Flying Operations

Flying Operation

Motion controllers are used in on-the-fly processing, such as cutting steel tubes, profiles or aluminum plates. The saw blade moves synchronously with the material to be cut. The movement depends on the feeder roller or a measuring wheel, from which the motion profile is transmitted to the controller via a sensor. So a high-precision cut can be guaranteed, even with high dynamics.

Application examples/movies:

Where Are On the Fly Machining Motion Controllers Used?

On-the-fly machining motion controllers are used wherever cutting, punching, or machining must be performed without stopping material flow.

• Flying saws and shears – Controllers like the FS340 manage saw blades and shears that cut material continuously, keeping the tool synchronised with the product speed.
• High-speed machining – Systems such as the FS641 are designed for precise on-the-fly cutting, drilling, or machining in production environments where downtime must be minimised.
• Packaging and converting – Synchronising cutting and sealing tools with continuous web feeds to ensure accurate packaging and reduced material waste.
• Printing and labelling – Supporting rotary punching and trimming, where tools must stay aligned with printed marks or labels on moving material.
• Extrusion and profile cutting – Used to cut profiles or extruded products to length while maintaining continuous flow through the line.
• Intermittent operations – Controllers like the MC700 are ideal for intermittent printing and punching where flexibility and precision are required.

For advice on the right solution for you, contact us, and our team will recommend the most suitable on-the-fly machining motion controller for your application.

Benefits of On-the-Fly Machining Motion Controllers

On-the-fly machining motion controllers allow manufacturers to achieve precise, continuous operations without needing to decrease line speed or machining accuracy.

• Uninterrupted production – Controllers synchronise tools with moving material, eliminating the need to stop and start lines, which reduces cycle times and increases throughput.
• High-precision cutting and machining – Designed to maintain perfect alignment between tools and product flow, these systems ensure consistent, accurate cuts or machining even at high line speeds.
• Versatility across applications – From flying saws to packaging and extrusion lines, controllers can be configured for a wide variety of processes, making them suitable for both continuous and intermittent operations.
• Reduced waste – By keeping tools precisely aligned with material flow, errors such as misaligned cuts or defective packaging are minimised.
• Fast system integration – Motrona controllers connect easily with PLCs, encoders, and sensors, simplifying integration into new or existing automation setups.
• Built for demanding environments – Robust industrial design ensures reliable long-term operation, with resistance to vibration, electrical interference, and temperature fluctuations.

Why Choose Encoder Technology for On-the-Fly Machining Motion Controllers?

At Encoder Technology, we make it straightforward to source reliable on-the-fly machining motion controllers for high-speed industrial processes. With decades of experience and global supply capability, we provide solutions trusted by manufacturers worldwide.

• Fast worldwide delivery – Same-day UK dispatch with next-day shipping to Europe and the USA.
• Over 50 years of expertise – Our extensive knowledge of motion control applications allows us to recommend the right controller for tasks such as flying saws, extrusion, and packaging.
• Comprehensive product range – From the FS340 for saws and shears to the FS641 for high-speed machining, we offer solutions for a wide variety of operations.
• Minimal lead times – With stock available and efficient supply chains, we help reduce downtime and keep production running.
• Trusted manufacturer – All of our controllers are supplied by Motrona, a recognised leader in motion control technology known for precision and durability.

Get Your On-the-Fly Machining Motion Controller Today

Increase efficiency and accuracy with a Motrona on-the-fly machining motion controller from Encoder Technology. With fast worldwide delivery, over 50 years of expertise, and minimal lead times, we make it easy to source the right controller for your production line.

Contact us today to make an enquiry or speak with a specialist, or browse our full motion controllers collection. You can also view related categories, including our firmware motion controllers, synchronization controllers, and eccentric shear controllers for additional solutions.

Frequently Asked Questions

What is an on the fly machining motion controller?
It’s a controller that synchronises cutting, punching, or machining tools with moving material, allowing operations to be completed without stopping the production line.

What is the difference between on the fly machining and standard motion control?
Standard motion controllers may require line stoppages for cutting or punching, while on-the-fly processing motion controllers keep tools aligned with material flow continuously.

Which industries use on the fly machining motion controllers?
They are widely used in packaging, extrusion, printing, labelling, and converting, where continuous cutting or machining improves throughput and reduces waste.

Do Motrona controllers support both continuous and intermittent operations?
Yes. Motrona offers controllers such as the FS641 for continuous machining and the MC700 for intermittent punching and printing tasks.

Can these controllers be integrated with PLC systems?
Yes. On-the-fly machining motion controllers are designed for seamless integration with PLCs, encoders, and industrial sensors, simplifying installation.

Are they suitable for high-speed production lines?
Yes. These controllers are built to maintain accuracy and synchronisation at high line speeds, making them ideal for demanding industrial environments.