Advanced EtherCAT Drives Simplify Industrial Motion Control

Modern industrial automation increasingly depends on deterministic communication, synchronized multi-axis motion and flexible machine architectures. To address these requirements, Dunkermotoren has expanded its EtherCAT-enabled drive portfolio with scalable solutions ranging from 10 W to 5,000 W. The portfolio includes both integrated smart servo motors and modular motor-controller combinations, enabling OEMs to develop drive systems tailored to different machine concepts and performance requirements.

Designed for applications such as packaging, warehouse automation, material handling, autonomous mobile robots (AMRs) and automated guided vehicles (AGVs), the EtherCAT-enabled drives aim to simplify system integration while supporting precise real-time motion control.

Flexible EtherCAT Architectures for Machine Builders
Machine builders often face varying installation constraints depending on available space, environmental conditions and control strategies. To accommodate these differences, Dunkermotoren offers two EtherCAT implementation approaches.

The integrated dPro drive combines the motor, encoder, drive electronics and EtherCAT interface within a single housing. This configuration is intended for decentralized automation systems where cabinet space is limited and reducing wiring complexity is a priority. By embedding intelligence directly into the drive, the integrated design can simplify installation while supporting compact machine layouts.

For applications that require control electronics to be separated from the motor, dCore motors can be paired with external EtherCAT controllers such as the BGE 5510 dPro EC. This modular configuration is suitable for installations exposed to high vibration or elevated temperatures, as well as machine designs that use centralized control cabinets. Together, these options allow OEMs to select the drive architecture that best matches their mechanical design and operating environment.

Real-Time Communication Improves Motion Performance
EtherCAT has become one of the leading industrial Ethernet protocols for applications requiring deterministic communication and tightly synchronized multi-axis motion. Dunkermotoren's EtherCAT drives support CANopen over EtherCAT (CoE) and the CiA 402 motion control profile, enabling straightforward integration with many existing automation platforms.

The protocol's low communication latency and minimal jitter allow multiple motion axes to operate with high precision. In packaging and labeling equipment, this supports accurate positioning, cutting and product handling. Warehouse automation systems benefit from improved synchronization in sorting and shuttle applications, while material handling equipment maintains stable operation even during frequent acceleration and deceleration cycles. These capabilities contribute to higher throughput, greater process consistency and reduced commissioning effort.

Simplifying Machine Design Through EtherCAT Integration
In addition to improving communication performance, EtherCAT can simplify machine architecture. Standard Ethernet cabling arranged in a daisy-chain topology reduces wiring complexity compared with more conventional network structures. Fewer communication layers and reduced hardware requirements can also lower installation effort while minimizing potential failure points.

The integrated drive concept further streamlines machine design by embedding drive electronics directly into the motor. This reduces or eliminates the need for separate servo drives within the control cabinet, resulting in more compact machine layouts, shorter installation times and lower overall system complexity.

Continuous Diagnostics Without Interrupting Operation
As industrial automation becomes increasingly data-driven, continuous access to operational information plays an important role in maintaining machine performance. Dunkermotoren supports Ethernet over EtherCAT (EoE), allowing engineers to access drive parameters, status information and diagnostic data through the existing EtherCAT network without interrupting deterministic real-time communication.

This capability enables faster commissioning, simplifies parameter adjustments and allows maintenance personnel to identify performance issues while machines remain in operation. The ability to perform diagnostics without affecting motion control helps improve machine availability and reduce unplanned downtime.

Integrated Functional Safety
Safety remains a key consideration in highly automated production environments. Dunkermotoren incorporates Safe Torque Off (STO) as a standard hardware feature throughout its EtherCAT-enabled drive portfolio. Integrating this safety function directly into the drive reduces the need for external safety components and supports more compact machine designs while helping OEMs implement functional safety requirements with less system complexity.

Applications Across Industrial Automation
The EtherCAT drive portfolio is designed for a broad range of industrial automation applications where synchronized motion, compact integration and reliable communication are essential. Typical applications include autonomous mobile robots, automated guided vehicles, warehouse automation systems, shuttle and sorting equipment, packaging and labeling machinery, and material handling systems. Across these sectors, the combination of deterministic communication, flexible drive architecture and scalable power supports efficient machine operation while allowing manufacturers to optimize system design for their specific application.

According to Andreas Winterhalter, Head of Products at Dunkermotoren, the EtherCAT portfolio enables machine builders to standardize on a single communication technology while selecting integrated, modular or hybrid drive architectures that best match individual machine concepts.

Additional Context
This section details technical specifications and competitive benchmarking not included in the original product announcement

EtherCAT, developed by the EtherCAT Technology Group, is widely adopted for industrial motion control because of its deterministic communication, low latency and efficient bandwidth utilization. Compared with industrial Ethernet protocols such as PROFINET, EtherNet/IP and POWERLINK, EtherCAT is particularly well suited to high-speed synchronized multi-axis applications where communication jitter must be minimized.

Several motion-control suppliers, including Beckhoff Automation, Bosch Rexroth, SEW-EURODRIVE and Kollmorgen, offer EtherCAT-compatible servo systems. Dunkermotoren differentiates its portfolio by supporting both integrated smart servo drives and modular motor-controller combinations across a power range of 10 W to 5,000 W, allowing OEMs to implement decentralized or centralized automation architectures using the same communication platform.

Edited by Sucithra Mani, Induportals editor – adapted by AI.

www.dunkermotoren.com