EP741x MDR controller offers built-in safety and integrated cables for smart conveyors

Rising automation demands in e-commerce and intralogistics applications require smarter conveyor systems that are more modular, flexible and reliable. Smart, powered MDR conveyors deliver major efficiency advantages through zone-based operation but can be restricted by the limitations of traditional fieldbus systems. The new EP741x MDR controllers are networked via EtherCAT to allow sub-millisecond update rates and nearly unlimited network size, including no limit on connecting the devices in a line topology and no performance impact on branching — all major weaknesses of other Ethernet networks. This enables tightly synchronized routing logic, even with extensive conveyor lines and complex material handling systems. Source: Beckhoff

Built on the established EP7402 EtherCAT MDR Controller Box architecture, the EP741x provides sensor-less control of BLDC motors in the 24 V to 48 V voltage range. Utilizing 48 V power permits higher conveyor speeds and longer cable runs without worrying about voltage sag. And because the modules are compatible with motor rollers from any supplier, engineering is simplified and spare parts inventories are significantly reduced. The controllers are available in a two-channel version (EP7412) and an especially cost-effective four-channel version (EP7414).

The fully cascadable IP54+ design with integrated cables and standardized M8 or M12 connectors reduces costs, eliminates wiring errors and minimizes installation time. A reduced installation depth also facilitates direct, space-saving mounting inside conveyor rail profiles.

An industry first for MDR solutions is the optional Safe Torque Off (STO) safety functionality networked via Safety over EtherCAT (FSoE). Unlike conventional controllers that meet emergency-stop requirements by shutting down the entire power supply, the EP741x-9071 uses an intelligent design: it safely disconnects the motor power stage internally without having to cut power to the module. As a result of keeping the control electronics’ logic voltage up, the system retains clear visibility of all input states, motor data and important safety diagnostics while remaining in a safe state.

A decentralized safety architecture allows users to define individually controlled safety zones within one EtherCAT network, increasing the modularity of material transport systems and eliminating the need for additional safety components or complex parallel wiring. For applications with lower safety requirements, Beckhoff also offers the new MDR controllers as cost-optimized two-channel and four-channel variants without the safety functionality (EP741x-0071).