Industrial production processes have undergone a series of transformative shifts. From steam-powered machines to intelligent robotics, each industrial revolution has reshaped manufacturing. Today, power semiconductors are at the heart of the factory automation transformation, enabling precise motor drives, energy efficiency and real-time decision-making in smart factories and cyber-physical systems.
At the core of modern industrial transformation, factory automation stands as the backbone of Industry 4.0. It encompasses a wide range of technologies designed to minimize human interaction in industrial processes. From collaborative robots (cobots) and automated guided vehicles (AGVs) to intelligent conveyor systems and precision-controlled pumps, automation is reshaping how factories operate. These solutions not only increase throughput, improve quality and reduce operational costs but also drive higher efficiency and lower power consumption.
Motors – the driving force of automation
Electric motors are quite literally the driving force of industrial automation, playing a fundamental role across nearly all industrial applications. With essentially four different motor types used depending on the application. However, the true intelligence and adaptability comes from the advanced electronic systems that precisely and efficiency control motor behavior. Motor drives act as the interface between digital control systems and physical motion, translating high-level commands into precise mechanical action. Delivering optimized speed, torque, direction and responsiveness.
Different motor types demand tailored control schemes and topology variations, and each drive systems must be carefully designed to match the electrical and mechanical characteristics of the motor, and to meet the performance requirements of the application.
- AC induction motors – widely used for their robustness and cost-effectiveness, particularly in fans, pumps, and conveyors. Typically use variable-frequency drives (VFDs) that regulate motor speed by adjusting supply voltage and frequency.
- Brushless DC (BLDC) motors – offer high efficiency and precise control, making them ideal for robotics and battery-powered systems. Rely on inverter-based drives with pulse-width modulation (PWM) for precise torque and speed control.
- Permanent magnet synchronous motors (PMSM) – deliver high power density and accuracy, often used in high-performance automation equipment. As with BLDC motors use PWM inverters.
- Stepper and servo motors – preferred in applications requiring fine positioning and repeatability, such as CNC machines and pick-and-place systems. Operate either via stepper controllers that send discrete pulses for controlled movement or servo drives with feedback loops to deliver high-precision positioning.
As automation systems become more intelligent and interconnected, motor drives are evolving in parallel. They are no longer limited to basic motion control, they now support real-time monitoring, predictive maintenance, and energy optimization. These advanced capabilities are made possible by the integration of sophisticated semiconductor technologies.
The intelligence behind motion control
As motor drives become more advanced, the role of semiconductors becomes increasingly central. They are the critical enablers of precision, efficiency and intelligence in modern motor control systems. At the heart of every motor dirve is a carefully composed suite of power and signal semiconductors, including:
- Wide-bandgap devices such as SiC diodes, SiC MOSFETs and GaN FETs, which switch electrical energy with high speed and minimal loss
- Silicon transistors like MOSFETs (including ASFETs for Motor Control) and IGBTs (Insulated Gate Bipolar Transistors) for efficient energy conversion
- Gate drivers to control the timing and behavior of power transistors and ensure safe and efficient operation
- Rectifiers and diodes for current management and protection
- Signal processing components such as Logic ICs, comparators and digital isolators, which enable communication between the motor drive and the broader control system
The demands on motor drives are also increasing. Higher efficiency, smaller form factors and greater functional integration are becoming standard expectations. Semiconductor innovation, particularly in wide-bandgap technologies, is playing a pivotal role in meeting these requirements. Devices based on silicon carbide (SiC) and gallium nitride (GaN) offer superior performance in terms of switching speed, thermal management and power density, making them ideal for next-generation motor drive applications.
Powering the future of automation
With factories becomming smarter, more connected environments, automation systems are expected to do more than ever before. Precision, efficiency and adaptability are no longer optional. They are essential. At the heart of every motor drive is a set of semiconductors, enabling everything from real-time control and energy optimization to supporting predictive maintenance and compact system design.
At Nexperia, we are proud to contribute to this evolution. With a broad and growing portfolio of power and signal semiconductor solutions, we support the development of efficient, reliable and scalable motor drive systems across a wide range of applications. As the industry continues to advance, we are committed to delivering the technologies that help our customers shape the factories of tomorrow.
