Modern automation systems often require controlled force rather than simply precise positioning. Whether pressing a component into place, tightening a cap, or detecting contact with a part, engineers need a simple and reliable way to control and verify applied force.
The Oriental Motor AlphaStep AZ Series combines closed-loop positioning, battery-less absolute encoder technology, and configurable Push Motion control to provide an easy-to-implement solution for force-limited applications.
In this tutorial, we demonstrate how to configure Push Motion using the AZD-KEP driver, monitor torque in real time, and validate performance using the MEXE02 software platform.
Why Use Push Motion?
Traditional positioning systems stop when they reach a target position. Push Motion allows the motor to continue applying a controlled amount of force after contact is made.
Benefits of Push Motion
- Protects products from excessive force
- Eliminates damage to tooling and fixtures
- Simplifies machine setup
- Reduces the need for external force sensors
- Provides repeatable force application
- Enables real-time process verification
Typical applications include:
- Press-fit assembly
- Connector insertion
- Packaging machinery
- Medical device assembly
- Semiconductor equipment
- Material handling systems
- Cap tightening and sealing
- Product seating operations
Hardware Configuration
The demonstration system consists of:
- Oriental Motor AlphaStep Components
- AZ Series Stepper Motor
- Battery-less Absolute Encoder
- AZD-KEP Driver
- 24 VDC Control Power Supply
- Ethernet/IP Communication Capability
- MEXE02 Configuration Software
The motor and encoder are connected directly to the AZD-KEP driver through a single cable assembly. Control power is supplied through the dedicated 24VDC input connector.
For machine integration, the drive includes:
- Digital Inputs
- Digital Outputs
- Dual RJ45 Ethernet Ports
- Industrial Network Connectivity
Industrial Communication Options
The AlphaStep AZD-KEP drive supports multiple industrial protocols, making integration straightforward regardless of the PLC platform.
Supported networks include:
- Ethernet/IP
- PROFINET
- EtherCAT
- Modbus TCP
- Modbus RTU
This flexibility allows machine builders to standardize on a single motion platform across multiple customer requirements.
Step 1 – Configure Push Motion
Using MEXE02 software, navigate to the Operation Data section.
Select:
- Continuous Operation Push Motion - This operating mode enables the motor to rotate continuously while limiting the maximum torque output according to the configured operating current percentage.
Example Settings
Parameter Value Motion Mode Continuous Operation Push Motion Speed 360°/second Operating Current 20%
The operating current directly influences the available push force.
After entering the parameters:
- Click Data Writing
- Download settings to the drive
- Confirm successful completion
The drive is now ready for force-controlled operation.
Step 2 – Configure the Waveform Monitor
One of the most powerful diagnostic tools within MEXE02 is the Waveform Monitor.
This feature allows engineers to observe and record:
- Position
- Speed
- Current
- Torque
- Input Status
- Output Status
- Additional drive parameters
For this demonstration:
- Channel Setup
Configure:
- Channel 4 = Torque
This channel will display actual torque generated by the motor during Push Motion.
- Trigger Configuration
Use:
- Commanded Speed
as the trigger source so recording automatically begins when motion starts.
Step 3 – Verify Torque Performance
After configuring the waveform monitor:
- Start recording
- Open Teaching Remote Operation
- Start motor operation
- Apply resistance to the motor shaft
- Observe torque response
As load is applied, the motor increases torque until reaching the configured limit. When resistance is removed, torque immediately decreases.
Results at 20% Operating Current
During testing, the waveform monitor showed:
| Condition | Torque Reading |
| No Load | Near 0% |
| Motor Restrained | 18–20% |
| Load Released | Near 0% |
The measured torque closely matched the configured 20% operating current setting. This confirms that Push Motion effectively limits output force while maintaining controlled motion.
Step 4 – Export Data for Process Validation
The Waveform Monitor can export captured data as a CSV file for additional analysis.
- Export Procedure
- Select Save
- Choose CSV Format
- Save to Local Drive
- Open with Microsoft Excel
- Benefits include:
- Process validation
- Quality documentation
- Machine commissioning reports
- Troubleshooting support
- Performance optimization
Engineers can correlate torque data with process results to improve consistency and product quality.
Step 5 – Increase Push Force
To demonstrate adjustable force control, the operating current was increased from: 20% → 50%
After downloading the new settings:
- Restart waveform monitoring
- Run the motor again
- Apply resistance
Immediately, the motor generated significantly higher force before reaching its configured limit.
Results at 50% Operating Current
The waveform monitor recorded:
| Condition | Torque Reading |
| Motor Restrained | 45–48% |
| Load Released | Near 0% |
Again, measured torque closely tracked the programmed operating current. This demonstrates how easily force levels can be adjusted without mechanical modifications or external sensors.
Why Engineers Choose AlphaStep
- Battery-Less Absolute Positioning - No battery maintenance required.
- Closed-Loop Performance - Maintains position accuracy without missed steps.
- Easy Force Control - Push Motion simplifies force-limited applications.
- Built-In Diagnostics - Waveform monitoring provides real-time visibility into system performance.
- Network Ready - Supports major industrial Ethernet protocols.
- Reduced Commissioning Time - Simple setup through the intuitive MEXE02 software platform.
Application Examples
- Electronics Assembly - Controlled insertion of connectors and components.
- Medical Device Manufacturing - Force-limited assembly operations to protect delicate parts.
- Packaging Machinery - Consistent cap tightening and package handling.
- Semiconductor Equipment - Precise force application for wafer and component handling.
- General Industrial Automation - Part seating, product alignment, and contact detection.
Partner with Valin
Valin's motion control specialists help machine builders and end users successfully implement intelligent motion solutions across life sciences, semiconductor, food and beverage, packaging, aerospace, and advanced manufacturing industries.
Our team can assist with:
- Motion system selection
- Network integration
- PLC programming
- EtherNet/IP, EtherCAT, and PROFINET implementation
- Application development
- Machine optimization
- Startup and troubleshooting support
Whether you're building a new machine or improving an existing process, Valin can help you deploy reliable, high-performance motion control solutions using Oriental Motor technology.
Ready to Learn More?
Contact Valin Corporation at (855) 737-4716 or fill out our online form to discuss your application and discover how the Oriental Motor AlphaStep AZ Series can improve performance, reduce complexity, and increase productivity.