Every OEM wants machinery that runs faster and lasts longer. Achieving that level of performance begins with one core decision: the motor. Servo motor optimization defines how efficiently motion is controlled. It impacts how compact a system can be built and how reliable it will perform within modern motion control systems.
In short, it’s incredibly important.
For most modern motion control systems, permanent magnet synchronous motors (PMSMs) — often referred to as servo motors — have become the preferred foundation. They combine high torque density with dynamic speed response and energy efficiency.
But motor selection is rarely as simple as picking what fits the specs. The real challenge lies in understanding how that motor choice affects every other aspect of the machine in order to have a fully optimized system.
Rethinking Motor Selection at the Design Stage
In the rush to meet timelines, engineers often rely on catalog selections that meet only basic servo motor technical specifications. This approach can limit what a machine can achieve. Servo motor optimization requires looking at the broader system and how the motor interacts with other components.
The questions mechanical engineers and machine designers should ask early in the process are the same ones outlined in TruTech’s Optimizing Servo Motors for Increased Machine Performance guide:
- Could choosing the first motor that fits limit your opportunities for better overall performance?
- How does implementation of the motor affect the entire system or process?
- Does my motor choice eliminate possible machine size reduction or performance gains from an alternative configuration?
Asking these questions ensures that every design decision contributes to better system-level outcomes instead of only meeting minimum specifications.
Why PMSM Servo Motors Excel in Modern Applications
Permanent magnet synchronous motors are known for their balance of precision, efficiency and reliability. With rotary PMSM design optimization, they can be configured for nearly any motion control task whether it’s robotics, assembly automation, medical devices, underwater operation or something else entirely.
These servo motors are available in power ranges from a few watts up to 30 kW, and their versatility extends far beyond the factory floor. Variants like the IP67 servo motor and IP68 servo motor operate dependably in harsh environments. PMSM servo motors also continue to replace pneumatic and hydraulic systems, reducing energy consumption and extending the lifespans of equipment they power.
Key advantages of PMSM motors include:
- High torque output with excellent acceleration and deceleration characteristics
- Compact and customizable form factors for space-limited systems
- Compatibility with sealed and high-ingress protection designs
- Long-term durability and consistent performance under load
- Efficient operation across a wide speed and torque range
Servo Motor Design Considerations for Better System Integration
Every servo motor system integration should start by examining how different motion control variables interact. TruTech’s approach focuses on tailoring PMSM design considerations to match each machine’s functional goals.
Core servo motor design considerations include:
- Torque-speed optimization: Adjusting winding configurations to balance current and torque output for the application.
- Voltage alignment: Designing windings to perform optimally across available supply voltages, whether DC or AC.
- Rotor inertia: Matching the PMSM rotor design to the load for smoother acceleration and precise control.
- Frame size and housing: Selecting standard or frameless designs for greater mechanical integration flexibility.
- Ingress protection (IP): Defining sealing requirements for clean room, food-grade or submersible use.
- Mounting and shaft configuration: Customizing interfaces to simplify installation and improve alignment.
- Housing material: Choosing aluminum, stainless steel or coated alternatives for durability and environmental compatibility.
By customizing these elements, OEMs can achieve true servo motor optimization to deliver motion solutions that consistently outperform off-the-shelf systems.
Considering Performance and Efficiency
When evaluating performance, many engineers ask: what is the true efficiency of a PMSM motor? PMSM designs are among the most efficient in modern motion control, offering high power density and minimal energy loss across the speed-torque curve.
Another common question: what’s the lifespan of a PMSM motor? While actual lifespan depends on application and environmental factors, the inherent design of PMSM motors — with fewer wear components than brushed or induction systems — enables more predictable, reliable longevity.
Together, these traits make PMSMs the foundation of sustainable, high-efficiency equipment design.
Custom Engineering for Competitive Advantage
Innovation doesn’t come from standard selections. By moving beyond catalog options, OEMs can achieve smaller, more capable machines. TruTech engineers collaborate directly with machine designers to develop integrated assemblies that meet exact motion and environmental needs.
This approach supports:
- Faster prototyping and validation cycles
- Reduced overall system complexity
- Improved torque-speed balance and control accuracy
- Seamless integration with intelligent drives and networks
Our experience in servo motor system integration and PMSM rotor design ensures each solution reaches its full potential.
The Bottom Line
A motor isn’t just a component; it’s the core of machine performance. Optimized PMSM servo motors allow OEMs to push performance boundaries while reducing total system size and cost.
Download TruTech’s white paper, Optimizing Servo Motors for Increased Machine Performance, to learn more about elevating motion control to the next level.