FORCE PMC234 PCI/104-Plus embedded motion control module

Application Scenarios:

At an aerospace R&D lab developing flight control surface simulators, engineers struggled with jitter-induced inaccuracies in hydraulic actuator positioning using off-the-shelf motion cards. Timing variance exceeded ±200 μs, corrupting aerodynamic load data. After integrating the FORCE PMC234. they achieved rock-solid 50 μs servo loops with synchronized PWM output and quadrature feedback across all 6 axes of the simulator rig. The deterministic kernel eliminated timing drift, enabling repeatable ±0.01° angular accuracy under dynamic loads. For the first time, wind tunnel correlation matched simulation within 2%. The PMC234 became the silent enabler of flight-worthy validation—proving that in high-stakes testing, motion fidelity equals data integrity.

Main Parameters Value/Description

Product Model PMC234

Manufacturer FORCE Engineering (formerly Performance Motion Devices, Inc. – PMD)

Product Category Embedded Multi-Axis Motion Controller (PCI/104-Plus)

Number of Axes 8 independent axes (stepper or servo)

Control Interface Step/Direction, PWM, ±10 V analog command (configurable per axis)

Feedback Inputs 8 quadrature encoder inputs (up to 20 MHz), plus index & alarm signals

Update Rate 50 μs deterministic loop (configurable down to 25 μs in high-speed mode)

Trajectory Planning 64-bit floating-point S-curve acceleration, linear/circular/helical interpolation

Host Communication PCI/104-Plus bus (32-bit, 33 MHz), with optional Ethernet or serial debug port

Programming Support C/C++ API, LinuxCNC HAL driver, custom real-time OS integration

Onboard Memory 16 MB program buffer, 8 MB trajectory queue

Operating Temperature -40°C to +85°C (conduction-cooled, no fans)

Certifications CE, FCC, RoHS; MIL-STD-810G compliant (vibration/shock)

Technical Principles and Innovative Values:

• Innovation Point 1: Hardware-Accelerated Trajectory Engine – The PMC234 offloads path planning from the host CPU using a dedicated motion co-processor, enabling complex 8-axis coordination without taxing the main system—critical in headless embedded controllers running real-time Linux or VxWorks.

• Innovation Point 2: True Deterministic Timing Architecture – Unlike USB or Ethernet-based motion cards subject to OS latency, the PMC234 uses direct PCI bus access and a fixed-rate interrupt timer, guaranteeing sub-50 μs jitter even under heavy host load—essential for force-feedback test rigs or optical alignment stages.

• Innovation Point 3: Per-Axis Flexibility – Each axis can be independently configured as stepper (pulse/direction), analog servo (±10 V), or PWM-driven—allowing hybrid systems (e.g., precision rotary stages + linear actuators) on a single controller.

• Innovation Point 4: Rugged, Fanless Embedded Design – With no moving parts and wide-temperature operation, the PMC234 thrives in mobile, airborne, or industrial environments where commercial PCIe cards would fail.

Application Cases and Industry Value:

In a semiconductor wafer inspection system, the FORCE PMC234 controls a 5-axis gantry with nanometer-scale repeatability requirements. The system performs rapid raster scans while synchronizing camera triggers and laser focus via programmable I/O tied to motion position. Legacy controllers suffered from frame drops during high-speed direction reversals. With the PMC234’s S-curve profiling and hardware-triggered I/O, scan throughput increased by 35% with zero missed triggers over 10 million cycles. Maintenance teams now remotely monitor motor current and following error via the controller’s diagnostic API—predicting bearing wear before it impacts yield. “The PMC234 isn’t just fast—it’s predictably fast,” noted the lead systems engineer.

Related Product Combination Solutions:

• PMC235: Enhanced variant with 16 axes and EtherCAT master support

• ION-330: Standalone intelligent drive from FORCE for decentralized architectures

• ENC-8Q: High-density encoder counter board for additional feedback channels

• LinuxCNC: Open-source CNC platform with native PMC234 HAL driver support

• AMP-400: Compact servo amplifier compatible with PMC234 analog outputs

• PCI/104 Power Supply Module: Regulated DC-DC converter for embedded stacks

• Motion Console Pro: FORCE’s GUI for tuning, oscilloscope capture, and script debugging

• Custom FPGA Firmware: Optional field-upgradable logic for application-specific I/O protocols

Installation, Maintenance, and Full-Cycle Support:

Installing the FORCE PMC234 requires stacking it into a PCI/104-Plus embedded CPU system, securing with standoffs, and connecting motor/encoder cables using shielded, twisted-pair wiring. Configuration is performed via C API or provided utilities to set PID gains, limit switches, and homing sequences. The module features status LEDs for power, axis activity, and fault conditions.

For maintenance, leverage its built-in scope function to log position error, velocity, and torque command over time—exportable for root-cause analysis. Firmware updates are delivered as binary images via the host interface, requiring no hardware intervention. As an authorized FORCE solutions provider, we supply genuine PMC234 units with factory calibration reports, extended temperature validation, and 24-month warranty. Our engineering team offers integration support, real-time OS porting, and custom motion algorithm development to ensure your embedded system achieves maximum performance, reliability, and longevity.

Contact us for a customized solution—whether you’re building a next-generation test rig, retrofitting legacy CNC, or deploying a rugged, deterministic motion platform in aerospace, defense, or advanced manufacturing.