In integrated drive solutions with electric motors, there is no single correct approach. What is the perfect solution for one application may be the worst possible choice for another. However, there are clear criteria that can support the decision-making process and enable a sound evaluation.
Standard Electronics for Electric Motors: Fast and Proven
When time is of the essence, standard electronics for electric motors are often the right choice. They integrate a variety of interfaces, making them easy to incorporate into motor designs. Their use is also recommended for small volumes, as the effort for a custom development only pays off from a certain quantity onwards.
Standard encoders for electric motors offer the advantage of immediate availability. Specifications are known, reliability is proven, and integration into existing systems is typically straightforward. For prototyping and small series production, standard solutions are often the most economical option.
Another advantage of standard electronics lies in the reduced development time. While custom solutions require weeks or even months of development, standard components can be used immediately. This is particularly valuable when tight schedules must be met.
Custom Solutions: Optimised for the Application
Custom electronics for electric motors, on the other hand, allow for a solution tailored precisely to the application’s requirements. This can lead to significant benefits in size, weight, power consumption and cost. Especially for larger production volumes, the development effort quickly pays off.
A practical example is a dosing unit for infusion pumps. The new pump needed to be around 15% lighter than its predecessor, weighing no more than 1.4 kilograms. The design was focused only on what was absolutely necessary – everything else was eliminated, saving gram after gram.
Decision Criteria for Motor Electronics
The choice between standard and custom electronics should be based on several factors. Time constraints argue for standard solutions, whereas specific demands regarding size, weight or energy efficiency point towards customised developments.
Production volume is a critical factor. A rule of thumb: for fewer than 1,000 units per year, standard solutions are typically more economical. Above 5,000 units annually, custom development often pays off. In the range between these figures, a detailed cost-benefit analysis is essential.
The technical requirements also play a key role. If standard components meet all needs, there is no reason for a new development. But if special features, harsh environments or extreme miniaturisation are needed, custom solutions are often the only viable path.
Cost Analysis for Motor Electronics
Cost evaluation must consider the entire product lifecycle. Standard components involve low development costs but may have higher unit prices. Custom solutions require significant upfront investment but can become significantly more cost-effective at higher volumes.
Indirect factors must also be considered. A more compact custom solution may reduce costs for housing, cooling or assembly. These secondary effects can greatly impact overall costs.
Minimising Development Risks
Both standard and custom solutions come with specific risks. Standard components may be discontinued or unsuitable for certain applications. Custom developments can be delayed, go over budget, or face technical challenges.
Early-stage prototyping helps minimise risks. With custom electronics, key functions should be validated early. For standard components, the manufacturer’s long-term availability and product roadmap must be assessed.
Hybrid Approaches for electric Motors
Often, a hybrid solution combining standard and custom elements is optimal. For example, standard microcontrollers may be combined with custom power electronics – or standard power stages used with application-specific control logic.
Modular approaches make it possible to use proven standard components and customise only the critical elements. This reduces development time and risk while still enabling an optimised solution.
Future Trends in Motor Electronics
The line between standard and custom solutions is becoming increasingly blurred. Configurable standard components meet a wide range of application requirements without the need for a new design. At the same time, modern development tools make custom solutions faster and more cost-efficient.
System-on-Chip (SoC) designs integrate more and more functions into a single component, reducing the number of parts required and making custom solutions more attractive. Meanwhile, new standard platforms are emerging to serve a broader range of applications.
Conclusion: Making the Right Choice for Motor Electronics
Choosing between standard and custom electronics for electric motors requires a careful evaluation of all relevant factors. There is no universal solution – only the best option for the specific application. A systematic assessment of requirements, quantities and costs leads to the right decision.
It’s crucial to make this decision early in the development process – not under time pressure. A well-founded analysis saves time and cost down the line and results in a better product.
Are you deciding between standard and custom electronics for your electric motors?
The experts at Antrimon will support you with a systematic evaluation and help you find the optimal solution for your application. You can find out more here:
