Beckhoff Introduces XTS EcoLine Motor Module for More Cost-Effective Intelligent Transport

Beckhoff Automation has launched the XTS EcoLine motor module, a new addition to its intelligent transport system lineup designed to make the technology more accessible for cost-sensitive applications. The design changes made to develop the EcoLine version delivers 95% of the performance of standard XTS motor modules while reducing costs by around 45% for equivalent track lengths, according to Beckhoff.

The XTS EcoLine motor module is compatible with existing XTS components, opening the door for industries such as assembly, battery manufacturing, packaging, pharmaceuticals and lab automation to adopt the transport technology at a lower price point.

The most immediately noticeable difference is the module's 500 mm length, which is double that of standard straight XTS motor modules. The modules maintain the same grid dimensions. In this extended format, the EcoLine offers travel speeds in line with its standard XTS technology, with speeds up to 4 m/s and acceleration up to 10 g.

Technical specifications for the EcoLine include 0.70 mm absolute accuracy with 0.075 mm repeatability, 70/80 mm minimum product distance, and force capabilities of up to 30/45 N nominal (80/105 N peak) per mover with 5/7 pole magnets.

Strategic engineering for cost reduction

According to Jeff Johnson, mechatronics product manager at Beckhoff Automation, the cost savings with EcoLine result from targeted engineering decisions that preserved core performance capabilities.

"We wanted to maintain as much of the performance from a speed and force standpoint for this lower cost solution," Johnson explained. "So what we've done with the EcoLine motor module is we took the motor module and, to maintain the force and other capabilities, we kept the coils and electronics the same, but we changed the feedback."

A primary modification involved switching to lower-resolution feedback systems. While standard XTS modules achieve up to 10 micrometer repeatability, the EcoLine delivers approximately 70 micrometer repeatability. Mover-to-mover distance increased from 60 mm to 70 mm pitch. 

The extended module length also contributed to cost efficiency. "We made the track sections 500 millimeters long instead of 250 millimeters long," Johnson noted. "So the combination of the new feedback and making a longer module, we're producing one part versus two parts needed just one big circuit board versus two circuit boards."

Flexible motor module integration options

The EcoLine's compatibility with existing XTS components provides significant design flexibility, according to Beckhoff. Johnson explained that users can strategically combine module types based on application requirements.

"You can mix and match EcoLine modules with our standard XTS motor modules," Johnson said. "From a motor module standpoint, this reduces the costs by about 45% of the cost of two standard motor modules. When this is incorporated into a machine design, mixing and matching components enables about a 30% cost reduction."

For applications where extreme precision isn't required throughout the entire transport path, the cost benefits are particularly notable. "In a lot of cases, there might be some machines where you just use EcoLine for all the straight track sections, because you don't need the high precision everywhere," Johnson noted.

He added that the EcoLine motor module's compatibility extends beyond standard XTS components. “You can even mix and match them with NCT modules," Johnson said. "So it gives users three different versions of modules. You can mix and match them in the same system using the same programming, same software, same movers."

• MTNA Transforms Legacy Manufacturing Ops with Smart Machine Monitoring 
• From Lab to Factory Floor: Actuator Innovations Driving Next-Gen Automation 
• Motion Control Technology Trends Transforming Packaging Equipment