What issue did the customer face?
A customer needed an EtherCAT P analog module for a moving machine part in a plastic injection mloding handling system. The desired combination of 16 analog inputs, a compact design, and the required connectivity options could not be provided by the standard I/O solutions available on the market, consisting of a head station and individual I/O modules.
Another key requirement was to supply power to the connected sensors driectly via an EtherCAT P (EtherCAT + Power) cable, so that no separate power supply is needed for the connected sensors. This requirement places special demands on hardware design and is only supported by a few vendors. The customer therefore needed a module that was precisely tailored to the requirements of his machine.
What does the solution look like?
esd electronics developed a customer-specific EtherCAT P SubDevice with 16 analog inputs, individually adapted to the required dimensions, interfaces, and connectors. Measuring just 94 × 62 × 25 mm, the module has a very compact design and can be integrated into the customer's moving machine section.
A key feature is the complete integration of communication and power supply via EtherCAT P. The module itself, as well as the connected sensors, can therefore be supplied directly through the EtherCAT connection. Two M8 connectors are used for the EtherCAT P connection, while the 16 analog inputs are connected via a pluggable terminal block. The hardware was designed specifically to integrate seamlessly into the customer's existing machine architecture.
In addition to the hardware, esd electronics developed the associated software/firmware and ESI file. The ESI file provides the device to be uniquely identified, configured, and used in the customer's engineering environment within the EtherCAT controller. The device is supplied with an esd electronics Vendor ID.
How does this solution benefit the customer?
The customized design ensures that the module's functions, interfaces, and connections are tailored precisely to the machine's requirements. This eliminates unnecessary components and reduces the space required within the machine.
The EtherCAT P interface also significantly reduces wiring effort. Data communication and power supply are handled through a common cable, simplifying installation and reducing the overall system complexity. The connected sensors can be powered directly through the EtherCAT P network, eliminating the need for an additional sensor power supply.
Another major benefit is the reduced integration effort for the customer. esd electronics provides the complete solution – from hardware development and software/firmware to the ESI file, EtherCAT integration, and conformance testing. The result is a compact, customer-specific EtherCAT P SubDevice with 16 analog inputs, fully adapted to the machine's requirements and delivered with a suitable device description and tested EtherCAT integration.
