In today’s fast-moving world of automation, precision and flexibility are everything. Industry 4.0—often called the fourth industrial revolution—is changing how we build, move, and control machines. At the heart of this shift are industrial servo motors.

Whether it’s a robotic arm, an automated packaging line, or a custom-built manufacturing machine, servo motors are what bring movement to life. And when it comes to compact, powerful, and fully customizable servo motors, HDD Servo leads the way.

What Makes Servo Motors So Important in Industry 4.0?

Servo motors play a critical role in smart, connected machines. They offer:

• Precise control over speed, position, and torque

• Quick response to signals from control systems

• High efficiency in tight, automated processes

• Real-time feedback from encoders or resolvers

Compared to stepper or induction motors, DC servo motors and AC servo motors are more responsive, more energy-efficient, and better suited to the high demands of modern automation systems.

1. Servo Motors in Robotics: Compact Power for Complex Motion

In robotics, size matters—but so does strength. Robots need motors that can fit in tight spaces but still deliver strong, controlled motion.

HDD’s ultra-compact servo motors are ideal for:

• Articulated robotic arms

• Pick-and-place systems

• Autonomous machines

• Medical and lab automation

With high torque-to-size ratios, customised servo motors from HDD can be built with hollow shafts, internal couplings, or open-frame designs to fit directly into robotic joints and arms.

2. Automation in Packaging: Speed and Precision

Packaging lines run fast. They label, fill, seal, and sort thousands of items per hour—and there’s no room for error.

HDD Servo motors help meet these challenges by delivering:

• Smooth, accurate movement

• Compact builds for space-limited machines

• Support for ball-screw servo applications

• Customised feedback and braking options

Thanks to HDD’s modular motor design, every motor can be tailored to your machine’s layout, control system, and operating environment.

3. Machinery Manufacturing: Tailor-Made Motion Solutions

Manufacturing machines come in all shapes and sizes, from CNC mills to automated assembly systems. What they often need is a servo motor that fits a unique mechanical or electrical setup.

HDD specialises in low-volume, high-performance custom motors, offering:

• Custom shaft shapes and lengths

• Special connectors or cable exits

• Cooling options (natural, forced, liquid)

• Multiple feedback choices: encoder, resolver, or sensorless

This means manufacturers can skip the bulky adapters and design more compact, efficient machines.

Why Choose HDD Servo?

HDD Servo (HDD Sweden AB) focuses on industrial servo motors that are:

• Ultra-compact yet powerful

• Fully customizable to your project

• Available in DC and AC configurations

• Designed and built in Sweden

• Supported by fast engineering and short lead times—even for small batches

From prototyping to full production, HDD helps customers in robotics, packaging, and machinery industries solve tough motion challenges.

Ready to Upgrade Your Automation?

Industry 4.0 is all about smarter, faster, more flexible systems—and servo motors are at the core. If you need a motor that fits your design instead of forcing your design to fit a motor, HDD Servo has a solution.

👉 Contact us to discuss your project or learn more about our range of industrial servo motors.

FAQ for Engineers & OEMs

1. What is the difference between a servo motor and a stepper motor for industrial automation?

Answer:
While stepper motors move in fixed steps and operate in open-loop systems, servo motors use closed-loop feedback(like encoders or resolvers) for precise control of position, speed, and torque. This makes servo motors ideal for high-speed, high-accuracy industrial applications where real-time adjustments and smooth motion are critical.

2. How do DC servo motors compare to AC servo motors in performance and application?

Answer:
DC servo motors offer faster response times and simpler control systems, making them well-suited for compact, low-voltage automation systems. AC servo motors handle higher power and are often used in heavier-duty equipment. HDD offers both types, with a focus on ultra-compact, high-torque DC servo solutions for space-constrained industrial environments.

3. What are the key specifications to consider when selecting a servo motor?

Answer:
When choosing a servo motor, consider:

• Torque output vs motor size (torque density)

• Rated and peak speed

• Voltage and current compatibility

• Feedback type (encoder, resolver, sensorless)

• Mounting, shaft configuration, and integration needs
  HDD offers fully customised servo motors to match your exact mechanical and electrical specifications.

4. What are customised servo motors and when should they be used?

Answer:
Customised servo motors are tailored to your specific requirements—mechanically, electrically, and thermally. Use them when off-the-shelf motors don’t fit due to:

• Unique shaft dimensions or hollow shafts

• Non-standard voltage or connectors

• Integration with specific gearboxes or cooling systems
  HDD specialises in low-volume, high-performance customised servo motors for OEMs and machine builders.

5. What are the typical applications of servo motors in industrial environments?

Answer:
Servo motors are widely used in:

• Robotics – for joint control and pick-and-place precision

• Packaging machines – for fast, repeatable movement

• Machinery manufacturing – such as CNC, lab automation, and printing

• Medical and test systems – where accuracy and small size are essential
  HDD motors are ideal for applications requiring compact size and high torque.

6. How do I integrate servo motors into a PLC or motion control system?

Answer:
To integrate a servo motor with a PLC:

• Match the motor’s voltage and feedback to your drive/controller

• Use supported feedback protocols (e.g., encoder resolution, resolver compatibility)

• Ensure proper wiring, grounding, and shielding
  HDD supports integration with standard PLCs and motion controllers from Siemens, Beckhoff, Omron, and others—offering engineering support if needed.

7. What are the most compact high-torque servo motors available for OEM use?

Answer:
HDD specialises in ultra-compact servo motors with torque-to-size ratios significantly higher than typical industry options. These motors come in:

• Solid-shaft and hollow-shaft versions

• Low-voltage and AC variants

• Open-frame and integrated designs
  They’re ideal for space-constrained applications like robotic joints, portable machines, and embedded systems.

Force sensors are devices used to measure the force or load applied to them. They are commonly used in various applications, including industrial, automotive, robotics, and medical fields. Read more about force sensors.

Here are some of the different types of force sensors:

Strain Gauge Load Cells:

Strain gauges are the most commonly used force sensing technology. Load cells based on strain gauges measure the strain experienced by the gauge when a force is applied, which is then converted into an electrical signal proportional to the force. They are available in various configurations, such as beam, shear, and S-type load cells.

Piezoelectric Force Sensors:

These sensors use the piezoelectric effect, where certain materials generate an electrical charge when subjected to mechanical stress. When a force is applied to a piezoelectric sensor, it generates an electrical output proportional to the force magnitude. They are known for their high-frequency response and dynamic range.

Capacitive Force Sensors:

Capacitive force sensors operate based on the change in capacitance between two conductive surfaces when a force is applied. The capacitance varies with the distance between the surfaces, which changes when force is applied. The change in capacitance is then converted into a corresponding electrical signal.

Magnetic Force Sensors:

Magnetic force sensors measure the force between two magnets or a magnet and a ferromagnetic material. When a force is applied, the magnetic field strength changes, which is detected by the sensor. These sensors are often used in non-contact force measurement applications.

Optical Force Sensors:

Optical force sensors utilize optical principles to measure force. They typically involve the use of optical fibers, gratings, or interferometers. When a force is applied, it alters the optical properties, such as the light intensity or phase, which can be measured to determine the force magnitude.

Load Buttons and Compression Cells:

Load buttons and compression cells are compact force sensors designed to measure compression or tension forces. They consist of a load-sensitive element, such as a strain gauge or a piezoelectric material, integrated into a button or a cylindrical shape.

Force Sensing Resistors (FSRs):

FSRs are resistive sensors that change their resistance in response to applied force. They consist of a conductive polymer material with interlocking particles. When a force is applied, the particles compress, causing a change in resistance. The resistance change is then measured and correlated to the applied force.

Force sensors for industrial purposes and in manufacturing are devices specifically designed to measure and monitor forces within industrial processes and manufacturing operations. They are utilized in various applications to ensure safety, improve quality, optimize production, and enhance efficiency. Here are some common applications of force sensors in industrial settings:

1. Quality Control and Testing: Force sensors are employed in quality control processes to verify the strength, integrity, and performance of manufactured products. They can be used to measure the compression or tension forces during material testing, assembly verification, and product validation.

2. Robotics and Automation: Force sensors are integrated into robotic systems and automation equipment to enable force-controlled operations. They provide feedback to robots, allowing them to detect and adjust their forces while interacting with objects or performing tasks like assembly, pick-and-place operations, and surface finishing.

3. Load Monitoring: Force sensors are used in manufacturing equipment, such as cranes, hoists, and conveyors, to monitor the loads being lifted or transported. By measuring the applied forces, they ensure that the equipment operates within safe load limits and prevent overloading or equipment failures.

4. Machining and Cutting Processes: Force sensors are utilized in machining and cutting operations to monitor and control the forces exerted during the process. They help optimize the cutting parameters, such as feed rates and tool pressure, to enhance efficiency, minimize tool wear, and ensure consistent quality.

5. Presses and Stamping: Force sensors are commonly employed in presses and stamping machines to measure the forces exerted during metal forming processes. They provide real-time feedback on the applied forces, enabling precise control and adjustment of the forming process for accurate shaping and improved product quality.

6. Assembly and Joining Operations: Force sensors are used in assembly and joining processes to ensure proper alignment and force application during component assembly. They assist in achieving consistent and accurate joining, whether it involves pressing, riveting, welding, or adhesive bonding.

7. Ergonomics and Workplace Safety: Force sensors play a role in ergonomic assessments and workplace safety by measuring the forces experienced by workers during manual handling tasks. They help identify potential risks and ensure that ergonomic guidelines are followed to prevent injuries and optimize working conditions.

8. Packaging and Bottling: Force sensors are utilized in packaging and bottling equipment to measure and control the sealing and capping forces. They ensure proper sealing integrity and avoid issues like leaks or damage to the packaged products.

These are just a few examples of how force sensors are applied in industrial settings and manufacturing processes. By providing accurate force measurement and feedback, these sensors contribute to improved productivity, quality control, and safety in various industrial applications.

Load Indicator

Aröds industriväg 58, 422 43 Hisings Backa

Contact Load Indicator for enquiries: https://loadindicator.se/kontakt/

More information on force sensors: https://loadindicator.se/kraftgivare/

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Europe witnessed many significant changes which have facilitated some of the most sustainable and competitive economies. In the year 2020, Europe is heading towards digitization with the plan for R and D finding and COP 21 for climate change which is a long term strategy which can be tricky down to the manufacturing sector. There are many technological innovations they are heading towards, which can be the reason for the right innovations which can have a productive outcome.

The factories

With all of the funding R&D development, we see that there is an allocation of approximately $17 billion on their budget. It is taken that manufacturing industry will see a lot of activities and advancement in computer and sensor technologies. The factor of the equation can easily grow information which can help them communicate better. There is also a 5G rollout plan which can help bring truth the vision allowing to connect these enterprises.

Nearshoring in the East

European countries like Poland, the Czech Republic, Hungary, Romania, Turkey, which can become a major hub for many of the manufacturing innovation that is happening. As there is an easy  way to access the money here is a lot of innovation which can grant them cash and also tax incentives. Poland is still the largest and the strongest growing economy which can see advancements in the manufacturing industry.

Energy and Geopolitics

From purely a political standpoint the lifting of Iran Sanctions. The countries of Russia and China are coming together, which can have the right economic climate in both countries. There would be a lot of cheaper dumping goods which can be seen in the steel industry. The country of Iran can also provide a lot of growth opportunities for Russia and China which can have an aviation, automotive and shipping opportunities.

Carbon Neutral Manufacturing

One of the major ways to curb climate changes is going to be the introduction of COP21. This is one way they are trying to make sure that they can optimize the energy consumptions, which is plant and focuses on the electricity which forms a renewable source. The Europen Union is aiming to ensure that it can reduce at least 40% of the carbon emissions and green house effects. The main solution they have come up with is by providing carbon neutral manufacturing. This strategy is to de-carbonize  by using intelligent distribution centres which can enforce sustainable power generation. This will lead to the creation of low power transmission systems which can later be shared by the organizations.

human-centred Manufacturing

With the changes that Europe is undergoing right, they are undergoing a huge structural shift which has seen a spike in the highly skilled workforce. They try to make sure that there is dynamic work which works by the context, skill development which becomes a core part of the operational policy.