"Eckelmann and Ferrocontrol stand for a wide-ranging spectrum of products and solutions for machine and plant automation."
"The whole is more than the sum of its individual components—this is especially true with regard to the automation of machines. In control technology matters, Eckelmann and Ferrocontrol therefore subscribe to an integrated approach. We create open and flexible machine control systems which exactly meet the requirements of machines."
Our automation solutions excel by a variety of technology-specific functions: For instance, we also provide optimal support for manufacturing technologies such as non-cylindrical grinding, knife and flame cutting, sewing, bar processing or laser processing. Various transformations are available for all kinds of machine kinematics. Due to the extensive technological know-how of our engineers and their eye for detail, the functionality of our firmware can be quickly adapted to new tasks such as new machine kinematics or manufacturing processes. As a result, technically and economically perfect solutions are generated both for series and special-purpose machines. As a matter of course, our support also extends to “classic” CNC applications such as turning, milling and grinding.
As a full-service provider for automation solutions, we help our customers by taking overall responsibility for implementing entire automation solutions. Our machine automation portfolio includes:
As a result of many years of development work and practical experience in various target industries of mechanical engineering, system components from Eckelmann and Ferrocontrol are optimally coordinated. This is the basis for creating complete solutions for all major machine automation applications:
Eckelmann’s system family for advanced machine automation includes:
CNC Cutting Solutions by Eckelmann
More and more cutting machine manufacturers worldwide trust in CNC Cutting Solutions by Eckelmann. In addition to technical and economic factors, the cooperative partnership and economic stability in particular are decisive when choosing Eckelmann
Supporting all current processing methods and their combination: Thermal and water jet cutting, drilling, thread cutting, labelling and marking.
The same control platform for all machine designs allows for streamlined procurement and warehousing as well as training and service.
We offer interfaces to all technology providers and thus a free coice of cutting equipment.
Control technology with long-term availability independent of short innovation cycles (in contrast to PC technology).
Free choice of Eckelmann's scope of delivery: One-stop-shop from procurement of the pure control core to complete control and drive equipment. Optionally also inclusive nesting software with macro library.
Free choice of Eckelmann's scope of delivery: One-stop-shop from procurement of the pure control core to complete control and drive equipment. Optionally also inclusive nesting software with macro library.
Industrial PC and Panel PC from Ferrocontrol meet the high requirements of the industry for robustness, reliability and long-term availability.
Whether controlling, operating and monitoring machines and systems, data acquisition or image processing, Industrial PC and Panel PC from Ferrocontrol are versatile. They all meet the high requirements of the industry for robustness, reliability and long-term availability.
"Whether compact, high-end or customised embedded controller, the scalable and flexible controllers from Eckelmann’s E°EXC controller family are the ideal basis for the robust and efficient automation of machines and plants."
The E°EXC controller is the all-purpose hardware basis for PLC, motion control and CNC solutions. It supports numerous technology-specific functions and permits the development of sophisticated applications.
Processor performance, interfaces, memory and programming can be selected so as to meet the needs of each individual application. The controllers are available in the following classes:
| Technical features & interfaces | E°EXC 55 | E°EXC 66 | E°EXC 66 compact | E°EXC 66 H 43 | E°EXC 66 Export |
|---|---|---|---|---|---|
| Processor | 32-bit-Micro-controller | ||||
| PLC | √ | √ | √ | √ | √ |
| CNC | √ | √ | √ | √ | |
| Motion | √ | √ | √ | ||
| Motion and CNC combined | |||||
| CNC axes | 12 | 16 | 16 | 4+4a | |
| Motion axes | 12 | 60 | 60 | ||
| CANopen® (number of separate buses) for drives and distributed I/Os | 2 | 4 | 2 | 2 | 4 |
| EtherCAT® for drives | √ | ||||
| EtherCAT® for distributed I/Os | |||||
| sercos III for drives | √ | ||||
| sercos III for distributed I/Os | |||||
| Ethernet TCP/IP | √ | √ | √ | √ | √ |
| local I/O | FBM | LBM | LBM | LBM | LBM |
| distributed I/O | CAN | CAN | CAN | CAN | CAN |
| RS-232 | 2 | 1 | 1 | 1 | 1 |
| USB | Host | Host | Host | Host | |
| SD card | √ | √ | √ | √ | |
| Protection class IP | 20 | 20 | 20 | 20 | 20 |
| Dimensions (W × H × D) in mm | 45 × 100 × 115 | 45 × 100 × 115 | 45 × 100 × 115 | 45 × 100 × 115 | 45 × 100 × 115 |
| Field of application Note | f | c, d | b |
(a) All controls subject to export licensing requirements are considered exports subject to a licensing requirement in accordance with Annex I of the EC Dual-Use Regulation (AL-No. 2D002)
(b) 4 + 4 gantry or auxiliary axes: limited to 4 interpolating axes for simultaneous path control, 8 axes in total.
All controls exempt from export licensing requirements are considered export versions, not covered by Annex I of the EC Dual-Use Regulation, or Part I of the Export Control List (Annex AL to the German Foreign Trade Regulations)
(c) for small and medium-sized PLC applications
(d) ultra-compact design complete with 24V supply
(e) for small to large-scale applications
(f) not intended for new installations
Extensive function libraries as well as the consistent use of standards for interfaces and programming make for flexible and lean engineering. The CNC offers a wide range of technology functions, from non-cylindrical grinding to flame cutting. CNC solutions from Eckelmann are used in a variety of applications such as turning, milling, drilling, grinding, bending, punching, sawing, etc. The extensive motion function library in accordance with PLCopen® is capable of controlling even sophisticated multi-axis systems with high demands in terms of synchronicity and precision, e.g. in printing machines or handling systems for solar wafers. And with CODESYS mechanical engineers may enjoy all the benefits of the object-oriented programming of PLC-applications in accordance with IEC 61131-3.
We offer solutions, not components! Therefore, our customers always have a direct connection to our application and development engineers who help them solve tricky tasks on the basis of extensive experience and modern development methods such as HiL simulations for special kinematics or complex path controllers. Due to customised adaptations, Eckelmann’s control technology can be adapted to almost any deployment scenario.
E°EXC 88 is a compact DIN rail controller that excels by the comprehensive instruction repertoire of the CNC core and the seamless integration of CNC and motion functionalities in controlling. 64 motion axes to PLCopen with extensive motion function library 32 CNC axes with comprehensive instruction repertoire Possibility of seamless combination of motion with CNC functions Extremely fast, robust and easy-to-wire real-time I/O system E°XBM Due to the seamless integration of CNC and motion functionalities to PLCopen, it is possible to operate additional handling axes next to the CNC and to select the optimal task-dependent technology, i.e. CNC or motion, or a combination of both. The CNC processing of a moving workpiece is also possible.
E°EXC 66
E°EXC 66 H43
E°EXC 66 Compact
| Prozessor | 32-Bit-Mikrocontroller |
| SPS | ✔ CODESYS V2 |
| CNC | ✔ |
| Motion | ✔ |
| Motion und CNC kombiniert | |
| CNC-Achsen | 16 |
| Motion-Achsen | 60 |
| CANopen® (Anzahl getrennte Busse) für Antriebe und dezentrale I/Os | 2 |
| EtherCAT® für Antriebe | ✔ |
| EtherCAT® für dezentrale I/Os | |
| sercos III für Antriebe | ✔ |
| sercos III für dezentrale I/Os | |
| Ethernet TCP/IP | ✔ |
| I/O lokal | LBM |
| I/O dezentral | CAN |
| RS-232 | 1 |
| USB | Host |
| SD-Karte | ✔ |
| Schutzart IP | 20 |
| Maße (B × H × T) in mm | 45 × 100 × 115 |
| Einsatzbereich Anmerkung |
The E°EXC 66 is the standard controller for CNC, PLC and motion control applications in the high-performance level. A RISC processor provides pooled computing power.
Integrated ethernet-based real-time communication between controllers, drives and I/O peripherals: the E°EXC 66 / H43 with sercos III interface provides modern communication solutions for all applications of industrial automation—open, manufacturer-independent and IEC-compliant.
The E°EXC 66 COMPACT is a space-saving controller, whose optimised scope of functions and interfaces offers a particularly favourable price-to-performance ratio. Its areas of application are small and medium-sized PLC applications. Compared to the full version, the compact controller has fewer interfaces and is only available as PLC. But in return it comes with its own power supply, providing also the expansion modules with power.
"I/O systems from Eckelmann—the quick, safe and application-oriented way of recording and transferring input and output signals: simple installation and wiring concepts that accelerate the development of your I/O infrastructure."
A robust and high-performance I/O system is the basis of any automation solution. Eckelmann offers versatile and highly practical I/O modules for the flexible development of centralised and decentralised I/O solutions that can be completely and seamlessly integrated into fieldbus networks via CAN and real-time Ethernet.
The protocols supported are CANopen TM as well as sercos and Profinet, both widely used in automation. All automation components—whether controls, servo drives, inputs and outputs, frequency converters, encoders, etc.—are precisely synchronised in real time with controls from Eckelmann and fieldbus.
The following modules are available for signal recording and communication on the I/O level:
"A wide range of drive controllers and motors provides the drive solution that perfectly fits each mechanical engineering requirement. The scalability of the solution ensures the appropriate dynamic performance and control quality as well as optimal energy efficiency. "
The components of the E°Darc range allow for the configuration of suitable drive systems with comprehensive functionalities and excellent drive performance, from simple transport tasks to complex applications. For 200 W up to 18 kW, the application-specific selection ensures suitably dimensioned solutions. This guarantees high economy in purchase and operation.
The newly developed servo controller E°Darc C (2 to 16 kW) transforms the potential of modern FPGA technology into tangible technical benefits for demanding mechanical engineers. It best displays its strengths where high levels of control quality and dynamic performance as well as absolute safety are required. Its RePower option ensures optimal energy yield. Due to the Open Motion Controller Platform (OMCP), algorithms developed by the customer can be easily integrated into the controller software.
The controller model E°Darc V provides the optimally tailored solution for the medium power range from 500 W up to 2 kW. This drive controller has a power feed of 230 V / 400 V and is suitable for AC drives. Via its CANopen® interface, it communicates with all controllers from the ExC range.
The controller model E°Darc M with a DC power feed of 10 to 60 V is available for low-power applications of 200 to 800 W. With its particularly small housing dimension, this compact drive controller for BLDC and DC motors is suited for DIN rail mounting. Also the E°Darc M model is equipped with CANopen® interface (device profile DSP402, protocol DS301), encoder interface, 1 analogue and 4 digital inputs and 1 digital output. It can be employed for PLC applications and is suited for motion control / path interpolation via CANopen®.
"Our software for your success: the engineering and programming tools from Eckelmann Group are ideally adapted to your machine automation."
We want to give your software development a sustainable and efficient design. Our engineering tools give you full control over your development costs and shorten time-to-market of your machine. Convince your customers with surprisingly simple solutions for innovative functions and the highest quality in engineering. Our state-of-the-art engineering tools support you in lean software engineering and reduce the costs for programming, testing and commissioning as well as the entire life-cycle maintenance of your application.
Our extensive software libraries include a large pool of functions which offer a wealth of application-specific experience. Whether you want to realise the contouring control for a CNC machine, a PLC or a demanding motion control—our reusable software modules are the ideal basis for the efficient programming for all of your applications.
"For more than 30 years, numerous machine manufacturers and operators from different fields of application have relied on the varied CNC competencies of Eckelmann and Ferrocontrol."
In the field of CNC applications, our solutions portfolio and applications experience are unparalleled. Take, for a start, the optimally integrated hardware components:
These components are capable of being configured to meet the needs of platforms for CNC complete solutions. Thus it is possible to support even the most sophisticated multi-channel CNC applications with up to 16 axes and cycle times of less than 1ms. In all this, the PLC functionality is already included. Solutions can be continuously improved through the development or upgrade of components.
The application-specific heart of CNC complete solutions is the CNC software library. Its functional scope has been significantly extended in the course of decades of experience. The library is the basis for an automation solution tailored to meet the technological and geometrical requirements of typical path-control applications:
Eckelmann has experience in numerous CNC applications from such areas, amongst others, as grinding, milling, handling, bar processing, shaping and many more.
As a current industry solution, Eckelmann offers the complete package "CNC for cutting". Both the relevant HMI package and the NC and PLC operating system provide many functions that are tailored to meet requirements typical for the cutting with different tools.
In addition, Ferrocontrol’s traditional key industry sectors include window installation and profile processing. Complex CNC applications whose productivity is optimally supported by image processing solutions from Eckelmann are realised here.
"PLC complete solutions from Eckelmann and Ferrocontrol have everything that complete machine controls need. And if necessary, they even grow along part of the way."
We have the PLC complete solution for all current machine control tasks ready for you. From the broad range of components, the appropriate platform for any PLC application including sophisticated time- and safety-critical tasks can be assembled.
The platform is turned into a complete solution by the PLC software package ELC based on the IEC 61131-3-compliant CODESYS standard, which efficiently supports the application development.
Solutions can be continuously improved through the development or upgrade of components.
PLC solutions are employed both as integral components of motion control and CNC applications and as stand-alone systems. There are numerous target sectors, from the packaging industry to intralogistics and medical engineering.
In all this, the PLC functionality properly speaking is open to further extension to include additional technologies from Eckelmann. This can be seen, for instance, in the intralogistics complete solutions for the transport and chaotic storage system of packages of various sizes. A suitable solution based on industrial image recognition has meanwhile been found for the PLC implemented in this project.
"Many machines require a coordinated motion sequence of several servo axes. Purely mechanical systems can be replaced with mechatronic solutions in a reliable, cost-efficient and flexible manner."
Eckelmann’s proven drive and control technology components are the platform for complete control solutions for motion control applications (of up to 64 axes
The motion sequences are programmed by Eckelmann’s function library, which is certified in accordance with PLCopen standard. And this is where the company’s many years of development experience in the control of coordinated axis motion is used for fast and safe new applications.
Solutions can be continuously improved through the development or upgrade of components.
As a result of many years of development work and practical experience, all components are optimally integrated. Their smooth interaction guarantees short project duration, custom functionality and a commissioning without delay.
Mechanical engineering customers employ motion control solutions from Eckelmann and Ferrocontrol in different areas such as
We are generating particularly sophisticated solutions for a long-standing customer from the job printing sector. The shaftless printing machine on the basis of ExC66 and the motion control software library is a real trendsetter in the printing industry.
"With the scalable safety products from Eckelmann and Ferrocontrol and security solutions fully integrated in the automation, mechanical engineers manage to combine safety, availability and productivity. Safe, efficient and comfortable!"
The range of safety products is perfectly tuned to Eckelmann’s and Ferrocontrol’s control and drive technology and makes for integrated security solutions that are seamlessly tailored to the automation technology, from programmable safety controllers with finished function blocks for the rapid development of a safety logic to high-performance and easy-to-configure drive-integrated safety functions, TÜV-certified up to SIL 3 (Safety Integrity Level in accordance with EN IEC 62061) or PL e (Performance Level according to EN ISO 13849-1).
Before their application in the plant, safety functions must demonstrate that the achieved safety level at least satisfies the specifications. A tool suitable for this purpose is the manufacturer-independent SISTEMA programme developed by the Institute for Occupational Safety IFA.
For the security modules from Eckelmann and Ferrocontrol, a library is available for download that can be opened in SISTEMA. It provides the performance indicators required for the proof.
The E°SLC safety module from Eckelmann can be used with little effort to monitor a variety of safety devices on machines and equipment; whether emergency stop switches, light barriers, laser scanners, two-hand operation, jog mode, door contacts or light curtains with muting function. The safety module makes the monitoring of individual sensors via safety relay obsolete. Thanks to the large number of predefined special function blocks, modern safety concepts can be easily implemented.
he safety functions can be quickly created on a PC using the E°Tools SLC graphical configurator. A safety logic system can be developed from available function blocks via drag & drop, simulation and commissioning can be implemented with the same development tool. The configuration data are easily transferred via USB.
The E°SLC safety module has 20 safe inputs and 4 safe outputs; using safe expansion I/O modules, it can, where necessary, be expanded up to 100 inputs and 44 outputs (up to 8 safe inputs and 4 safe outputs per module, 4 ports can be switched as inputs or outputs, i.e. the module has either 8 inputs and 0 outputs or 4 inputs and 4 outputs).
Via CAN fieldbus coupler (CANopen™), the complete process image and the internal states of the safety module are comfortably transmitted to the superior control and operating level (maximum of 92, optionally pre-processed signals). The result is well-integrated and user-friendly security solutions with advanced diagnostic functions.
The E°Darc SCM safety controller module makes it easier for mechanical engineers to implement modern drive-side safety concepts. For this purpose, they can rely on a wide range of certified security functions, e. g. STO (Safe Torque Off), SLP (Safely-Limited Position) or SLS (Safely-Limited Speed) (see graph).
All Eckelmann components are closely integrated to work together: the application on the non-safe PLC controls the drive controllers via field buses such as CAN or sercos. Safety features requested by a safe sensor or operating mode selector are handled by the safe control of the E°Darc SCM or an additional E°SLC safety module which, via bus coupler, transmits the change to a different operating mode to the non-safe PLC, and simultaneously activates safety functions in the E°Darc safety controller module. The E°Darc SCM monitors the parameterised limits of the safety features active and performs the parameterised safety responses, if necessary.
The wide variety of safety features make for a differentiated system responsiveness. While, in the event of an error, conventional solutions only offer STO, i. e. uncontrolled coasting to a stop, the E°Darc SCM also allows for operating the system at a reduced speed and, thus, for the continued production or the controlled shutdown of an axis. This is important for all axes that need to support load torque at standstill, such as hanging axes.
The E°Darc C drive control system is equipped with a safe standstill monitor that evaluates the encoder signals of high-frequency spindles. The system is designed to meet safety integrity level 2 (EN 62061) or performance level d (DIN EN ISO 13849-1). Engines with a speed of up to 40,000 rpm can be monitored via plug-in modules that are integrated in the controller. The motor standstill is displayed via safe module outputs. Compared to external solutions this saves cost as well as space in the switch cabinet. The standstill monitor is integrated in the safety technology of the machine which actuates, for example, the door locking device.
Via CAN fieldbus coupler (CANopen™), the complete process image and the internal states of the safety module are comfortably transmitted to the superior control and operating level (maximum of 92, optionally pre-processed signals). The result is well-integrated and user-friendly security solutions with advanced diagnostic functions.
"Eckelmann and Ferrocontrol support customers from various fields of mechanical engineering. A thorough understanding of customers’ technology and the application-tailored selection of standard components guarantee sector-specific automation solutions."
In all major fields of automation technology, Eckelmann and Ferrocontrol cultivate a know-how which is perfectly up to date. However, there is another decisive factor for the quality of a complete solution – namely, that our developers fully acquaint themselves with the respective customer’s technology. In the course of many projects, they have thus acquired solid applications expertise in many sectors.
The combination of these two competencies allows taking a decision on a control design that is geared to the customer and end user. Part of this decision is the competent judgement on the scope of industry standards and on the options of application-specific adjustments. Reusable sector-specific technology is employed in the form of application packages and software libraries.
Eckelmann AG and its subsidiary Ferrocontrol Steuerungssysteme GmbH have thorough applications expertise in the following sectors: