The Flex-7 EtherCAT Motion Controller is a high-performance, compact machine controller designed for complex, high-axis-count motion control applications. Its re-architected communications interface and 1.2 GHz quad-core ARM processor provide dedicated processing resources for motion and communications, supporting fast and reliable machine performance.

The Flex-7 supports up to 80 EtherCAT axes with selectable motion update rates from 125 μs to 4 ms. It is supplied with two built-in EtherCAT axes and can be expanded using Trio P912 Remote Axis Feature Enable Codes as machine requirements grow.

Two Gigabit Ethernet ports support general Ethernet communication and industrial protocols including Modbus TCP and EtherNet/IP. A dedicated EtherCAT master port provides deterministic communication with compatible servo drives, I/O modules and other EtherCAT devices.

Machine applications can be developed using TrioBASIC or IEC 61131-3 programming with PLCopen through Trio’s Motion Perfect software. The controller also includes USB connectivity, MicroSD storage expansion, CAN communication, a real-time clock and an integrated graphical display.

The Flex-7 can operate as a standalone controller or connect directly to Trio’s Flexslice system, enabling expansion with digital and analogue I/O, encoder interfaces, temperature measurement and stepper control modules.

Typical Applications

• Multi-axis machine automation
• Packaging and processing machinery
• Robotics and kinematic systems
• High-speed production equipment
• Printing and converting machinery
• Semiconductor manufacturing equipment
• Pick-and-place systems
• Complex EtherCAT motion systems

Need help specifying the right motion controller?

As the exclusive Trio Solutions Partner in the UK, Micromech can help you specify, configure and integrate a Flex-7 EtherCAT motion control solution for your machine.
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Technical Data

^c)  Based on reference sizes

Technical Data

^c) In relation to reference sizes

Highlights

• Motion + PC solution for Automation Machinery
• Fanless Compact PC with a choice of processors
• Up to 64 EtherCAT axes
• Plug and play EtherCAT configuration
• Built on Trio’s Motion iX advanced motion core
• Programmable in Trio’s multi-tasking language or IEC61131-3
• Shared memory API interface to allow PC side applications to interface with Motion-iX
• RTX64 Real Time Extensions to Windows
• 4 Gbyte DDR4 + 64 Gbyte SSD
• Built in Gbit ports for vision cameras

Software Integration
Trio's next generation PC-MCAT-2 combines PC technology with the Motion-iX advanced motion core allowing PC applications to run alongside real-time motion control and deterministic EtherCAT communication.

Fast and Flexible
User programs can be written in Trio’s established multi-tasking programming language or industry standard IEC61131-3 using the powerful Motion Perfect application development software. Alternatively, applications can be written and executed under Windows and use a shared memory API to communicate with Trio’s Motion-iX advanced motion core, allowing maximum flexibility in application development.

Expanding the System
PC-MCAT-2 supports a wide range of communication ports including Ethernet (up to 1000Mbit), USB (3.0 and 2.0) COM ports (RS232 and RS485) and HDMI for connectivity to PC peripherals. In addition to the communication ports, PC-MCAT-2 has 16 GPIO points, 8 DIN and 8 DOUT.

Performance
Supporting PC peripherals and off-the-shelf Windows applications alongside Trio’s Motion-iX advanced motion core gives a high-performance flexible solution for applications where specific external devices are required (e.g. vision applications).

Highlights

• 1.2 GHz, 64 Bit Dual Core ARM Cortex A55 Processor
• 2 - 64 Axes
• 1 GBit DDR3 Memory
• Memory can be Expanded with a Micro SD Card
• 1 GBit Fast Serial Flash Memory to Store Data Such as Programs, VRs and Tables
• Built in Retention RTC
• Built in EBUS Coupler for Direct Access to Trio’s Flexslice Slaves
• Cycle Time as Low as 125us!
• Field Programmable with Motion Perfect
• High Performance, Flexible Topology and Simple Configuration
• Bus Cycle Time Synchronised with Motion Coordinator Servo Period
• Ethercat Protocol to Individual Modules Using the EBUS System
• I/O Functions Tightly Synchronised to Motion Using Ethercat Distributed Clocks
• Practical Push-In Connector Options – No Break Out Required
• Clip-Together Design With ‘Quick Release’ Locks For Mechanical Integrity

More Axes Please!
The P660 has 2 built-in EtherCAT axes which can be user upgraded with the purchase of P912 Remote Axis FECs. Up to 64 axes are supported using CSP, CSV and CST modes of operation.

Each P912 doubles the available axes, i.e:

P660 + 1 x P912 = 4 Remote Axes
P660 + 2 x P912 = 8 Remote Axes
P660 + 3 x P912 = 16 Remote Axes
P660 + 4 x P912 = 32 Remote Axes
P660 + 5 x P912 = 64 Remote Axes
Of course, the Flex-X Nano can be purchased with axes factory loaded ie:

P660 = 2 Axes
P661 = 4 Axes
P662 = 8 Axes
P663 = 16 Axes
P664 = 32 Axes
P665 = 64 Axes

Fast and Flexible
Trio’s Flexslice input/output modules provide a robust, high speed and flexible solution for both motion control and general automation. EtherCAT cycle times down to 125μsecs are supported and the bus coupler uses EBUS technology to bring all the sub-modules on to the EtherCAT network with no degradation in performance.

EtherCAT slave nodes (Flexslice Modules) are connected via the Flexslice EBUS and the EtherCAT connector. Total slave connections can be up to 128 nodes including I/O and complex devices.

Expanding the System
More "stations" (EtherCAT linked blocks of Flexslice Modules) can be added to the network using the second EtherCAT port on the P660 to connect to one or more P366 Flexslice Couplers.

Kollmorgen has designed custom solutions for challenging environments since our founding in 1916. The most notable were the motors used in Jason Jr., the ROV that was used to explore the Titanic. The culmination of these experiences has been leveraged in the AKMH series of motors. Designed for food contact and splash zones, the AKMH reduces cleaning time and maintenance, thus directly contributing to higher overall OEE for machines.

Features

Reduced Recall Risk. The Food Modernization Safety Act (FMSA) gives the US federal government the ability to shutdown facilities, recall food products, and levy stiff fines to ensure public safety in regards to food product manufacturing. The AKMH is designed to meet the toughest hygienic requirements in the industry in order to reduce the possibility of food borne illnesses and costly recalls.

Designed for Fast Cleaning and Increased Uptime. The AKMH stainless steel motor is designed to meet the standards for IP69K, EHEDG, and 3A and is built with FDA approved, food grade materials. The careful elimination of flat surfaces, cracks, and crevices prevents the build-up of foreign material and bacteria. The AKMH housing and cable can endure daily wash downs with high pressure, high temperature, and caustic chemicals. The robust design means that guards and covers are not required to protect the motor from harsh cleaning regimens. These AKMH features constitute quicker cleaning, keeping your machine running, and increasing the OEE of your manufacturing line.

Bottom Line. The Stainless Steel AKMH series is designed for strict aseptic machine applications. The AKMH comes in 19 standard motor sizes, with multiple standard windings for each to fit the many motor applications found in food, beverage, and pharmaceutical industries. Kollmorgen’s AKMH helps maintain the highest standard of machine cleanliness, increases OEE, and reduces the possibility of devastating recalls.

• Increase your machine’s OEE through superior wash-down design reliability
• Reduce your machine’s cost of ownership due to reduced cleaning time and increased reliability
• Enhance the value of your machine by lowering your customer’s risk of recall… due to the superior hygienic design of the AKMH
• IP69K certification for motor and cable
• Unique design techique to eliminate condensation
• FDA Approved, food-grade O-ring seals
• All exposed surfaces are 316L Stainless Steel, superior to 303/304 for hygiene & corrosion resistance
• Round design with no nooks or crannies
• Sloped rear cover to eliminate puddling, even in vertical mounting
• No external hardware (no bolts, washers, or screws) to trap soil or pathogens or fall into food
• Smooth surface meeting EHEDG & 3A criteria, promotes rapid cleaning and no harboring of pathogens
• FDA Approved, food-grade bearing lube
• FDA Approved, food-grade shaft seal
• Cable designed to elminate the need for conduit
• No protective covers needed for washdown.. No secondary cleaning disassembly required
• FDA approved, food-grade tubing option for applications where the cable is in the food zone
• Single cable for increased reliability, faster cleaning, and fewer places to harbor pathogens
• Hygienic marking method eliminates harboring of pathogens
• Hygienic, IP69K shaft seal, that includes special shaft treatment for long life

Kollmorgen AKM™ Washdown and Washdown Food Series motors are available in frame sizes 2 through 6. These innovative motors incorporate our industry-leading AKM electromagnetics within a housing protected by a 2-K coating and IP67-rated seal configuration. Stainless steel hardware is used on all precision interfaces. The food-grade model incorporates greases that are safe for incidental contact and consumption.

Features

• Frame sizes 2 through 6
• Static torques from 1 to 25 N-m
• Available with a wide range of standard lengths, windings, feedback systems and connection technologies
• Resistant to corrosive chemicals including highly alkaline or acidic cleaning products
• Food-grade version complies with FDA requirements, including lubricants and materials safe for incidental contact and consumption
• IP67 seal design featuring PTFE shaft seal
• Stainless steel shaft

Benefits

• Ideal for applications subject to strict hygiene regulations
• A cost-effective solution for any application that requires periodic washdown
• Increased motor life
• Higher purification rating
• No additional cover or special protection required for the motor casing
• Meets the needs of a wide range of applications without requiring expensive, high-grade stainless steel for the motor casing
• Stainless steel used for motor shaft, screws and connectors