MX-System delivers maximum flexibility for machine builders, control cabinet manufacturers and end users
The MX-System from Beckhoff is a flexible, space-saving, and intelligent system solution that can completely replace conventional control cabinets, opening up entirely new possibilities for fulfillment and parcel automation solutions. As a modular control cabinet replacement that can also be decentralized on the machine, the MX-System cuts down on engineering, assembly, installation and maintenance work for wide-ranging intralogistics applications. This enables highly efficient processes for machine builders, systems integrators and distribution center staff, ranging from planning, setup and installation of the MX-System right through to the maintenance of MX-System-equipped machines.
The basic concept of the MX-System is to standardize the electrical and mechanical interfaces for all electronic and electromechanical components. Implementing this idea results in two interfaces:
The data interface integrates each functional unit into an EtherCAT network and supplies it simultaneously with 24 V DC and, if necessary, also with 48 V DC.
A second interface has been defined as standard for the high-voltage range. These interfaces distribute the mains voltage of up to 530 V AC and a DC voltage of up to 848 V.
This standardization allows all functionality traditionally found in a control cabinet to be mapped as an IP67 cabinetless backplane system.
The various baseplates available are equipped with standardized interfaces as described above. The MX-System baseplates provide both the electrical and mechanical interface for accommodating the modules. The combination of MX-System baseplate and MX-System function modules resulting from the modular construction kit combines all tasks and features of a control cabinet: energy supply, fuse protection and distribution, generation and monitoring of auxiliary voltages, sequence control with the inputs and outputs, control of motors and actuators as well as the connection level for the field devices.
A full range of function modules from the areas of IPC, bus coupler, I/O, drive, relay and system are available. These are simply plugged and screwed onto the baseplate. The completed solution kit results in an IP67-protected unit that is optimized in terms of space utilization and can be mounted directly on the machine. The MX-System stations are connected via EtherCAT and thus can be flexibly distributed along the equipment in line, star or other topologies.
In terms of how this connection is established, the MX-System relies on the portfolio of Beckhoff hybrid connectors and the corresponding cables. Similar to the backplane interfaces, the hybrid connectors combine EtherCAT, low voltages, and higher voltages in various combinations. The corresponding function modules can either feed power and EtherCAT communication into or out of a baseplate. It is also possible to connect any of the wide variety of existing Beckhoff EtherCAT EP/EPP box signal modules or distributed servo drives to the outputs in addition to other MX-System stations. In fact, any device that requires EtherCAT and/or voltage can be connected, regardless of the connector type. The integration of the peripheral level, which has already been around for many years, demonstrates the flexibility of the MX-System, as does the possibility of using an MX station as a control cabinet substation.
A special feature of the system for distributing EtherCAT and voltage is that the DC voltage of the drive’s DC link is also distributed via this path. This voltage can be generated at a central point so that both servo drive modules and frequency converter modules can then be used at different stations. This is the first time that Beckhoff has broadened its portfolio to include frequency inverters for the operation of simple asynchronous motors, which are often used in large numbers in the logistics industry. As has been the case in servo modules for many years, Beckhoff also offers the frequency inverters as a dual-axis module, as well as with Safe Torque Off (STO) via the integrated EtherCAT FSoE functionality, which means no separate wiring and safety inputs are required for this safety functionality.
Advantages for engineering
The system architecture of a baseplate combined with function modules results in a modular solution that can be used to solve a wide range of automation tasks. A particular advantage is that the MX-System function modules integrate individual functions, such as line protection for outgoing power lines. This facilitates project planning and significantly reduces the number of components.
These advantages are evident in the fact that the number of pages in the circuit diagrams and parts lists is reduced by up to 80%. Even in the engineering phase, the MX-System’s low installation space requirements prove to be yet another advantage. This facilitates better coordination between departments, as there is usually no need to design special installation spaces and holders for the MX-System. Another important aspect is that the MX-System meets the requirements of relevant control cabinet standards and, in contrast to conventional control cabinets, it is also IEC-, UL- and CSA-compliant, making it a globally standardized solution.
Advantages for industrial automation setup
The principle of plugging function modules onto a baseplate and fastening them with screws not only revolutionizes control cabinet design, but also completely replaces it in the form known today. Mechanical assembly of the control cabinet and its mounting plate are eliminated, as is time-consuming manual wiring. This is directly noticeable in the time required to set up the MX-System.
As a result, an MX-System can be set up within just one hour, including the necessary tests and checks. For a comparable control cabinet, the total setup time would require at least 24 hours. In this way, the MX-System also counters the shortage of skilled workers, as individual employees are tied to a task for a much shorter period of time. In addition, wiring errors are completely eliminated. From a logistical point of view, there are also clear advantages for control cabinet design, as the complete elimination of mechanical work steps means that the assembly requires considerably less time and workspace on the production floor. Processes such as external control cabinet design can be completely eliminated.
Advantages in machine installation
The MX-System can be integrated visually and functionally into the machine installation space due to its considerable compactness in contrast to conventional solutions. This reduces the machine footprint many times over. Modular machine concepts can be put together very easily due to the possibility of cascading MX-System installations. In addition, there are significantly shorter cable runs to the sensor or actuator level. The use of pre-assembled cables further shortens the installation time and provides a high level of protection against errors during cable connection. Connections do not have to be completed by specially trained electricians due to the simple pluggability of the modules.
Advantages for the machine end user
For the machine end user, there are clear advantages in terms of service and maintenance: The MX-System consists of EtherCAT components that are networked throughout, so comprehensive system diagnostics are available at any time. In addition to classic status LEDs, each function module has a unique serial number in the form of a DataMatrix code. This can be scanned via a smartphone app, which causes the smartphone to connect to the control and output diagnostic data for the corresponding function module.
The process of replacing modules is also very easy, since these are hot-swappable and can be plugged in and unplugged during operation. Just like the manufacturer of the machine, operators also benefit from the fact that the modular MX-System covers the complete spectrum of automation technology with considerably fewer parts and therefore fewer assemblies to stock as spares. Through their simple basic principle, MX-System modules can also be reused very easily beyond the life cycle of the machine.
With the complete elimination of the freestanding control panel on the plant floor, along with all quick-disconnect connections, the control system adds to the flexibility of the equipment. This enables easy adaptability to changes in the equipment from fluctuating business requirements and changing consumer demands.
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Daniel Siegenbrink is Product Manager MX-System for Beckhoff Automation
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