Tag: technical setup video

Stepper motor step loss is a common problem in motion control systems, especially in CNC machines, robotics, and automation equipment. Lost steps can cause positioning errors, vibration, reduced accuracy, and unexpected production failures.  To solve stepper motor losing steps, it is necessary to optimize the entire drive system. This article explains the most effective methods to reduce or eliminate step loss and improve stepper motor reliability.

In PLC servo control systems, the Servo ON signal (S-ON) determines whether the servo drive is enabled and ready for motion control. Traditional systems usually turn S-ON on and off through external commands, but some applications require the servo drive to remain enabled continuously. This article explains how to configure a PLC servo position control system with the S-ON signal always ON.

Inductive and capacitive proximity sensors are two widely used non-contact detection devices in industrial automation systems. Although they look similar, they work based on completely different sensing principles and are designed for different detection requirements. Understanding the differences between these two proximity sensors helps you select the right sensor for specific industrial applications. If you’ve ever found yourself wondering which one to choose for your application, this article will clear up the confusion.

Dual emergency stop is one of the important safety functions of servo motion control systems. It provides an extra protection layer for PLC-based servo motion systems, enabling emergency shutdown from two independent positions. Integrating hardware and PLC software emergency stop circuits to build two independent cut-off paths is a reliable solution. This article explains the full implementation workflow to improve machine safety and minimize equipment downtime.

Industrial communication protocols are the foundation of every modern automation system. PLCs rarely operate alone—they continuously communicate with HMIs, sensors, servo drives, robots, industrial PCs, and other field devices. Communication protocols define how these devices exchange data accurately, efficiently, and reliably.

In a servo positioning system, reliable motion control requires more than simply driving a motor. The system must also be able to detect over-travel conditions, stop motion before mechanical damage occurs, and provide a safe method for clearing alarms after faults are resolved.

This guide demonstrates how to upgrade a PLC pulse-controlled servo system by adding overtravel protection and alarm reset functionality using three interposing relays. The result is a safer and more robust servo position control system suitable for industrial applications.

If you're installing an gas detector controller, this guide explains how to complete both the 3-wire 4-20mA analog output wiring and the 4-wire RS485 communication wiring. Whether you're connecting a single gas detector or integrating multiple detectors into a monitoring system, following the correct wiring procedure is essential for reliable operation and accurate gas monitoring.

A gas detector controller serves as the central management unit of a fixed gas detection system, allowing users to configure connected gas detectors, manage alarms, record historical data, and monitor gas concentrations in real time. This guide introduces the basic operation of the ATO gas detector controller, including menu navigation, 4-20mA output configuration, and historical data export. By following these procedures, users can quickly configure the controller, ensure reliable gas monitoring, and simplify routine maintenance.

Reliable gas detection is essential when working in environments where hazardous gases may be present. The ATO 4-in-1 multi-gas detector is designed to simultaneously monitor carbon monoxide (CO), oxygen (O₂), hydrogen sulfide (H₂S), and combustible gases (%LEL), helping users quickly identify dangerous atmospheric conditions and improve workplace safety.

This guide explains how to operate the gas detector, including powering on, accessing the menu, performing calibration, configuring alarm settings, managing data logging, exporting recorded data, switching measurement units, restoring factory settings, and viewing system information.

A current transformer (CT) is a fundamental device used in power systems and industrial automation for measurement, protection, and control. Current transformer polarity defines the directional relationship between the primary and secondary currents. If the polarity is incorrect, it can lead to reversed measurements, inaccurate fault current calculations, and even malfunction of protection systems such as relay misoperation or failure to trip. Because of this, verifying current transformer polarity is a critical step during installation and commissioning. In the following sections, we will introduce two reliable methods to test current transformer polarity: a simple DC method for quick field verification and a professional tester approach for more accurate and efficient testing.

Have you ever wondered if a motor could generate electricity instead of consuming it? In this tutorial, we’ll show you how to convert a Brushless DC (BLDC) motor into a DIY generator, perfect for renewable energy experiments, small-scale energy recovery, and off-grid projects.

Positioning control technology is an indispensable tool in the development of high-tech products. As a vital part of modern technology, it drives advancements in fields such as automated manufacturing, computing, and materials processing. This article will show you how to use a PLC and a servo drive to build a complete pulse-based servo motor position control system in position control mode, a classic industrial solution widely used in both professional automation and high-precision DIY & home automation projects.

Accurate measurement of liquid and bulk material levels is essential across a wide range of industries, including chemical processing, wastewater treatment, food production, oil and gas, and power generation. Maintaining proper level control helps prevent overflow, dry running, material waste, and potential safety hazards. It also plays a key role in ensuring product quality, optimizing resource usage, and maintaining stable, continuous operation within industrial systems.

Level sensors play a critical role in modern automation systems. Whether in water treatment plants, chemical facilities, food processing lines, or residential water, accurate level measurement ensures safe operation and stable process control. This article will introduce the basic knowledge of level sensors.

Electric motors are the driving force behind modern industry and everyday technology, converting electrical energy into mechanical motion. From household appliances to large-scale industrial machinery, motors play a vital role in countless applications.

A constant-pressure water supply system is essential for applications where stable water pressure directly affects performance and reliability. In traditional pump systems, fixed-speed motors or manual valve adjustments often lead to pressure fluctuations, higher energy consumption, and increased mechanical wear. By using the GK3000 upgraded Variable Frequency Drive with built-in PID control, a fully automated pump control solution can be implemented. Combined with a pressure sensor, the system automatically regulates pump speed to maintain stable water pressure under varying load conditions. This article provides a complete guide to the system architecture, wiring method, parameter configuration, and commissioning process for a GK3000-based constant-pressure water supply system.

Accurate and stable temperature control is essential in industrial heating systems, laboratory equipment, and automation applications. PID temperature controllers are widely used due to their precision, reliability, and ability to maintain stable temperatures automatically. In this article, we demonstrate how to build an automatic heating control system using a PID temperature controller, focusing on wiring logic, terminal functions, and system operation. The example shown is a three-phase heating control circuit with built-in safety and alarm functions.

In industrial automation applications, pick-and-place is one of the most common and fundamental motion control scenarios. Many users perceive robotic arm systems as complex and high-cost, but in reality, a structured, logically complete 2-axis robotic arm control system can be quickly built using PLCs, HMIs, and stepper motors. Taking a simulated 2-axis robotic arm project controlled by a PLC + HMI with dual stepper motors as an example, this article will detail the system architecture, wiring methods, driver configurations, PLC & HMI programming concepts, as well as the full operation and emergency stop logic. It aims to help you quickly understand and get started with similar applications.

This guide explains how to build a constant-pressure pumping system using the upgraded GK3000 Variable Frequency Drive (VFD) from ATO. The system adjusts pump motor speed based on real-time pressure feedback to maintain stable output pressure while improving energy efficiency and reducing mechanical wear.