Applied Motion Systems Application Story

In high-performance manufacturing environments, motion systems need to deliver speed and precision without compromising reliability. Applied Motion Systems (AMS), a system integrator and machine builder specializing in motion control and automation solutions, works closely with manufacturers to retrofit and optimize production lines burdened with inefficiencies and downtime. 

The Challenge: Pneumatic Cylinders Driving $50,000/Hour Downtime in LVL Production

In LVL production, veneer handling is a high-speed, high-stakes process where repeatability directly impacts downstream quality and uptime. At AMS’s customer’s facility, pneumatic air cylinders were originally used to place the veneer sheets onto a moving belt for downstream lamination, but achieving consistent performance became increasingly unreliable in a hot, dirty production environment.

Pneumatic cylinders operate with various components; in addition to the actuator there are compressors, coolers, separators, receivers, air treatment systems, control valves, flow controls, shaft seals, and more. Due to the compressible nature of air, even minor fluctuations in pressure, flow rate, or ambient temperature can result in inconsistency in stroke lengths, velocity, and force output. Due to unreliable force outputs, further inconsistencies exist in achieving coordinated motion of multiple cylinders. Finally, due to the multiple components required to operate pneumatic air cylinders, there are many points of failure. They are prone to degradation, and the downtime on AMS’s customer’s line costs up to $50,000 an hour. The operating environment on the end customer's line is hot and dirty. Over time, the pneumatic cylinders became inconsistent and uncontrollable, simply slamming to an end stop with no profiling ability.  

ORCA Series Smart Linear Electric Motors as an Ideal Fit for High-Speed Veneer Handling

The Feeder Knockdown retrofit used four ORCA-6-48V motors with extended shafts for higher force capability. The Dryer Stacker Knockdown application used four ORCA-3-36V motors with extended shafts, controlled via ORCA-EIP (EtherNet/IP) to enable synchronized, high-speed motion directly from a Rockwell PLC. 

Integrated System Architecture Reduces Maintenance and Downtime

Pneumatic systems rely on a network of supporting components; compressors, valves, air treatment/filtering systems, and much more–all of which introduce mechanical points of failure. A modern electric tubular motor such as the ORCA motor uses an all-in-one architecture, where position and force sensing, communication, and logic is handled on the motor’s PCB. The PCB is fully enclosed in epoxy, making its design durable and rugged, enabling one single moving part: the stainless steel-enclosed steel shaft. One low friction moving part offers significantly less downtime. The serviceable wear component in the ORCA motors is the Igus bushings. In this application, assuming normal operating conditions with a payload of eight lbs split between two ORCA motors, running 10,000 cycles per day, the bushings would require replacement approximately every 540 working days [Igus calculator]. With a single moving part and fully integrated driver, feedback, and control, the ORCA platform reduces mechanical friction, minimizes wear, and extends overall service intervals. 

High Repeatability and Precision Motion Control

Pneumatic systems struggled to deliver consistent motion due to the compressibility of air and sensitivity to pressure and temperature fluctuations. This resulted in variation in stroke, velocity, and force, directly impacting veneer placement and stack quality. Over time, wear and environmental exposure further compounded these issues leading to increasing variability and loss of control. ORCA motors eliminate these inconsistencies through closed-loop control with integrated position sensing and real-time force feedback. This allows the system to execute precise, repeatable motion profiles with consistent force output on every cycle. By maintaining tight control over position and force, AMS was able to achieve uniform veneer placement and significantly improve stack quality, reducing misalignment, overhang, and downstream handling issues. 

Durability in Harsh Industrial Environments

The LVL production environment exposes equipment to high temperatures, airborne debris, and continuous mechanical stress, all of which accelerate wear in traditional pneumatic systems. Components degrade quickly under these conditions, leading to inconsistent performance and increased maintenance, and in this case downtime costs up to $50,000 per hour.

ORCA motors are designed for these environments, featuring an IP68-rated, fully encapsulated design that protects internal components from dust, moisture, and contamination. With one moving part and no external components susceptible to ingress or wear, the system maintains consistent performance over time. This robust design allows the motors to operate reliably in high-temperature, debris-heavy conditions, reducing degradation and ensuring long-term durability on the production line.

Native Control with ORCA-EIP

ORCA-EIP allowed AMS to control four ORCA motors directly from the Rockwell PLC using EtherNet/IP, creating synchronized, profile-driven motion without relying on separate software or intermediary control layers. For the Dryer Stacker Knockdown application, this meant AMS could create motion profiles in the PLC, adjust them on the fly, and coordinate multiple motors within the plant’s existing control environment. 

Technical Specifications

Seamless Integration into PLC-Controlled Motion Systems

AMS approached integration with a focus on minimizing disruption to existing systems, while enabling rapid validation and scalability. Custom mounting brackets, designed and manufactured by AMS, installed ORCA motors directly into the footprint of the original pneumatic cylinders, preserving the existing mechanical layout. The control enclosure was designed and built by AMS and the initial system was installed and commissioned within a single day, enabling immediate evaluation in a live production environment.

Integration progressed in two phases. In the initial phase, AMS used IrisControls and the IO SmartHub to interface with the plant PLC through analog and digital I/O, enabling quick deployment and validation without modifying the existing control architecture.

In the second phase, the system was upgraded to ORCA-EIP, allowing the four motors to be controlled directly from the Rockwell ControlLogix PLC using virtual motion axes. This enabled motion profiles to be generated and streamed from the PLC, eliminating the need for separate control software. The result was seamless integration into the plant’s existing workflow, with control engineers able to program, monitor, and adjust motion using the same tools and interfaces already used in the line, simplifying operation while significantly expanding the system’s flexibility and performance.

About the Partners

Applied Motion Systems (AMS) is a systems integrator and machine builder specializing in custom machine design and motion control integration for complex industrial environments. Iris Dynamics is a trusted OEM manufacturer, developing smart linear motion technology that simplifies motion control through integrated electric actuation.

Together, AMS and Iris Dynamics deliver high-performance, reliable, and precise motion solutions where uptime and control are critical. Iris Dynamics’ smart linear motors reduce system complexity at the component level, while AMS integrates that capability into complete, production-ready systems.

With a shared focus on building intuitive, dependable systems, the result is less time spent on system development and more time focused on innovation. Through close collaboration, particularly on ORCA-EIP integration, this partnership enables streamlined system design, seamless PLC-based control, and reliable, high-performance operation.