How to prevent the motion controller from crashing due to MC voltage drop?

To prevent the motion controller (MC) from crashing during voltage drops or short-term interruptions, design considerations are needed from both the power supply hardware and software logic perspectives.

On the hardware side, the power module should have a wide input voltage range, and a large-capacity energy storage capacitor should be added to the input. A switching power supply with a holding function should be used, or a supercapacitor/battery backup module should be added. Large local capacitors should be added to the power supply of core chips such as the CPU and FPGA, and their voltage should be monitored, generating an early warning when it falls below a threshold. Digital outputs should be designed to enter a safe state upon power failure.

On the software side, power monitoring and watchdog functions should be implemented. Upon detecting an anomaly, critical data should be quickly saved to non-volatile memory, and the system should enter low-power sleep mode or orderly shutdown.

The communication protocol should have a timeout reconnection mechanism. Testing should be conducted according to IEC 61000-4-11/34 to verify that the module does not crash, lose data, or malfunction during the voltage drop to 0% and recovery process, and can automatically resume operation.