The estimated market value of electronics manufacturing is 580 billion USD, reaching app. 773 billion USD in 2029.² The smart factory, also known as industry 4.0, is leading to a huge increase in efficiency and productivity of electronics manufacturing. In addition, advances in the field of industrial IoT and artificial intelligence (AI) continue to drive market growth thanks to efficiency-boosting monitoring and predictive maintenance capabilities. Even if the electronics manufacturing industry has not yet reached the desired degree of intelligence and automation, the continuous industry 4.0 developments pave the way for those visions, as shown by latest trends at the electronics manufacturing market.³

» The production of printed circuit boards consists of many individual production steps, all of which must be carried out with the utmost precision. Electric motor technology is used throughout the entire value chain - from semiconductor production to electronics production and logistics management.

Thanks to an increased level of automation in both the individual production steps and the handling steps in between, it is possible to realize a highly efficient and reproducible manufacturing process. This is required especially when looking at the continuous shortage of skilled labor and increased labor costs in Germany and can be achieved by using electric motor technology.

Energy costs have also increased over the recent years, which makes it crucial to not only achieve a high level of automation, but also a certain level of connectivity and utilization of energy-efficient components.

Stepper motor: These motors achieve precise, controlled movements by rotating their internal electromagnets in exact, predefined steps. Each electrical pulse a stepper motor receives corresponds to a specific, fixed rotation angle, typically 1.8 degrees. This characteristic makes them a cost-saving solution for applications demanding precise position control. Since each step is distinct and controllable, stepper motors don‘t require complex feedback mechanisms, simplifying their design.

Brushed motor: This technology combines simple and efficient design while offering good speed control. Electricity flows through brushes that physically contact a segmented commutator on the rotor and generates a Graphic: Schematic process - Production of assembled printed circuit boards Motor Technology Solutions for Smart Electronics Manufacturing 05 magnetic field. This interacts with the stator in the outer housing, making the motor turn. By switching the current direction, the motor direction and speed are controlled. Their simplicity makes brushed motors a reliable partner with good speed control on the one hand. But the characteristics must be gauged with the friction between brushes and the commutator on the other hand, which can limit the motors lifespan.

Brushless motor: Similar to brushed motors, brushless motors use electromagnets to rotate a permanent magnet rotor. However, instead of brushes, they rely on electronic controllers to create a rotating magnetic field. This eliminates friction and wear, increasing their lifespan and efficiency. Thus, brushless motors are often used in applications with high cycle times or those requiring high speeds and extended operation.

Asynchronous motor: In contrast to stepper, brushed, and brushless motors using DC technology, this motor type is an AC motor, utilizing alternating current to create a rotating magnetic field within the stator. This rotating field „induces“ current in the conductive bars or windings of the rotor, causing it to rotate in the same direction as the stator field. As it moves at a slightly slower speed than the stator field, it is called asynchronous motor. AC motors are known for their simplicity, robustness, and ability to handle high power loads.

Each motor technology, from stepper motors to brushed or brushless DC motors to asynchronous motors, has an individual set of characteristics which are beneficial for a specific application. It is often a question of the manufacturer’s or end users’ philosophy, which features are considered most important. If efficiency is the most important decision factor, a brushless motor might be the best choice. If acquisition costs are of highest importance, the machine builder could also use a stepper motor, if this meets all necessary technical requirements. The following table shows a simplified comparison of the different motor technologies´ product characteristics. Before making a decision for a specific project, it is important to understand their advantages and disadvantages based on individual requirements.


The electronics manufacturing industry faces ever-growing demands for dynamic performance, energy efficiency, and longer equipment lifespans. This has led many customers to choose brushless DC motors. While brushless motors may have a higher initial cost, they offer significant benefits that justify the investment. These benefits include a remarkably long service life, virtually eliminating the need for maintenance, and the exciting possibility of integrating digital services for even great control and optimization.

Predictive maintenance enables users to optimize their maintenance processes. The following chapter provides a detailed explanation of how this concept works in practice

4.2.1. How it works

At its core, predictive maintenance is about making the motor and its operation data available beyond just the controls system, and to use the motor as a sensor to monitor the condition of the entire gearmotor. This is based on the principles of physics: wear or defects generally cause more friction or other changes within the gearmotor, which lead to a change in the applied torque, and thus to a changed torque-generating current. As most motors are also equipped with temperature sensors and encoders, these parameters can be used to generate a very precise picture of the wear condition of the gearmotor without the need for additional sensors, such as an acceleration sensor.

4.2.2. Digital service vs. control system

The control system (PLC) generally takes a snapshot of the available sensor technology, derives actions from this data, sets the outputs, and then forgets this snapshot before moving on to the next one. The focus here is set on control and regulation functions.
For features such as long-term measurement or AI analysis of data, which are necessary for predictive maintenance, a different approach is required. This is where EDGE gateways usually come into play, which fulfil these tasks in parallel with the control system. It is not recommended or target-oriented to use a separate gateway for each component within a system. Docker containers unlock a powerful approach for integrating your gearmotor seamlessly into your machine´s IIoT system. Think of them as pre-packaged software units containing everything needed to run a specific application. This simplifies integration by allowing you to directly incorporate the gearmotor’s software modules into your machine’s IIoT solution. Docker containers enable you to monitor your gearmotor’s health directly “on the edge” (the device itself) using interfaces like MQTT or OPC UA. This grants you the ability to detect potential wear issues before they cause downtime, allowing for predictive maintenance strategies.

4.2.3. Further digital services

Energy monitoring: this service allows the monitoring of the motor´s current energy consumption for evaluating product specific CO2 footprints or optimizing the applications overall energy efficiency.

Digital Twin: the digital twin based on the asset administration shell enables users to share data with the manufacturer directly via Cloud services to get even more detailed insights regarding the operation and current state of the gearmotor. Sharing informatoin such as handover documents and specifications is already commonplace. At the same time, initiatives like Catena-X and Manufacturing-X are pushing current boundaries by actively developing concepts and architectures that will unlock a future of seamless data exchange between companies, revolutionizing the industrial data economy.

Motor as a service: New business models such as “motor as a service” no longer simply sell the motor hardware, but instead offer a guaranteed availability, which is charged as a service fee. Those models are getting increasingly common and are already possible with the current state of technology.

4.3. Safe Torque Off (STO)

The Safe Torque Off (STO) function is a critical safety feature for motors, ensuring they don’t generate torque during emergencies. This prevents machines from unexpected movements or operation that could endanger users or other people. STO is particularly valuable in safety-focused applications like industrial machinery, conveyor belts, and robotic systems. By guaranteeing no torque generation even when powered, the function significantly reduces the risk of accidents and injuries. The independent certification of the STO function further ensures compliance with safety regulations.

Benefits of STO in the electronics manufacturing:

Safety:
STO reduces risk of accidents and and increases the safety of employees by making sure that the motors, which are driving the machine, no longer generate any torque incertain circumstances.

Easy Implementation:
STO can be used to improve safety functions in existing systems without making any additional hardware changes.

Cost efficiency:
As the safety function is directly integrated into the motor, separate expensive safety components are no longer necessary.

Ease of maintenance:
By making sure that the installed motors do not generate any torque, machines can be maintained without additional safety measures.

»Which motor to use?

Power requirement: What power is required to move the module/conveyor belt/axis? Vertical or horizontal movement, torque, acceleration, and speed are typical characteristics that should be known.

Precise positioning: What are the requirements for positioning accuracy? Possible tasks could be e. g. placing loads in a specific location or performing complex movements.

Reliability and service life: The smooth operation of all components within a manufacturing system is crucial for their functionality. The failure of a gearmotor, for example, can stop the entire production process. The reliability of a motor therefore plays an important role in keeping a production machine running.

Efficiency: Efficient motors can reduce operating costs. This is particularly important in applications with continuous movements and high cycle rates.

Controllability: What does the task look like? Is it only necessary to easily transport something from A to B? Is speed control required? Are there complex motion profiles? Will the motor be used in short-time or continuous operation? These questions should be answered when designing the gearmotor solution.

Working conditions: The motor must be able to withstand the individual environmental conditions over its entire service life. Considerations about special protection or sealing against dust or splash water or ambient temperature might be necessary.

Costs: Costs play an important role in making a purchasing decision. Transportation modules are particularly affected by increasing competition from Asia. The available budget is, therefore, a decisive factor for the design. The total system costs should be considered (motor, gearbox, motor feedback, control electronics, cabling, assembly costs, etc.).

In electronics manufacturing, an increasing degree of automation is crucial for higher efficiency and, thus, improved competitiveness. In this transformation, electric gearmotor solutions are key components of each automated machine. To make a solid decision regarding suitable motor technology and dimensioning, various considerations are necessary, based on the project’s individual requirements. A thoughtless decision could lead to improper drive dimensioning, which results in a motor

that might not fulfil its task with the required speed or efficiency. Low quality motors, which do not work reliably, in turn lead to additional costs and an increased need for resources. Both can be avoided with a suitable motor solution. To ensure costeffective decision making, a clear distinction should be made upfront between mandatory technical features and those that are simply desirable.