The development of modern dosing units is a good example of the importance of software for electric motors. While the hardware engineers are grappling with the question of whether it is better to use standard electronics or a customised solution, the software department is already busy generating code for the electric motors. And a lot of this code is needed, as modern systems need to integrate all common interface standards.
The growing importance of software for electric motors
Software is becoming increasingly important for electric motors, as modern drive systems need to be able to do much more than just rotate. Intelligent electric motors should be able to be integrated into networks, provide diagnostic data, configure themselves and communicate with other system components. These functions require extensive software development.
The integration of electric motors in Industry 4.0 environments requires standardised communication protocols. Ethernet-based protocols such as EtherCAT, PROFINET or Ethernet/IP are becoming increasingly important for networking electric motors. At the same time, classic fieldbuses such as CAN, PROFIBUS or Modbus must continue to be supported.
The software complexity of electric motors increases exponentially with the number of supported protocols and functions. A modern drive system may well contain 100,000 lines of code or more. This complexity requires professional software development processes and tools.
Standard software vs. in-house development for electric motors
The decision between standard software and in-house development for electric motors depends on various factors. Standard software offers the advantage of immediate availability and proven functionality. Many manufacturers of electric motors offer extensive software libraries and development tools.
In-house development, on the other hand, enables precise customisation to the application requirements of electric motors. Special functions, optimised performance or proprietary protocols can only be implemented through in-house development. However, this also significantly increases development time and risk.
A mixed strategy is often optimal: standard components for proven functions combined with in-house developments for special requirements for electric motors. This reduces development time and risk, while still allowing for differentiation.
Bus systems for electric motors: Overview and selection
Selecting the right bus system for electric motors is crucial for successful integration into higher-level systems. Various bus systems have become established for different areas of application for electric motors.
CAN bus is widely used for electric motors in the automotive industry and in mobile applications. Its robustness and real-time capability make CAN a proven choice for electric motors in harsh environments. However, the data rate is limited, which can be problematic in complex applications.
Ethernet-based protocols are becoming increasingly important for electric motors. EtherCAT offers deterministic communication with high data rates and is particularly suitable for precise motion control in electric motors. PROFINET is widely used in German industry and offers good integration in Siemens environments.
Development tools for electric motor software
Modern development tools make software development for electric motors much easier. Graphical programming environments such as MATLAB/Simulink enable the model-based development of control algorithms for electric motors. The generated code can be executed directly on microcontrollers.
Code generators for bus systems automate the implementation of communication protocols for electric motors. Instead of manually programming protocol stacks, developers can choose from ready-made modules and configure them.
Debugging tools for electric motor software must consider both software and hardware aspects. Oscilloscopes with protocol decoders enable bus communication to be analysed. In-circuit debuggers allow software execution to be tracked in real time.
Security and reliability in electric motor software
Security is becoming increasingly important in electric motor software, as networked systems open up new attack vectors. Cybersecurity aspects must be incorporated into the software architecture for electric motors from the outset. Encryption, authentication and secure boot processes are essential.
Functional safety in accordance with IEC 61508 or ISO 26262 places special demands on software development for electric motors. Safety-critical functions must be designed redundantly and tested extensively. Formal verification methods can help to prove the correctness of the software.
The reliability of electric motor software depends heavily on the quality of the development process. Systematic tests, code reviews and continuous integration are essential for robust electric motor software.
Future trends in electric motor software
Artificial intelligence is finding its way into electric motor software. Machine learning algorithms can optimise the behaviour of electric motors, predict wear or detect anomalies. Edge computing makes it possible to execute these algorithms directly in the electric motors.
Over-the-air updates are also becoming increasingly important for electric motors. The ability to install software updates remotely reduces maintenance costs and enables continuous improvements. However, safety aspects must be carefully considered.
The standardisation of software interfaces for electric motors is progressing. OPC UA is increasingly being established as a universal communication protocol for Industry 4.0 applications. This could significantly simplify the integration of electric motors from different manufacturers.
Development partners for electric motor software
The complexity of modern electric motor software often exceeds the capacities of individual companies. Specialised development partners can provide valuable support, from the conception to the implementation of electric motor software.
Choosing the right partner for electric motor software is critical. The partner should have both software expertise and a deep understanding of drive technology. References in similar applications are an important indicator of suitability.
Agile development methods have also proven their worth for electric motor software. Short iteration cycles and close collaboration between client and development partner lead to better results than traditional waterfall models.
Costs and ROI of electric motor software
The costs of software development for electric motors are often underestimated. Software can account for 50% or more of total development costs. A realistic cost estimate must take into account all phases from conception to maintenance.
The ROI of software investments in electric motors is often difficult to quantify. Improved efficiency, reduced maintenance costs or new business models can create considerable value. These indirect benefits must be included in the profitability calculation.
The total cost of ownership (TCO) of electric motor software includes not only the development costs, but also maintenance, updates and support over the entire product life cycle. A long-term view is essential for well-founded decisions.
Conclusion: Software as a success factor for electric motors
Software is becoming a decisive differentiating factor for electric motors. Companies that invest in software expertise at an early stage create sustainable competitive advantages. The decision between standard software and in-house development must be carefully weighed up.
The networking of electric motors via bus systems opens up new opportunities for increasing efficiency and innovative business models. At the same time, the requirements for software safety and reliability are increasing.
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