We chose EtherCAT as control network for the Sysmac NJ Machine Controller series. The convenience of standard Ethernet cabling combined with extremely fast on-the-fly data exchange have resulted in a new machine control architecture. The resulting openness, modularity and determinism are the key elements in today's machine automation.

• Using open standards for programming and networking assure exchangeability and interoperability with external systems
• Modularity allows flexibility in system configurations for fast adaptation to end-user requirements
• Determinism is needed to keep control of the machine while increasing performance and accuracy

EtherNet/IP uses the CIP protocol over standard Ethernet infrastructure to offer efficient yet reliable data exchange. Using the EtherNet/IP bus coupler, NX-series I/O - including safety control - can be connected to CJ/CS-series PLC's.

ProfiNet bus coupler expands NX I/O platform capabilities enabling a wider range of possible architectures.

For the design of the NX-series, we used our experience in distributed I/O systems combined with customer feedback.

• The units are compact, with a standard width of 12 mm per unit, yet offer up to 16 channels per unit
• The front connectors feature toolless push-in wiring with 8 mm ferrules for wire up to 1.5 mm2
• The terminals are removable to allow pre-wiring and safe step-by-step testing
• Matching labels on unit and connector reduce the chance of incorrect assembly
• You can insert 6 keys in the terminal and the unit to mechanically prevent a mismatch

The NX-series let you mix economical standard I/O's with high-speed synchronous models. The standard digital I/O's have 16 connections per unit, with a choice of:

• 3-wire sensor connection with power supply (4-channel units)
• 2-wire contact inputs or actuator outputs (8-channel-units)
• 1-wire connection for sensors and actuators already connected to a common power supply (16-channel units)

High-speed I/O's all use 3-wire connection, and have On/Off response times of less than 300 ns. Using the EtherCAT Distributed Clock, all inputs can be latched, and outputs can be controlled synchronously, with less than 1 µs jitter.

For even more control over the exact I/O timing, time-stamp inputs will tell you the exact time of each signal transition. Similarly, time-stamp outputs anywhere in the EtherCAT network can be independently controlled with sub-microsecond accuracy.

Input signals from analog sensors, 4-20 mA transmitters, thermocouples or resistance thermometers can easily be connected and used for monitoring, data logging, trending or PID control. Analog units are offered with sampling times down to 10 µs per channel and high resolution (1:30,000). Built-in filtering, offset correction, broken wire- and overrange detection are all standard functions. The user can select from 12 different thermocouple characteristics, °C/°F and indication resolution down to 0.01 degree. With up to eight inputs in just 12 mm width, the NX-series are among the most compact modules on the market today.

The High-speed Analog Input Unit allows an up to 5µs sampling rate on analog signals. The fast measuring of analog signals enables an improved quality inspection or a vibration analysis for predictive maintenance. Machine’s Quality and Availability can be improved resulting then in a better OEE (Overall Equipment Effectiveness) rate. This unit can read up to 4 different signals at the same time by keeping the 5µs even if the 4 channels are used. The isolation between channels prevents from distortion between channels.

Various types of encoder signals can be connected, from incremental to Synchronous Serial (SSI) encoders. The ability to synchronize the position data with the EtherCAT Distributed Clock means that the encoder can be used as a motion axis for gearing or following. Pulse outputs up to 500 kHz can be used for discrete control or positioning and can also be mapped as a motion axes when used with the Sysmac NJ machine controller.

IO-Link makes communication down to the sensor level visible

• Machine downtime can be reduced.
• Abnormality detection for shortest recovery.
• Condition monitoring for predictive maintenance.
• Individual identification for reduction of man hours.
• NX I/O Series Master unit with screw-less terminal block or GX Series with IP67 protection class for watery and dusty environments.
• Up to 4 sensors can be connected with one NX I/O Series IO-Link master unit.
• Photoelectric and Proximity sensors available.

Safety control units and safe in- and output units can be added to any NX-series EtherCAT I/O stations, to fully integrate safety and standard control in one network. The NX-series fulfills all safety Performance Levels from PL a to PL e. Since the standard NJ-series controllers (V1.06 and up) and NX-series bus couplers (V1.1 and up) can be used, standard control and safety can be scaled independently. 

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Optimize Control by Detecting Status Changes Easily Satisfy Both Productivity and Quality

• Adaptive control for self-optimization of control setting due to process changes
• Specialized function for better sealing application (packaging) and for water-cooled extruders (plastic)
• Easier integration thanks to ProfiNet, Ethernet-IP and EtherCAT Fieldbus support