Motor Control

Remote Industrial IoT Motor Control

Motor control is a simple but core foundation for many industrial applications. From automated gates to hydraulic pumps, motors perform functions that are necessary to the full system.

The core of motor control is 1) on/off and 2) variable power control. On/off control is the simplest form of motor control, where the motor is either fully powered (on) or not powered at all (off). It’s often used in applications where precise speed or position control is not necessary. ControlByWeb® controllers can perform dry contact monitoring to provide logic based on the contact state (on/off). Variable power control involves adjusting the power supplied to a motor to control its speed or torque. This can be achieved through variable frequency drives (VFD), resistors, and other analog methods.

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Motors can be enhanced by ControlByWeb® IoT relays, which provide real-time monitoring, control, and automation at the edge. Our controllers are equipped with versatile input/output (I/O) options to interface with various sensors and actuators. Here are several advantages that make them ideal for motor control applications:

• Easy to use: ControlByWeb modules feature a user-friendly, browser-based interface that simplifies setup and management. The no-code logic builder allows users to create automated tasks without programming knowledge.
• Reliable: Designed for industrial environments, these controllers are robust and can operate independently of central systems, reducing downtime and diversifying process control.
• Scalable: ControlByWeb’s peer-to-peer communication allows for the expansion of control systems by linking multiple modules. This scalability is essential for large-scale industrial applications.
• Real-time data: The ability to monitor motor performance in real-time and receive instant alerts for any abnormalities helps in proactive maintenance and reduces downtime.
• Automation: Automated control algorithms can adjust motor operation based on predefined conditions or sensor input.
• Integration-capable: With built-in REST API and support for various communication protocols, these controllers can easily integrate with large SCADA systems and HMIs.

Variable Control: VFD, PWM, & Analog

As explained above, industrial processes involving motors aren’t always simply on/off. Variable power control can achieved through variable frequency drives (VFD), a component that changes the frequency of the power supply to control the speed of AC motors. An AC motor connected to a VFD designed to run at 60 Hz will run at half speed if the frequency is reduced to 30 Hz. An IoT controller communicate with a VFD through an analog signal to change the frequency based on user input or sensor data, allowing precise speed control.

Variable resistors and other analog methods can be used to adjust the voltage or current supplied to a motor. For example, consider a potentiometer connected to a DC motor. By turning the knob on the potentiometer, the resistance changes, which in turn adjusts the voltage supplied to the motor. Lower resistance increases the voltage and speeds up the motor, and vice-versa. An analog IoT controller, such as the X-417, can simulate this by varying output voltage.

Variable Voltage with the ControlByWeb X-417

The X-417 has 1–5 individually configurable analog outputs that can be set to various voltage ranges (±5VDC, ±10VDC) or current ranges (4-20mA). Each output channel is equipped with a precision 16-bit DAC, allowing for fine control over the output signal. This precision is necessary for applications requiring accurate adjustments in voltage or current.

Using the web interface, you can configure the desired output voltage or current supplied to the VFD, effectively controlling the motor speed or torque. Control logic created through the Task Builder allows for dynamic adjustments based on feedback from the motor or other sensors.

A common use-case is duplication of an analog signal over a network. For example, the X-417 can be programmed to “duplicate” the reading from a 0-5VDC sensor in one area, outputting to a 0-5VDC in another area to a specific piece of equipment.

Another method of representing a signal to control average power or amplitude is pulse width modulation (PWM). Note that ControlByWeb devices do not support PWM—but our sales engineers can work with you to find the best motor control solution.