Beckhoff MDR Controllers: Intelligent decentralized controllers for motor rollers and BLDC motors

Efficient material flow without a control cabinet – with the compact EtherCAT Box modules, you can control 24 V and 48 V DC roller motors decentrally and directly on the conveyor belt.
Benefit from minimal cabling work, integrated ZPA (Zero Pressure Accumulation) logic, and compatibility with any manufacturer. Want to know more?

Advanced conveyor systems require flexibility, scalability, and high throughput. Traditional centralized control cabinet architectures often reach their limits in this context (due to costs, cabling, and space requirements). The benefits for you:

• control cabinet-free installation (IP65): modules are mounted directly on the machine frame; no additional protective cover is required
• manufacturer independence: complete control of the roller motor irrespective of the manufacturer of the conveyor or the motor
• daisy-chain cabling: power and EtherCAT are looped through from box to box (one-cable concept for the 48 V modules), which cuts installation time by up to 50%

Why use distributed drive technology for 24/48 V DC roller motors?

• SELV/safety level: both voltages are below the standard SELV limit (60 V DC), resulting in a lower risk of electrical hazards and simplified safety measures
• standardization: high parts availability, because many sensors/controllers and decentralized drives support 24/48 V
• easy integration: direct control, simple wiring, and plug-and-play modules
• 48 V DC: lower current at the same power output – the current is halved but output stays the same compared to 24 V, line losses are lower, and cable cross-sections are smaller, saving energy and allowing for thinner, less expensive cables
• better scalability for higher performance and longer distances: 48 V is particularly suitable for cases where many motors are connected in series or cable runs are long
• more power per supply: with 48 V, more powerful motors or a greater number of motors can be operated from a single power supply – resulting in less voltage drop under load

Results in practice

• in small, compact systems, or in cases where there are already many 24 V power supplies → 24 V is often more cost-effective and simpler
• longer conveyor lines, higher motor power ratings, or many motors operating in parallel → 48 V saves on cabling, reduces losses, and is more efficient
• 24 V DC motors can also be operated using a 48 V DC power supply with the MDR controllers from the EP74xx series

ZPA and TwinCAT integration

Controlling conveying zones for pressureless conveying requires precise logic. Beckhoff offers maximum scalability for this purpose:

• stand-alone operation (without a PLC): modules such as the EP7402 handle the ZPA logic independently – in pure conveying mode, no superordinate PLC is required (single-item or batch discharge)
• TwinCAT integration: for highly complex systems, the modules are seamlessly integrated into TwinCAT, with engineering tools such as the Automation Interface enabling efficient implementation of the often numerous roller motors in the system

Full compatibility through standardization

The drive controllers support the standardized DS402 device profile via EtherCAT – for maximum flexibility in the system architecture. The controller is seamlessly incorporated into TwinCAT environments and can also be easily integrated into third-party EtherCAT masters without any additional effort. Choose a control system that offers true interoperability and independence.

TwinSAFE: integrated, open, and scalable safety technology

TwinSAFE offers solutions for all key areas of automation technology, including control, I/O, motion, and automation, and the MX-System. All components can be combined across areas to provide a fully comprehensive security architecture for almost any customer application.

The integrated FSoE safety electronics allow individual system components to be safely shut down in a targeted manner without interrupting the rest of the flow of goods. This is a first for the MDR controller family. In addition, TwinSAFE Logic has been integrated into the MDR controllers, which greatly expands the range of possible use cases and application scenarios.

Whether you’re using conventional 24 V systems or high-performance 48 Varchitectures, Beckhoff offers the right EtherCAT Box for your materials handling systems.

EP741x series | Highly efficient 48 V architecture with integrated cabling, with or without safety features

For systems that require higher performance. The built-in power and EtherCAT cables eliminate the need for expensive patch cables. L-coded M12 cables for up to 16 A

• EP7412-0071 (2-channel) and EP7412-9071 (TwinSAFE Logic): controls two 48 V motors, with an integrated I²T model for load monitoring
• EP7414-0071 (4-channel) and EP7414-9071 (TwinSAFE Logic): the high-density solution that controls up to four 48 V motors simultaneously – perfect for compact conveyor zones

EP740x series | 2-channel MDR controller with hybrid cable, 28 A

• EP7402-0057 and EP7402-0x67: the industry standard in IP67 – extremely compact (60 x 174 mm) for direct installation in the side profile
• integrated ZPA logic, eight additional digital I/Os for light barriers, M8 connectors, 3.5 A rated current (12 A peak)

The PC and EtherCAT-based control technology from Beckhoff offers open and flexible automation solutions for your industry. On our industry pages we present the advantages of PC- and EtherCAT-based control technology, tailored to your industry. We supply you with further information around the typical areas of use and properties of our products, and we provide you with an overview of our reference reports.