30 n MACHINE BUILDING October 2026 www.drivesncontrols.com Centralised intelligence and the rise of the lean drive In recent years, many automation players have been promoting the advantages of decentralised control to machine-builders. This approach means using “intelligent” drives, tasked with controlling the motor, as well as managing I/O and elements of machine logic. Now though, the demand of more sophisticated machines, combined with advances in computational power and real-time connectivity, is changing machine architectures. Instead of using multiple intelligent drives, machine-builders are transferring intelligence to the latest generation of capable motion controllers, combined with “lean” high-performance drives with reduced logic capabilities but enhanced control of servomotors. For machine-builders, this means machines that are easier to use and less expensive to develop, as well as offering enhanced performance. The CPUs used in the previous generation of automation technology had much less processing power than today. These CPU limitations in PLCs forced distributed control architectures, including the adoption of multiple controllers and programmable devices to create complete machines. What’s more, fieldbus networks were less capable of transmitting data with the speed and determinism required for motion control applications. While machine controllers were focussed on managing sequential machine logic, the computationally intensive role of controlling servo axes was handled by drives. Equipped with dedicated processors to manage current, velocity and position loops, these drives were located close to the motor to reduce lags in communication. The proliferation of fieldbuses also required drives to integrate option cards or communications stacks. As a result, drives became more flexible to accommodate varying machine architectures, machine I/O, programmability, and advanced peripheral devices. However, this extra flexibility added cost and complexity to every axis. Today, end-users demand more advanced machines and production lines across all verticals served by discrete automation. Consider packaging, for example: end-users want fast format changes to adapt existing lines rapidly to new products, as well as full food traceability to safeguard consumers, and safer machines to improve operator working conditions and satisfy regulations. While decentralised controls using intelligent drives have been popular with machinebuilders, higher demands on machine complexity, combined with advances in controller processing power and communications, is making centralised architectures more attractive. Dario Dallefrate, director of strategic marketing at Trio Motion Technology, argues they allow faster machine development, especially when motion control is required. Lean, high-performance servodrives can optimise motor control in applications such as labelling Many machine-builders are moving from distributed control architectures with decentralised smart servodrives (top) to centralised motion and logic controls combined with “lean” high-performance servodrives (below)
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