When servo motors meet modern software architecture: A conversation about reliability

Imagine this scenario: You have designed an automated production line, and each link relies on the coordinated work of precision servo motors and steering gears. Suddenly the response of a critical link is delayed by a few milliseconds - the entire line may have to be paused. Many people must have encountered this annoying moment.

The traditional centralized control approach is a bit like putting all your eggs in one basket. A problem with one module affects the entire system. In the software world, a similar situation has long given rise to the evolution from "large and comprehensive" web services to "small and specialized" microservices. Interestingly, this idea also inspires the design of hardware and mechanical systems.

What exactly affects system reliability?

Someone may ask: My device configuration is already very high, why do I still experience unpredictable jitter or delay? In fact, many times, the problem is not the hardware itself, but the way information and instructions flow.

In traditional architecture, all functions are often squeezed into the same "brain" for processing. This brain must simultaneously receive sensor data, calculate motion trajectories, drive motors, and handle human-computer interaction... With too many tasks, it is inevitable to focus on one and miss the other. Just like asking one person to do five or six delicate tasks at the same time, the efficiency may decrease.

The decentralized idea is to assign different tasks to different "cerebellums". Each cerebellum focuses on one thing: one is responsible for position feedback, one is responsible for torque control, and the other is responsible for communication interaction. They talk to each other through clear interfaces and work independently of each other. Even if one of them needs to be restarted or updated, the others continue to function as usual. Is this idea similar to the design philosophy of microservices?

From software to hardware: cross-border enlightenment of reliability

existkpowerIn our R&D discussions, we often talk about a point: a good electromechanical system should also have the characteristics of "loose coupling" and "high cohesion".

Loose coupling means minimizing direct dependence between motor drive, control logic, and communication modules. Changes in one part should not always affect other parts. High cohesion allows each unit to maximize its core functions - such as optimizing the response speed of the positioning module and maximizing the energy efficiency of the drive module.

The benefits of doing so are real. For example, if a certain function needs to be upgraded, you only need to replace the corresponding module without re-verifying the entire system. Or, when a certain communication link is temporarily busy, the motion control unit can still maintain stable operation based on local policies - the robot arm will not be "dazemed" because of a slight fluctuation in the network.

This architecture also has a less obvious, but important, advantage: it makes problems easier to locate. When the system behaves abnormally, you can often narrow down the scope faster and know which "cerebellum" is causing the emotion, instead of facing a whole complex black box with no way to start.

How to implement this idea specifically?

There is no need to overthrow all existing designs at once. Many times, you can try to start locally.

For example, in a line usingkpowerIn the robotic arm of the servo system, we can first separate the two tasks of "path planning" and "real-time tracking". Let one processor concentrate on calculating the optimal path, and the other is only responsible for calibrating the actual position and the target position every millisecond. Information is exchanged between the two through defined data formats. In this way, even if the plan is performing complex iterative calculations, real-time tracking can still maintain a fixed refresh rate without lagging.

Another common scenario is the separation of status monitoring from the main control loop. Traditionally, system health checks (such as temperature, vibration, current) are often intertwined with motion control code. But in fact, the health check can be independent as a resident service, quietly collecting data in the background, and only sending notifications to the main controller when the threshold is triggered. The main loop becomes cleaner and more responsive.

These sound like software engineering concepts, but in the world of electromechanical integration, they are embodied in actual module division, communication protocol design, and processor task allocation. The core idea is the same: to improve the maintainability and robustness of the overall system through clarifying the structure and responsibilities.

Sometimes, changing the perspective is more effective than changing the hardware

In the pursuit of higher performance and reliability, it is easy for us to think of using faster chips, more precise encoders, and more expensive motors. Of course these are important, but system architecture can often bring about lower costs and more significant improvements.

This is like organizing a team: instead of blindly asking everyone to work overtime, it is better to clarify the division of labor first, let everyone focus on what they are best at, and establish efficient communication rules. The output of the entire team will be more stable and of higher quality.

kpowerIn servo and machinery, it is this kind of thinking of "soft and hard combination" that is continuously explored. Rather than simply stacking up hardware, we think about how to coordinate information flow, control flow and mechanical action more elegantly. With every iteration, you’re trying to make the system a little smarter—not more complex, but clearer and tougher.

After all, the best technologies are often the ones that don’t feel like they exist. It runs quietly in the background, does its job reliably, and you almost forget it's there. This may be the common, small pursuit behind all projects.

Established in 2005, Kpower has been dedicated to a professional compact motion unit manufacturer, headquartered in Dongguan, Guangdong Province, China. Leveraging innovations in modular drive technology, Kpower integrates high-performance motors, precision reducers, and multi-protocol control systems to provide efficient and customized smart drive system solutions. Kpower has delivered professional drive system solutions to over 500 enterprise clients globally with products covering various fields such as Smart Home Systems, Automatic Electronics, Robotics, Precision Agriculture, Drones, and Industrial Automation.