The trend towards modularization in mechanical and plant engineering is closely linked to changes in production. Smaller batch sizes, individualized products and shorter development cycles require machines that can be adapted quickly.

To this end, functions are divided into mechanical and logical modules - each of which is designed, manufactured and maintained independently. This creates flexible modular systems that shorten time-to-market and facilitate maintenance and modernization. The prerequisite is a clear decoupling of power supply, control and drive technology. Real-time capable fieldbus systems connect the modules, while scalable drive systems ensure efficient energy flow and high precision.

Architecture variants in drive technology

In classic machine concepts, all control and drive components are combined in a central control cabinet. This makes servicing and diagnostics easier, but requires more space and cooling capacity. Multi-axis systems such as KeDrive D3, which supplies several axes via a shared DC bus, are suitable for such architectures. This topology allows energy to be exchanged between axes and regenerative energy to be buffered or fed back into the grid - a plus for efficiency and resource conservation.

The most consistent form of modular architecture completely dispenses with central control cabinets. Here, the control and power electronics are integrated directly in the module or on the motor - compact, protected (e.g. IP54) and space-saving. Due to thermal limits, the outputs are usually designed for smaller axes. Power is increasingly supplied via DC networks, often in the form of daisy-chain cabling, which combines power and communication in one cable.

Open DC systems are becoming increasingly important here. In the DC industry research project, a concept was created with which products from different manufacturers can be connected to a common DC bus. Keba has implemented connection and protection concepts in the KeDrive D3 system so that external drives can be seamlessly integrated. The following examples show how different machine architectures can be covered with a uniform platform - from central control cabinets to decentralized modules:

• In a labeling machine, KeDrive D3 takes over the synchronous operation of several axes
• In a sheet metal processing system, each module is operated with its own KeDrive D3 or D3-AC
• In assembly cells, KeDrive D5 drives provide compact, quickly scalable solutions
• Mobile transport systems use KeDrive D5 Micro, powered by battery voltage

Decision criteria for the right architecture

Platform strategy:

A standardized platform approach with consistent interfaces, identical safety functions (e.g. STO and SafeMotion) and standardized diagnostic software reduces engineering costs and simplifies maintenance and spare parts management.

Energy efficiency and sustainability:

A shared DC bus enables energy recovery, intermediate storage and peak load limitation - crucial for high efficiency and sustainability. In decentralized or mobile applications in particular, this ensures lower grid loads and higher system availability.

Security:

Safe movement monitoring, emergency stop functions and integration into safety control systems are mandatory. Modern systems offer all essential safety functions already integrated.

The KeDrive D3-AC all-in-one drive. © Keba

The large number of technical parameters makes the selection process complex. Software tools such as the KeDrive configurator support the correct combination of controllers, motors and accessories - including compatibility checks and automatic documentation.

The requirements of modern production systems make modular machine architectures indispensable. Choosing the right drive system is the key. It determines energy efficiency, scalability and cost-effectiveness. Whether centralized, decentralized or cabinet-free - the decisive factor is the ability to implement all variants on a common platform.

With solutions such as KeDrive D3, D3-AC and D5, Keba offers a scalable portfolio that enables machine builders to make their automation future-proof, efficient and modular. The future belongs to open DC systems that allow cross-manufacturer integration. This is the next step towards flexible, sustainable and intelligent machine automation.

SPS, Hall 7, Stand 470