💰 Flexible and Economical: New Generation Frequency Converters Take the Stage! 🚀

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For those seeking cost-effectiveness and flexibility in the world of industrial automation, there's exciting news! Beckhoff has launched its new AF1000 series of variable frequency drives (VFDs), compact and EtherCAT-integrated, specifically designed for applications with lower demands. This innovative series offers a cost-effective solution optimized for basic industrial drive needs.

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💡 TwinCAT Integration and Easy Commissioning​

The AF1000 series stands out due to its full integration with the TwinCAT automation system. This means that the standard commissioning workflows and internal diagnostic features used in Beckhoff's servo drive technologies are also available in these new VFDs. It's an ideal choice for a wide range of basic drive applications, from conveyor systems to pumps and fans.

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⚡ Electrical Infrastructure and Module Structure​

The AF1000 VFD series is produced in two distinct power supply versions to accommodate different industrial electrical configurations:

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  []Single-Phase Platform: Designed for 240 V AC single-phase supply, covering a power range from 0.37 kW (0.5 HP) to 1.5 kW (2 HP).
  
  []Three-Phase Platform: Supports three-phase supply up to 480 V AC and offers a higher power range from 0.37 kW (0.5 HP) to 5.5 kW (7 HP).
  

Despite their small mechanical dimensions and gap-free side-by-side cabinet installation, the hardware design includes an integrated control power supply unit, DC bus capacitors, and a dedicated ballast circuit. The internal 24 V DC control voltage is generated directly by the integrated power supply using the internal DC bus voltage.

Both voltage variants are available as a single-axis drive module or a high-density 2-axis module. The dual-axis option reduces hardware costs while minimizing the total physical space and footprint requirements within the control panel.

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⚙️ Motor Compatibility and Engineering Software​

This drive platform supports various motor configurations, including synchronous servo motors, asynchronous motors, and reluctance motors. It can operate these systems via standard U/f (voltage/frequency) mode or specialized vector control profiles, without the need for external feedback sensors.

For software commissioning and axis parameters, the series utilizes TwinCAT Drive Manager 2. This unified software approach eliminates the need for existing operators to learn or deploy a new engineering tool environment.

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🔬 Sensorless Control and Communication Protocols​

Variable frequency drives designed for sensorless (feedback-free) motor control use mathematical models of the connected motor to estimate rotor position and magnetic flux linkages without relying on physical encoders or resolvers. In U/f control mode, the VFD maintains a constant ratio between output voltage and frequency to keep the stator flux constant, making it suitable for quadratic torque loads such as centrifugal pumps and fans.

For applications requiring high dynamic response and torque at low rotational speeds, sensorless vector control (field-oriented control) separates the stator current into torque-producing and flux-producing vector components. This computationally intensive method allows the drive to manage independent current loops, providing precise speed regulation and high starting torque even under varying load conditions in asynchronous and synchronous reluctance motors.

Communication between the VFD and the central programmable logic controller (PLC) uses the CANopen over EtherCAT (CoE) protocol and strictly adheres to the CiA 402 drive profile according to the standard IEC 61800-7-201. This protocol maps operational data such as target speed, actual speed, control words, and status words to cyclic process data objects (PDOs) refreshed at sub-millisecond intervals.

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🛡️ Safety Functions and Certifications​

To meet industrial machine safety directives, the VFD includes optional TwinSAFE technology to execute hardware-based safe drive functions according to IEC 61800-5-2. These functions include:

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  []Safe Torque Off (STO): The VFD gates are electronically de-energized to stop torque production until the motor comes to a standstill.
  
  []Safe Stop 1 (SS1): The drive actively decelerates the motor along a controlled ramp before executing the STO safety function.
  

These safety protocols achieve certification up to EN ISO 13849-1 (Category 4, Performance Level e) and EN 61508 (SIL 3) standards.

The Beckhoff AF1000 series offers a powerful solution for businesses seeking cost, flexibility, and safety in industrial automation. These next-generation VFDs aim to increase efficiency by meeting the needs of modern manufacturing facilities.