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Building a Custom Automation Machine
OEM & Machine Builders · Machine Build Basics
Building a Custom Automation Machine:
Core Control Components
Every custom machine — whether it's a single-station cell or a multi-axis production platform — needs the same core control architecture underneath it. Here's what goes into a set of OEM machine controls, how the pieces relate, and what to check when you're specifying each one.
01 / Overview Why Start With Controls
The control system decides what the rest of the build can do
When an OEM starts speccing a new custom machine, it's tempting to think about mechanical design first and controls second. In practice, the control architecture — how many axes need coordinated motion, how much I/O the machine needs, what safety category the application demands — shapes decisions about the mechanical build just as much as the reverse. Getting the automation build components right early avoids expensive rework later.
This is a walkthrough of the core OEM machine controls that show up in almost every custom automation build, what each one is responsible for, and where to start when specifying them for a new machine.
02 / Architecture Core Control Components
The building blocks of a custom machine's control system
01
Main Drive
Handles the machine's primary process motor — a main conveyor, spindle, or bulk material handling motor that doesn't need tight positioning.
02
Axis Drives
Servo drives controlling individual motion axes with closed-loop position feedback, coordinated together for multi-axis moves.
03
PLC
The central controller coordinating every axis, I/O point, and safety function — the logic that turns a mechanical design into a working sequence.
04
HMI
The operator's interface for setup, recipe selection, changeover, and diagnostics — critical for a machine that will run multiple product variants.
05
Encoders
Feedback devices mounted on each axis, reporting position and velocity back to the drive so motion stays accurate under load.
06
Safety
E-stops, safety relays or safety PLCs, and guarding interlocks — sized to the risk assessment and safety category the application requires.
07
I/O
Local or remote I/O blocks wiring field sensors, actuators, and pushbuttons back to the PLC — the machine's connection to the physical world.
03 / Concept Main Drive vs. Axis Drives
Not every motor on the machine needs the same kind of drive
One of the first architectural decisions on a new build is separating what needs simple speed control from what needs coordinated motion. A main drive — typically a VFD — runs a motor at a commanded speed with no positioning requirement: a bulk conveyor, an agitator, a fan. It's simpler to spec and tune, and doesn't need feedback beyond basic speed monitoring.
Axis drives are a different category. Each one is a servo drive paired with an encoder-equipped servo motor, running in a closed loop so the PLC's motion controller can command precise position, velocity, and acceleration — and coordinate several axes together for something like a pick-and-place or a synchronized multi-axis transfer. Getting this split right up front — deciding which motors are "main" and which are "axis" — determines the rest of the drive and encoder spec.
04 / Selection Specifying Each Component
What to check before you commit to a part number
| Component | What to Check | Common Brands |
|---|---|---|
| PLC | I/O count, program complexity, motion control needs, and the communication protocol the rest of the plant standardizes on | Siemens |
| Main & axis drives | Motor horsepower, number of coordinated axes, feedback type required, and whether the application needs servo-level accuracy | Yaskawa, ABB |
| HMI | Screen size for the operator's task, protocol compatibility with the PLC, and recipe/data-logging requirements | Maple Systems, Red Lion |
| Encoders | Resolution, incremental vs. absolute output, and mounting/shaft configuration matched to the motor | Fagor, EPC |
| Safety | Required performance level or safety category from the machine's risk assessment | Pilz |
OEM build checklist — questions to answer before speccing controls
- How many axes need coordinated motion vs. simple on/off or speed control?
- What communication protocol does the end customer's plant already standardize on?
- What safety category does the risk assessment call for on this machine?
- Will the machine need to run multiple product recipes, and does the HMI need to store them?
- Is there a preferred or required brand standard from the end customer, or is the OEM free to choose?
05 / Sourcing Getting a New Build Sourced Fast
IAC stocks the full OEM control stack
IAC carries the components that make up a custom machine's control system — Siemens PLCs, Yaskawa and ABB drives, Maple Systems and Red Lion HMIs, Fagor and EPC encoders, and Pilz safety components — so a new build's parts list doesn't mean chasing a dozen separate vendors on a tight timeline.
Browse PLCs, drives, HMIs, encoders & safety
Shop the CatalogWarranty and verification
Every component IAC ships carries a 2-year in-service warranty — twice the industry standard for refurbished industrial parts. Components are functionally tested before they leave the warehouse, and IAC's engineers can help cross-reference a full bill of materials before you order.
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In-stock parts ordered before 4:00 PM Eastern ship same day. For urgent needs, call (877) 727-8757 during business hours — quote turnaround is typically under five minutes. You can also submit a part number via the quote form ↗ or email sales@iac.us.com.
Spec the build. Source it in one call.
PLCs, drives, HMIs, encoders, and safety components — in stock and cross-referenced by IAC's engineers. Quotes in 5 minutes during business hours. Same-day shipping on in-stock units.