I think it is really application oriented question, such as what kind of level of real-time and sychronzation you are looking for, or pre-defined indutry-oriented feature, programming enviroment and languages preferred. You can then run simulations and watch your system move, tune it, and analyze the results. NI also offers the ability to import models of your motion system from Solidworks and and incorporate them seamlessly into your project using NI SoftMotion. But, the flexibility, wide hardware selection, and ease of use usually outweigh the cost. It's more expensive than a PLC-based system, that's for sure. These days all I use is National Instruments cRIO (with or without FPGA) systems and NI's LabVIEW Real-Time Module. I've used Parker controllers in the past and also controlled Kinetix drives directly from either Siemens or AB PLCs. "Need to update your mission-critical PID loop? Sorry, I need to poll the print spooler, your request will processed in the order it was received." There's too much happening that's non-deterministic, Windows doesn't care about what priority you feel your motion control task has. You're 100% correct, direct Windows-based control is absolutely not real-time control.
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