Beckhoff Introduces Controller For Motor-Driven Roller Conveyors

As e-commerce and intralogistics industries grow, the demand for smarter, more efficient conveyors increases. In response, Beckhoff Automation has released a motor-driven roller conveyor (MDR) controller for 24 V to 48 V brushless DC motors. The controller is cascadable and makes use of the EtherCAT communication protocol that can communicate on a sub-millisecond range. 

The EP741x MDR controller is especially geared toward the logistics industry, which uses conveyors and diverters to move packages around a facility for packaging and shipping. 

Beckhoff’s EP741x MDR controller for 24 V to 48 V brushless DC motors. Image used courtesy of Beckhoff Automation

The EP741x MDR Controller

Roller conveyors are typically made up of multiple rollers connected by gears or sprockets, which allow the rollers to slip in the event that something stops the object on the conveyor. These conveyors use small DC motors that typically operate on 24 VDC to 48 VDC, which is far more efficient than a typical conveyor that uses 120 VAC or 240 VAC. The DC motor is driven by a device that manipulates the speed and direction of the rollers.

Beckhoff has designed its new EP741x MDR controller to work with virtually any roller conveyor driven by a brushless DC motor on the market, supporting 24 V to 48 V. The EP741 can be ordered in two- or four-channel versions and uses standard M8 or M12 connectors. Multiple controllers can be connected in a cascade to reduce wiring runs.

Mounting the EP741x is easy with its integrated mounting features. To save space, the controller can be mounted directly in the profiles of the conveyor rails. Each controller has two additional inputs and outputs for connecting light barriers and actuators. This feature enables designers to create independent conveyor control without the need for a PLC.

The EP741x MDR controllers are available with safe torque off via safety over EtherCAT (FSoE). Image used courtesy of Beckhoff Automation

Conveyor System Safety

In the event of an emergency stop, conveyors need to be powered down to prevent motion within the system. The EP741x can be ordered with an optional safe-torque-off (STO) feature over EtherCAT using the FSoE protocol. This allows designers to create safety zones and only stop the sections of the conveyor in specific zones. When the STO signal is low, the system drops motor power while maintaining logic power for the control electronics. With the STO function being used over an industrial protocol, Beckhoff intends to save machine builders time with less wiring and less troubleshooting.

A roller conveyor that uses BLDC motors connected via gears. Image used courtesy of Beckhoff Automation

Smarter Conveyors and More Efficiency

By using a conveyor powered by DC motors and a controller like the EP741x with its integrated I/O and EtherCAT communication, system builders are able to create conveyor systems that can dynamically react to each package that travels past sensors and barcode readers. Motor speed and direction can be changed virtually instantly and specifically for each motor. This creates a smart, efficient, and safe conveyor system, with an integrated STO option over EtherCAT.