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-rated modules are available with or without integrated safety, depending on requirements. In combination with the control of 24- and 48-V motors from a wide range of manufacturers, system integrators and operators benefit from maximum flexibility, reduced wiring effort, and significantly lower system costs.

The ongoing expansion of capacity in e-commerce and intralogistics requires modular, flexible, and reliable conveyor systems. Motor-driven roller conveyors (MDRs) offer enormous efficiency advantages thanks to zone-based operation, but often reach their performance limits when using traditional bus systems. Not so with the new EP741x MDR controllers. The integration of EtherCAT enables update rates in the sub-millisecond range. This ensures absolute synchrony of the routing logic even with extended conveyor routes and complex systems.

Building on the established EtherCAT Box architecture, the EP741x handles the sensorless control of brushless DC motors (BLDC) in the voltage range of 24 to 48 V. A key advantage: The modules can be combined with motor spools from any supplier, which simplifies engineering and significantly reduces spare parts inventory. The controllers are available in a two-channel (EP7412) and a particularly compact four-channel version (EP7414). The fully cascadable design with IP54+ protection, integrated connection cables, and standardized M8 or 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 the profiles of the conveyor rails.

An absolute industry-wide innovation for MDR solutions is the optional Safe Torque Off (STO) safety function via Safety over EtherCAT (FSoE). While conventional controllers typically require a complete shutdown of the power supply to meet emergency stop requirements, the EP741x-9071 employs an intelligent design. It safely isolates 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 renders additional safety components or complex parallel wiring obsolete and takes 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).