KEBA KeControl series controllers

KEBA KeControl: Modular High Performance Control System for Industry 4.0

In today's rapidly evolving industrial automation towards intelligence and flexibility, the performance, openness, and scalability of control systems have become the key factors determining equipment competitiveness. As an innovative leader in the global industrial automation field, KEBA's KeControl series controllers provide machine manufacturers with a high-performance and high degree of freedom control system solution with a full range of coverage from economical to high-end, EtherCAT based hard real-time communication architecture, unified Linux software platform (FlexCore), and ultimate modular design concept.

KeControl Product Family Overview: Accurately Matching Application Needs from Standard to High End

The KEBA KeControl series is not a single product, but a highly scalable control family designed to meet the automation needs of different industries and complexities

KeControl C5 series: a paradigm of modularity and distributed control

Positioning: High performance compact controller designed specifically for modular or distributed architecture machines.

Core features:

Extremely compact: Compared to traditional solutions, it saves up to 69% of control cabinet space, making it an ideal choice for space sensitive applications.

Bidirectional expansion: The right side is directly connected to the KeConnect C5 I/O module through the EtherCAT module bus; On the left side, function expansion cards (such as additional EtherCAT master cards, multi protocol fieldbus cards, etc.) are plugged in through the Card Edge connector.

Performance Rating: Provides multiple CPU models ranging from CP 50x (compact) to CP 5x0 (high-performance). The CP 50x series is based on Intel Atom processors (single core to quad core) and integrates standard interfaces such as CAN and serial ports, making it suitable for cost optimized solutions. The CP 5x0 series (such as the CP 530/C with Intel Core i7 processor) provides top-notch computing performance, suitable for high-end tasks such as machine vision and complex computing.

Integrated visualization: The multi-core CPU architecture supports the execution of modern visualization interfaces (such as KEBA KeView) without interference while running control tasks, and can be used in conjunction with economical passive panels.

KeControl C1 Series: Highly Integrated Central Control Expert

Positioning: Optimize for machines with a large number of I/O points and high concentration, such as injection molding machines, die-casting machines, extruders, etc.

Core features:

On board integrated I/O: directly providing a large number of digital/analog input/output, proportional valve drive, and temperature sensor interfaces, achieving highly integrated control of a single machine.

Specialized control algorithm: innovatively integrates proprietary technologies such as Fast Cut Off Reaction, Fast Reaction Control, and Fast Closed Loop Control. Taking the injection molding machine as an example, with an injection speed of 500 mm/s and a control cycle of 1ms, Fast Cut Off Reaction can achieve a switching point accuracy of 32 microns, significantly improving process quality and reducing scrap rates.

Flat design: Optimize the spatial layout of the control cabinet.

KeDrive D3 Series: Integrated Drive and Control Integration

Positioning: An all-in-one solution integrating PLC, motion control, robot control, and safety control, compatible with KeDrive D3 drive technology in appearance.

Core features:

Highly integrated: the controller, driver and (optional) safety controller are integrated into a single module, saving 76% of the control cabinet space compared with the traditional single axis control scheme.

Powerful and scalable performance: CPUs ranging from Intel Atom to Celeron are available, supporting low-cost operation of driver control, visualization, closed-loop control, and standardized PLC programs on the same controller.

Built in safety control (D3-DU 3x5 series): integrates safety controllers that comply with CAT 4, PL e (EN ISO 13849-1), and SIL 3 (EN 62061/61508) standards, including safety I/O. Especially suitable for robot applications, in addition to secure fieldbus communication, it also provides single axis secure motion monitoring and synchronized secure space monitoring (TCP, tool center point).

Core technological advantage: Defining the future of high-performance control

Revolutionary real-time communication: EtherCAT hard master station and fast response control

One of KeControl's core competencies is its EtherCAT master station based on FPGA hardware implementation. This design brings advantages that traditional software main stations cannot compare to:

Ultimate Cycle and Certainty: Supports a cycle time of 62.5 microseconds, data transmission jitter is controlled within 100 nanoseconds, EtherCAT data bandwidth utilization exceeds 95%, while reducing CPU base load by up to 20%.

Unique Fast Reaction Control: This feature can reduce dead time in the control loop by up to 66%. Practical application has shown that it can shorten the system stability time by 46% and reduce overshoot by 6 times, thereby Dramatically (significantly) improving dynamic control performance, especially for fast response applications such as hydraulic and servo presses.

Unified software foundation: Linux based FlexCore platform

Regardless of which hardware from the KeControl family is chosen, users develop based on the unified FlexCore software platform. This brings huge engineering advantages:

Platform consistency: Application code can be ported between controllers of different performance levels, protecting software investments and simplifying upgrade paths.

Openness: Based on Linux's open-source nature, it facilitates the integration of customer owned or third-party software components, libraries, and algorithms.

Powerful ecosystem: Supports OPC UA, advanced language programming, etc., laying the foundation for building Industry 4.0 and IoT solutions.

Ultimate modular and open design

KeControl， Especially for the C5 series, the modular concept is fully implemented:

Hardware customization: The interface board provides a variety of standard interfaces that can be customized; Customers can choose to customize KEBA technology cards or develop specialized function cards based on the external dimensions of the expansion card and integrate them.

Flexible network expansion: EtherCAT master interface can be added through FE 571/573 expansion card (supporting RJ45 or M8 connectors); The FE 560 multi protocol card supports EtherCAT slave, EtherNet/IP adapter, or PROFINET IO Device roles, making it easy to access higher-level networks of different brands.

Intelligent service concept: firmware, application, and process data are stored on replaceable storage media (CFast/MicroSD cards). The built-in service display screen (from 7-segment digital tube to LCD display screen) supports tool free backup, software deployment, and after-sales diagnosis, greatly improving operation and maintenance efficiency.

Expanding ecosystems and selection considerations

KeControl does not exist in isolation, it seamlessly integrates with KEBA's complete automation ecosystem:

Seamless integration with KeConnect C5 I/O system: Through the right module bus, high-density and high-precision distributed I/O stations can be built, achieving ultimate expansion of control and acquisition.

Rich accessory support: including power/signal connectors, Mini I/O communication cables, Ethernet/EtherCAT cables, storage cards of different capacities, etc., ensuring system integrity and usability.

Flexible licensing system: Provides runtime licenses for different functional levels from Basic, Realtime, PLC to Motion, Robotics, CNC, as well as workstation licenses required for engineering configuration. Users can purchase them on demand to optimize costs.

Selection Guide:

Pursuing ultimate compactness, distributed architecture, and high-performance real-time control: KeControl C5 series is preferred, and CP 50x or CP 5x0 can be selected according to computing needs.

Traditional large-scale equipment, centralized control with high I/O points, and pursuit of specific process optimization (such as injection molding): The KeControl C1 series is the best choice.

Extremely limited space, requiring highly integrated servo drive and safety control (such as robots, multi axis precision equipment): The integrated design of the KeDrive D3 series provides unparalleled integration and space saving advantages.

Application prospects and industry value

The KeControl series is widely used in fields that require high control performance, space efficiency, and intelligence due to its outstanding performance, flexible architecture, and open ecosystem

Plastic machinery: precision injection molding and pressure control of injection molding machines; The multi temperature zone of the extruder is synchronized with the traction.

Packaging and assembly: Collaborative motion and visual guidance of high-speed labeling, filling, and picking robots.

Metal forming: fast and high-precision position and pressure control for stamping and die-casting machines.

Robots: Joint control, path planning, and safety monitoring for collaborative or industrial robots.

Testing and measuring equipment: complex systems that require highly synchronized data acquisition and real-time processing.