Trends and Innovations in Motion Systems for Machine Design

Machine Design caught up with Brandon Snell and Paxton Shantz from Beckhoff Automation at the Fabtech Show in Chicago to learn about the company’s advancements in motion control technology.

Snell, product manager for the MX System, said this system is redefining machine control architecture. The modular, cabinet-free automation platform integrates power distribution, control and communication on a single base plate that supports high-voltage AC power (480 V), DC bus power for drives and variable frequency drives (VFDs) as well as low-voltage power and communication channels over EtherCAT.

The modular design allows engineers to directly plug IO blocks, servo drives, power supplies and industrial PCs into the base plate, which can be mounted externally on the machine frame. Snell says this setup significantly reduces wiring complexity and panel footprint, accelerating machine assembly and potentially lowering costs.

He demonstrated the system’s diagnostics and maintenance features. The system incorporates front-facing LED indicators to provide quick visual cues about operational status. Also, each module is labeled with a data matrix code that, when scanned by a mobile diagnostic app, presents real-time operational data, including servo position, torque output and component health metrics without opening control cabinets. This can facilitate faster troubleshooting and support predictive maintenance strategies, Snell said.

The company’s TwinCAT software platform provides a unified environment for developing and running PLC, CNC and motion control applications. Its integration with EtherCAT, Snell noted, supports the MX System’s modularity and real-time performance. For machine design engineers, this offers a flexible and scalable software and communication framework that supports complex system topologies while simplifying integration and diagnostics.

Advances in Regeneration Technology with the AX8820 

Shantz, digital manufacturing industry manager, highlighted a development in motion system power management, the AX8820 regeneration module. Shantz explained how this module captures energy generated during motor braking or deceleration and feeds it back into the mains power supply. It accomplishes this without requiring additional external components such as chokes or filters, which are traditionally used to manage electromagnetic interference (EMI) and voltage smoothing.

For machine design engineers, this reduction in components translates into more power system layouts and simplified wiring schemes, potentially lowering system cost and reducing cabinet space requirements, Shantz said, adding that it can operate either integrated into the AX8000 servo drive system (see below) or as a standalone unit for design flexibility and application needs.

Compact Servo Drives and Connector-Free Modules Streamline Integration

In line with the broader industry trend toward simplification and miniaturization, Shantz says Beckhoff's ELM series of servo drives offer single- and dual-access configurations rated between 0.5 kW and approximately 0.75 kW. These drives leverage single-cable technology, enabling a single cable to carry power feedback and control signals. This reduces installation time and wiring complexity while facilitating automatic motor recognition and preconfigured tuning parameters, easing commissioning efforts for applications requiring lower power.

The company’s EJ ultra compact modules, which go up to 500 W, are made to provide a connector-free design solution, Shantz said. The use of header-based connections instead of traditional connectors streamlines assembly, reduces potential failure points and improves serviceability. This approach is useful in dense machine builds where reducing cabling bulk and connector count is important.

Modular Power Distribution, Control in the AX8000 Series

The AX8000 servo drive series remains central for higher power applications with modular single -or dual-access servo units capable of delivering up to 7.5 kilowatts per module, Shantz said. All servo modules are powered via a centralized DC bus generated from a single mains input point. Integrated choke and filter components on this input help mitigate EMI, supporting compliance with relevant industrial standards for machine builders.

This modular DC bus architecture simplifies both power distribution and wiring efforts. It also facilitates scalable system expansion by allowing additional servo modules to be added without redesigning the power supply infrastructure.