Multiple servo drive axes

Synchronization of multiple axes is one of the key challenges of modern industrial automation. Growing demands for productivity, precision and flexibility of production lines are driving machine manufacturers to increasingly rely on advanced drive systems and PLC controllers with motion control functionality. Siemens, as a provider of a complete ecosystem — from PLC controllers and servo drives to the TIA Portal engineering environment — delivers comprehensive tools that enable the design of both simple and highly complex multi‑axis systems.

Modern industrial machines, particularly in sectors such as packaging, assembly, material processing and logistics, require perfectly synchronized motion of multiple axes. Achieving a high level of precision demands the use of advanced motion algorithms, high‑speed communication between the controller and the drives, and carefully selected hardware capable of delivering these functions.

1. SINAMICS servo drives

Foundation of axis synchronization

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A cost‑effective drive for single‑ and multi‑axis applications

SINAMICS S200 is a servo drive designed for typical assembly, packaging, pick‑and‑place applications and simple production machines. It supports position, speed and torque control modes, works with absolute encoders, integrates with the PROFINET IRT network, and is fully compatible with S7‑1200 G2 and S7‑1500 controllers, including technology versions. In multi‑axis systems, it performs particularly well as a slave axis.

2. Controllers

Meeting axis synchronization requirements

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A cost‑effective control platform with motion control functionality

Second‑generation SIMATIC S7‑1200 controllers offer significantly increased computing power, support for axis synchronization, electronic camming and positioning. They integrate natively with SINAMICS S200 and S210 drives, enabling the implementation of basic multi‑axis systems while maintaining high precision.

3. Key aspects

Axis synchronization

Electronic synchronization – Electronic Gearing

Synchronization enables the replication of a mechanical connection between two shafts. The slave axis follows the master axis with a defined gear ratio. This functionality is essential in printing, packaging and conveying machines.

Electronic cams – Electronic Cam

Electronic cams define the relationship between axis movements in a non‑linear manner. They enable precise control of cutting knives, wrapping modules and forming stations. TIA Portal provides a graphical environment for creating and configuring electronic cam profiles.

Multi‑axis interpolation

Interpolation is essential in CNC applications, laser cutting, industrial printing and advanced pick‑and‑place manipulators. SIMATIC S7‑1500T controllers enable linear, circular and multi‑axis interpolation.

Robotic kinematics

T‑CPU controllers enable the configuration of Cartesian, SCARA, delta and custom robots by defining the kinematic structure. Inverse kinematics calculations are performed automatically by the controller.

4. Integration TIA Portal

Advantage of a single ecosystem

The Siemens TIA Portal ecosystem

Within a single project, PLCs, HMIs, drives and networks can be engineered and managed together. All components share unified diagnostics, a common data model and full mutual compatibility.

Reduced commissioning time

Automatic wizards for axes, cams and kinematics, along with ready‑to‑use motion blocks, significantly reduce machine commissioning time.

Lower cost of ownership

A single engineering environment, one supplier and unified documentation significantly simplify servicing, modernization and technical support.

Cybersecurity

Both TIA Portal and S7 controllers, as well as the latest drive systems, offer advanced protection mechanisms such as secure communication, user roles, encryption and certificates — everything required to meet the requirements of the NIS2 Directive.

Example applications of synchronization

Packaging system with high-performance flow and fold wrapping machines for chocolate bars.

Packaging machines

synchronization of film, cutting and forming modules

Pick-and-place

dynamic motion synchronization, multi‑axis interpolation and delta kinematics

Customer reference MAKA - MAKA PM 270 CNC machining center in an industrial facility, shown with control panel and precision worktable for automated material processing.

Material processing

real‑time control of multiple motion axes

A multi-spindle gantry machine at NWI Aerostructures.

Cartesian gantry robots

Cartesian kinematics and multi‑dimensional interpolation

Summary

Synchronization of multiple drive axes is a key element of modern automation systems. By delivering a complete ecosystem — PLC controllers, SINAMICS drives, SIMOTICS motors and the TIA Portal engineering environment — Siemens enables the design of systems offering the highest levels of precision, flexibility and performance. A unified platform simplifies integration, shortens commissioning time, ensures system stability and reduces operating costs. As a result, engineers can develop machines that meet the most demanding industrial standards.

Bartosz Toczko
Siemens Sp. z o.o.
Kwiecień 2026