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Motion Controllers

Motion Controllers from FAULHABER: precise positioning

The motion controllers from FAULHABER ensure precise positioning when using our DC-motors, BLDC-motors and linear motors. Apart from their high quality and compact design, they are also characterized by their extremely easy operation and a large number of different operating modes. They enable precise and efficient control of the motor movement (motion control), which is matched perfectly to the respective application.

Selection of FAULHABER Motion Controller portfolio
Key Features
Supply voltage:
6 ... 50 V DC
Max. continuous output current:
10 A
  • RS232 / CANopen
  • EtherCAT
  • RS232
  • CANopen
Compact design
Controlled via RS232, EtherCAT or CAN interface
Minimal wiring requirements
Parametrization with “FAULHABER Motion Manager“ software and USB interface
Wide range of accessories
Simple start-up

What is a motion controller?

A motion controller is a control unit that implements 4-quadrant regulation. Using motion control, predefined positions can be approached selectively and dynamically in the application.

How are FAULHABER motion controllers designed?

The three most important components of a motion controller are the processor, the control electronics and the output stage. From the predefined parameters and the feedback data from the drive, the microprocessor calculates the dynamic control variable used to control the movement of the motor. The control electronics process the relevant signals; the output stage is responsible for supplying power to the motor.

Motion controllers require feedback containing information about the movement of the motor. Depending on the device version and the motor connected, this information can come from different sources: analog value, Hall sensor signal or encoder signal.

The motion controllers are available with or without housing. Devices with housing are connected using screw terminals; without housing, they are plugged directly into a master board. In order to network motion control, either RS232, CANopen and EtherCAT interfaces are available.

How does motion control work?

Motion controllers from FAULHABER are highly dynamic positioning systems for actuating different drive combinations comprising motor and sensor system. They define the required speed for the motor by adjusting the power supply voltage (analog value) or by means of pulse width modulation (PWM). From the feedback, the motion controller calculates the extent of the performed movement and adapts control to the specifications.

The direction of rotation is changed via a separate switching input; the speed signal is transmitted via the frequency output. The preinstalled firmware allows the execution of complex sequence programs for motion control as well as fully automatic operation of the connected motor. The available operating modes include:

  • Positioning mode to move to predefined target positions
  • Movement profiles with predefined acceleration and brake ramps as well as maximum speed
  • Autonomous mode with freely programmable sequences (RS version)
  • Speed control of the predefined target speed by means of PI speed controller
  • Current control as a protective function with integrated thermal models

Protective function

The integrated current control limits the torque and protects the electronics as well as the motor against overloading. The protective function also includes protection against electromagnetic discharge (ESD), self-protection against overheating as well as overvoltage protection in generator mode.

Motion Controllers from FAULHABER

Motion Control – Generation V3.0

The motion controllers of generation V3.0 are characterized by their higher performance, faster control and additional operating modes. They enable optimum solutions for applications with particularly high dynamics. Controllers of this type can control all motor types with all sensor systems. They allow the flexible use of the I/Os for set-points and actual values. Furthermore, apart from the RS232 or CAN interfaces there are additional I/Os as well as an EtherCAT interface. Up to eight sequence programs programmed in BASIC can be saved in the device. They also offer expanded diagnostic functions and simple commissioning using the FAULHABER Motion Manager. The electronics and motor are always supplied with power from separate power supply units.

Criteria for the selection of motion controllers

The performance data of the motion controller (voltage and current) must match the connected motor. Further criteria are size, compatibility with the ambient conditions as well as the available EMC filters to ensure electromagnetic compatibility within the application. In the wide range of motion controllers and accessories, users of FAULHABER motors will almost always find the right device.

Motion controllers from FAULHABER can be used to actuate DC-motors, brushless DC-motors as well as linear motors. Depending on the version, different combinations with incremental and absolute encoders as well as with analog Hall sensors are possible. Various sizes and flexible connection options open up many potential uses for most applications that are driven by FAULHABER motors.

Webinar SIMULINK programming library – Slider
Brushless DC-Motors
Drive Electronics
Motion Controller
Testing drive systems virtually

How will the drive actually behave in the real-life application? For brushless DC-motors from FAULHABER, this question can be answered without any hardware whatsoever. They were recently added as virtual modules to a library and can be integrated into modeled applications using the simulation…

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