New Controller from Beckhoff for Motor-Controlled Roller Conveyors

[Semih Asil]

### Beckhoff EP741x Motor-Driven Roller Conveyor Controller

The EP741x controller can control sensorless brushless DC motors operating between 24 V and 48 V. Using the EtherCAT protocol, the device optionally supports safe torque off (STO) functionality via FSoE.

With the growth of e-commerce and intralogistics sectors, there is an increasing demand for smarter and more efficient conveyor systems. In response to this need, Beckhoff has developed a specialized controller for motor-driven roller (MDR) conveyors with 24 V to 48 V brushless DC motors. The EP741x provides microsecond-level fast communication thanks to EtherCAT, and its cascaded connectivity allows multiple controllers to be used in a single system.

### Application Area and Features

Designed specifically for the logistics sector, this controller is ideal for use in facilities where packages are transported via conveyors and sorters. Roller conveyors typically consist of multiple rollers connected by gears or chains. This design allows the rollers to slip freely when an object stops on the conveyor.

The small DC motors used in conveyors typically operate in the 24 VDC to 48 VDC range, which is much more energy efficient compared to conveyors using 120 VAC or 240 VAC. The EP741x controller is designed to be compatible with almost all brushless DC motor-driven roller conveyors on the market, using standard M8 or M12 connectors with 2 or 4 channel options.

### EP741x Controller Technical Specifications

• Motor Voltage Range: 24 V to 48 V brushless DC motor support
• Number of Channels: 2 or 4 channel models
• Connection Type: Standard M8 or M12 connectors
• Communication: EtherCAT protocol with microsecond speed
• Cascaded Connection: Wiring can be reduced with cascaded connection between multiple controllers
• Mounting: Integrated mounting features allowing direct mounting to conveyor rail profiles
• Inputs/Outputs: Additional 2 inputs and 2 outputs for light barriers and actuators
• Safety: Safe torque off (STO) option via EtherCAT with FSoE

### Safety and Efficiency

In emergency stop situations, conveyors must have their power cut to prevent internal movements within the system. When the EP741x is used with the FSoE protocol over EtherCAT, it enables the creation of safety zones that will only stop the relevant conveyor sections. When STO is active, motor power is cut, but the logic power of the control electronics remains. The use of safety functions via this industrial protocol saves machine manufacturers time in terms of less wiring and less troubleshooting.

### Innovative Control and Smart System

The integrated inputs/outputs and EtherCAT communication provided by the EP741x controller together with a BLDC motor-driven conveyor allow system designers to dynamically manage conveyors based on packages. The motor speed and direction can be changed instantly and individually for each package detected by sensors and barcode readers. In this way, a smart, efficient, and safe conveyor system can be created with the integrated STO option.