Smart processes with integrated security technology

Beckhoff's EP741x MDR controllers set new standards for safety, efficiency, and modularity in automated material flow. The IP54-protected modules are available with or without integrated safety features, depending on requirements. Combined with the ability to control 24V and 48V motors from a wide range of manufacturers, system builders and operators benefit from maximum flexibility, reduced wiring effort, and significantly lower system costs.

The ongoing expansion of capacity in e-commerce and intralogistics demands modular, flexible, and reliable conveyor systems. Motor-driven roller conveyors (MDRs) offer enormous efficiency advantages through zone-based operation, but often reach their performance limits when using conventional bus systems. The new EP741x MDR controllers change that. The integration of EtherCAT enables sub-millisecond update rates. This ensures absolute synchronization of the routing logic, even with extensive conveyor lines and complex systems.

Building on the established EtherCAT box architecture, the EP741x provides sensorless control of brushless DC (BLDC) motors in the 24 to 48 V voltage range. A key advantage: The modules can be combined with motor rollers from any manufacturer, simplifying engineering and significantly reducing spare parts inventory. The controllers are available in a two-channel version (EP7412) and a particularly compact four-channel version (EP7414). The fully cascadeable design with IP54+ protection, integrated connection cables, and standardized M8 and M12 connectors reduces costs, eliminates wiring errors, and minimizes installation time. At the same time, the reduced installation depth facilitates direct, space-saving mounting in conveyor rail profiles.

An absolute industry first for MDR solutions is the optional Safe Torque Off (STO) safety function via Safety over EtherCAT (FSoE). While conventional controllers typically require a complete power shutdown to comply with emergency stop requirements, the EP741x-9071 utilizes an intelligent design. It safely disconnects the motor power stage while maintaining the logic voltage for the control electronics. The system thus remains in a safe state. This allows users to benefit from a decentralized safety architecture that enables the definition of individually controlled safety zones. This eliminates the need for additional safety components or complex parallel wiring and elevates the modularity of material handling systems to a new level. For applications with lower safety requirements, Beckhoff also offers the new MDR controllers as cost-optimized two-channel and four-channel variants without safety functionality (EP741x-0071).