TRIO
MOTION-PLC
INDUSTRIAL DESIGN . MECHANICAL ENGINEERING . PROTOTYPING . DESIGN FOR MANUFACTURE
A PARADIGM SHIFT IN THE WORLD OF MOTION AND FACTORY AUTOMATION
Trio Motion Technology commissioned Smallfry to design and engineer their latest, landmark product, the Motion-PLC. Packed full of new features and technology, the new product range delivers Trio’s advanced motion control performance with the functionality and simplicity of a PLC.
From industrial design to mechanical engineering, Smallfry worked closely with Trio to ensure the product excelled in performance, aesthetics, usability, and manufacturability while navigating a busy IP landscape and conforming to tight dimensional constraints.
A modular front-loading slice expansion system enables engineers to easily swap out and expand modules as needed. To achieve this, we developed a new BUS electrical connector, integrated into the Trio red striped side panel, that provides a repeating colour accent visible across the front when installed together, guided by the tightly controlled sliding rails.
These efforts resulted in a compact product range with a distinctive Visual Brand Language that maximises on convenience and performance whilst minimising production costs.
DISTINCT VISUAL BRAND LANGUAGE
A key technical challenge of the project was fitting so many features into a compact package while developing a distinct, cohesive, and flexible visual brand language for Trio’s products.
The enclosure uses simple monolithic form with rounded corners, calculated dot-pattern venting, and timeless texture detailing to give a precise yet robust feel. The design capitalises on Trio’s red to accentuate the side panel, the product’s unique standout feature, which when mounted in series, creates an eye-catching repeated colour accent from the front.
These elements make up the visual brand language of the new range – ultimately resulting in an ecosystem of products that is distinctly Trio.
COMPACT AND POWERFUL
Trio’s next generation of precision motion controller offers greater performance whilst achieving a 60% reduction in size in comparison to other products, solidifying its competitive presence in the market.
To achieve such a compact yet powerful package, we worked closely with Trio’s electronics team whilst engineering the casing in order to maximise PCB footprint without compromising its structural integrity, appearance, and product features.
A MODULAR AND ADAPTABLE SYSTEM
A defining feature of the product range is the incorporation of a modular front-loading slice expansion system. This enables users to tailor system configurations to their needs whilst also providing the flexibility to expand and service modules up to 16 I/Os.
Achieving this required a total rethink of the entire approach. We developed a new BUS electrical connector, integrated into the striped side panel, that enables modules to instantly connect when installed together guided by the tightly controlled sliding rails. The last piece in the puzzle was to develop a custom DIN rail latch that would reliably lock and unlock products in place.
MECHANICAL ENGINEERING TO CREATE NEW IP
In order to create a modular front-loading slice expansion system, Smallfry engineered a new locking latch mechanism, actuated by a single motion that would work in conjunction with the sliding rail system to provide a strong lock to the DIN rail. The challenge was in delivering a robust solution that would operate under tight dimensional constraints, with a minimal part count across the entire range of products, all whilst navigating a busy IP landscape.
To achieve this, the latch was engineered with a compliant mechanism that enables it to actuate on both sides of the DIN rail, translating upward motion into downward. Using 3D CAD and in-house rapid prototyping, our team produced parts that simulated injection moulded components without the need for upfront tooling investment. This enabled us to explore, evaluate, and refine a range of ideas quickly to hone in on the final solution, ready for tooling release.
REDUCING ENVIRONMENTAL IMPACT AND COST
A strategic approach was critical to simplify product construction without compromising performance or usability. Our design and engineering teams reduced the number of parts and made use of shared tooling and components where possible. This ultimately enabled Trio to:
· Reduce environmental impact
· Save on tooling and reduce overall production costs
· Take advantage of economies of scale
· Increase production quality and consistency
DESIGN THROUGH TO MASS PRODUCTION
Smallfry worked with Trio to design and engineer the product from concept though to production. Our hands-on approach, utilising our in-house prototyping capability, ensured that every detail was captured and tested along the way.
Moving into production, Smallfry created a complete 3D and 2D data pack ready for injection moulding. Once parts had been tooled, our engineers worked alongside the manufactures to review off-tool samples, identify issues as they arose, and ensure that any tooling adjustments targeted the root cause of issues.
Taking this pro-active approach has ensured that Trio maintain control of their production.
VISUALISATION TO DELIVER IMPACT AT LAUNCH
Smallfry were the obvious choice to create CGI marketing visuals and media to support Trio’s product launch and effectively communicate the new range.
In order to do this, we created a digital replica of the product range. This enables us to quickly and easily create new high quality marketing content as needed and on demand.
Other benefits include:
· Fast turn around
· Scalable images across different platforms
· Animation
· Consistent visual aesthetic over time
· Create impossible shots
· Varied lighting scenarios
· No reshoots
See below some of our success stories within the industrial sector.
