performance, flexibility and cost. The challenge is increasingly less about maximising performance and more about choosing automation that keeps machines simple today while remaining adaptable tomorrow.
Over-specifying a machine can increase upfront costs, commissioning times, engineering effort, cabinet space, spare parts inventories and maintenance demands. However, selecting a basic control platform can create problems as requirements evolve, potentially forcing hardware replacement, software migration or control system redesign.
A scalable architecture addresses both challenges. Machine builders can start with a compact controller for straightforward positioning and move to a high-performance industrial PC for advanced motion control without changing the underlying software or communications architecture.
Beckhoff extends this approach to motion hardware with products including the AX1000 economy servo drive, AF1000 variable frequency drive and ASI/AMI integrated stepper and servo drive. These solutions provide optimised performance for applications that do not require the highest levels of precision control, while offering flexible mounting and architecture options. EtherCAT connectivity also helps simplify cabinet design and reduce component count.
By maintaining a consistent engineering environment through TwinCAT, EtherCAT and PC-based control, machine builders can add coordinated motion, enhanced safety or greater data connectivity as requirements develop.
More information
More information www.beckhoff.com/en-gb
