Beckhoff presented its MX system at a major trade fair for the first time at Hannover Messe 2022. What has happened since then?

The MX system was launched at a time when development had not yet been completed. We see the MX system as a revolution for the market. By publishing it, we wanted to show the potential of replacing the control cabinet with our pluggable modular automation system at an early stage. We achieved precisely this effect by exhibiting at the Hannover Messe 2022, among other things: customers and interested parties from various industries approached us with a request to test its use in certain applications. In that one year, we converted the control cabinets, including the electrical installation, of more than 60 machines and systems to MX systems. Some of these were very small machines with just one three-phase motor, but there were also systems with over 60 servo axes. We have learned a lot about the MX system and identified where there are still gaps to be closed. However, the general feedback is that customers are convinced by the idea of the MX system and would like to use it sooner rather than later.

A lot has also happened with the MX system itself. The development of many modules has been completed to such an extent that we can switch to the customer test phase. We currently still need a few more modules for this. The test phase is expected to begin this summer.

From connection to control technology, there are modules for all areas. What role does the software play in the MX system?

The most important "ingredient" for the MX system is EtherCat. The protocol makes it possible to use just one fieldbus via the backplane to control and synchronize a wide range of functions such as reading and writing inputs and outputs, very large networks with a large number of axes and to map functional safety. In addition, unlike a "normal" control cabinet, the MX system consists exclusively of (EtherCat) networked modules. These are processed by software in the MX system modules and can be further processed or evaluated in the central controller - in our case TwinCAT.

We also use EtherCat to connect our smartphone diagnostics app, which we are currently developing. Of course, EtherCat cannot be connected directly to a smartphone, so we have developed an EtherCat Bluetooth gateway. This allows our customers to very easily define access points for the smartphone or the app via EtherCat at various points and without further cabling of machines and systems. We are also working on software that will be used to configure and plan the MX system. It will then also be possible to implement the simple assembly of the MX system in the software using drag-and-drop. This will simplify the planning phase of machines and systems.

The question of the role of software can be summarized as follows: The development of the MX system is a textbook mechatronic project. One third of the work involved relates to mechanics, the second third to electronics and one third to software. The software therefore plays one of the main roles.

In addition to standard modules, there are also modules that users can use to implement their own functions. How exactly does this work?

We already presented a baseplate extension box last year. This is basically a terminal box that is connected to the right-hand side of the baseplate. The 24 VDC and 400 VDC voltages from the baseplate are then available inside the terminal box, whereby the 24 VDC is already fused. EtherCat can also be found on a standard RJ45 plug as well as four digital inputs/outputs. This terminal box can be used in particular to accommodate customer-specific electronic assemblies or IP assemblies for special actuators or sensors, for example.

This year, we will be introducing the same functionality in the form of a plug-on module. There will then be less installation space available. However, this type of empty housing is very suitable for integrating a VPN router into the MX system, for example. We also offer modules that can be used to connect special user functions or devices from other manufacturers to the MX system. These modules offer various combinations of voltages and EtherCat via standardized hybrid connectors. For example, there is an output with 400 VAC, 24 VDC and EtherCat, which can be used to control a geared motor with an integrated frequency converter. We and our customers hope that there will be a general trend towards equipping a wide range of devices with hybrid connectors. Regardless of the MX system, a single-cable solution for connecting devices is always an advantage.

How does Beckhoff support the implementation?

For modules in which external devices are installed by the customer, only the documentation describing the mechanical and electrical interface is required. Should the need for even more specialized solutions arise, we will look into this and offer appropriate solutions. Both the MX system and Beckhoff as a company have this flexibility. What we are happy to advise on is the use of hybrid connectors or EtherCAT P technology for other field devices. Our colleagues from the EtherCat Technology Group (ETG) are also available for EtherCAT P implementation.

What's next for the MX system?

A number of customer applications are being planned for the second half of the year. The more than 100 modules and baseplates that we have already announced as products will be available in series production in the course of the coming year. At the same time, we are developing further functions, some of which will be new for Beckhoff, but also for the market in this form. To ensure that these - in our view - special features do not get lost in the mass of modules, we have decided to present them for the first time in the context of major trade fairs. For example, at Interpak and also at Automatica, the corresponding innovations will be on display. The size 3 modules are a large package: we announced these right from the start, but initially focused on the size 1 and 2 modules. For power supplies up to 125 A or servo axis modules >25 A, we need a little more installation space, which size 3 provides. In addition, we still have ideas for further modules and functions for all sizes. It is therefore unlikely that the MX system will become boring in the coming years.