KEBA KeControl C1 CP 03x: Highly Integrated Embedded Industrial Controller

KEBA KeControl C1 CP 03x: an embedded controller designed for high-density I/O and precision processes

In the field of industrial automation, especially in large-scale equipment such as injection molding, die-casting, extrusion, etc., controllers not only require powerful computing cores, but also must directly face hundreds or thousands of sensors and actuators, and complete closed-loop adjustment under strict real-time requirements. The CP 031/Z, CP 033/Y, and CP 033/Z CPU modules in the KEBA KeControl C1 series are tailor-made embedded controllers for such scenarios. They are based on Motorola PowerPC processors, equipped with VxWorks real-time operating system, and integrate massive digital I/O, high-precision analog channels, dedicated temperature measurement interfaces, and multiple industrial bus interfaces on the same hardware platform, achieving a highly integrated control solution of "one machine, one cabinet".

Product positioning: The central brain of K2-200 module system

The CP 03x series module belongs to KEBA's mature K2-200 modular control system. As a central processing unit, it works in conjunction with various I/O expansion modules through a backplane bus, and carries an extremely rich on-board I/O, enabling many small and medium-sized applications to complete all control tasks without any expansion. This design significantly reduces system complexity and control cabinet volume, as well as reducing the risk of contact failures.

This series includes three models:

CP 031/Z: Basic type, balancing I/O quantity and cost;

CP 033/Y: Enhanced I/O configuration;

CP 033/Z: The highest specification, providing the most I/O channels and higher power supply.

The three modules maintain the same processor performance and software compatibility, allowing users to flexibly select based on the number of machine I/O points and achieve precise cost control.

Core hardware architecture: mature, reliable, and high-performance

1. Processor and Memory

The CP 03x series uses Motorola PowerPC 400MHz processors, which reflects KEBA's pursuit of long-term supply stability and industrial grade real-time performance. The PowerPC architecture has excellent interrupt response characteristics and low power performance in the embedded field, coupled with 128 MB SDRAM system memory, capable of handling complex PLC logic, motion control algorithms, and multitasking scheduling. The module is equipped with an additional 512 kB battery buffer SRAM to maintain critical process parameters and counter values during power outages, without the need to reset to zero every time the device is turned on.

2. Real time operating system

Unlike the Linux FlexCore platform commonly used in KEBA high-end controllers, the CP 03x series uses the VxWorks real-time operating system. VxWorks is known for its hard real-time deterministic scheduling and extremely small kernel footprint, and has unique advantages in microsecond level interrupt response, which is very suitable for the demand of microsecond level fast cutting response in the injection molding process of injection molding machines.

3. Program and Data Storage

Firmware, application programs, and recipe data are stored in Compact Flash Type I cards. CF cards have excellent seismic resistance and industrial temperature adaptability, are easy to replace, and support quick on-site maintenance without software. Users can download and debug projects through Ethernet or USB interfaces.

4. Diagnosis and operation interface

The front of the module is equipped with a 7-segment digital diagnostic display screen, status LED indicator lights, and mode selection switch. During the startup process, the 7-segment screen displays self-test codes and error codes; During normal operation, it can be configured to display CPU load, cycle time, or custom status values. This design allows operators to determine the health status of the controller without the need for a computer, greatly improving on-site troubleshooting efficiency.

On board I/O: a versatile interface optimized by the industry

The most prominent feature of the CP 03x series is its industry-specific I/O board, which highly integrates traditional I/O channels that require multiple expansion modules to accommodate, especially optimized for commonly used signal types in plastic machinery and die-casting equipment.

1. Digital Input (DI)

Number of channels: CP 031/Z and CP 033/Y provide 32 channels; CP 033/Z provides 48 routes.

Electrical characteristics: Complies with EN 61131-2 Type 1 standard, input voltage "1" is 15~30V, and "0" is -3~5V.

Special function: The first two inputs (DI/PIO, DI/VII) are designed as speed measurement inputs and can receive frequency signals from 0.5Hz to 100Hz. It has a built-in 16 bit counter and is directly used to monitor the position of hydraulic valve cores, shaft speed, or flow meter pulses.

Update cycle: Minimum 1ms, meeting general switch quantity acquisition requirements.

2. Digital output (DO)

Number of channels: CP 031/Z provides 40 channels; CP 033/Y and CP 033/Z provide 56 channels.

Drive capability: rated voltage 24V DC, single channel rated current 2A, simultaneous rate of 50% per group. This means that in typical applications, medium-sized solenoid valves and contactor coils can be directly driven without the need for additional intermediate relays.