mm-apr-hardware
SKILL.md
APR Hardware Configuration Guide
Version: APR-2026.01 | TwinCAT: 3.1 Build 4024.65
Hardware architecture for the HIWIN LMSA13L dual-axis linear motor test station.
Overview
This skill covers the complete hardware configuration for the APR dual-axis linear motor system, including the Beckhoff C6030 IPC, EK1100 coupler, HIWIN E1 drives, and all peripheral devices.
System Specifications
| Component | Model | Specification |
|---|---|---|
| IPC | Beckhoff C6030-0060 | TwinCAT 3.1 Build 4024.65 |
| Linear Motor | HIWIN LMSA13L | 4200mm (14×300mm segments) |
| Servo Drive | HIWIN E1 (ED1x-xx-75) | 380VAC 3-phase, CoE/CiA-402 |
| EtherCAT Coupler | Beckhoff EK1100 | 100BASE-TX |
| Safety Light Curtain | Keyence GL-VM72HP | 1440mm protection height |
| IO-Link Master | Keyence NQ-EC8L | 8-port EtherCAT |
System Architecture (ASCII Blueprint)
=====================================================================
C6030 Controller (IPC / EtherCAT Master)
=====================================================================
+------------------------------------------------+
| IPC C6030 |
| Port X1 → Management Network |
| Port X2 → EtherCAT Master |
+------------------------------------------------+
|
| EtherCAT (100BASE-TX, CAT6, <50m)
v
=====================================================================
EK1100 + Beckhoff Terminal Rack
=====================================================================
+---------------------------------------------------------------+
| EK1100 EtherCAT Coupler (Term 1) |
|---------------------------------------------------------------|
| SLOT1: EL1008 8DI 24V |
| SLOT2: EL2004 4DO 24V / 0.5A |
| SLOT3: EL6900 TwinSAFE Logic |
| SLOT4: EL1904 TwinSAFE DI (E-STOP / Guard Door) |
| SLOT5: EL2904 TwinSAFE DO (STO / Contactor / Brake) |
| SLOT6: EL9011 End Terminal |
+---------------------------------------------------------------+
|
v
=====================================================================
HIWIN E1 Servo Drives (Axis A & B)
=====================================================================
+==================================================+
| E1 Drive (Axis A) |
+==================================================+
| EtherCAT IN ←─── from EK1100 |
| EtherCAT OUT ───→ to Axis B |
| Power: 3Ø 380VAC |
| STO1/STO2 ←── EL2904 (TwinSAFE DO) |
| Motor: U/V/W → LMSA13L |
| Feedback: Hall A/B/C + TS1/TS2 |
+--------------------------------------------------+
|
v
+==================================================+
| E1 Drive (Axis B) |
+==================================================+
| EtherCAT IN ←─── Axis A OUT |
| EtherCAT OUT ───→ Keyence NQ-EC8L |
+--------------------------------------------------+
|
v
+==================================================+
| Keyence NQ-EC8L (IO-Link Master) |
+==================================================+
| Port 1-8: IO-Link / DI / DO |
+--------------------------------------------------+
Linear Motor Physical Layout
=================================================================
LMSA13L Linear Motor (4.2m = 14 × 300mm segments)
=================================================================
+------------------------------------------------------+
| Stator Segments: S1 ~ S14 (each 300mm) |
| Mover: Hall sensors (A/B/C) + Temperature (TS1/TS2) |
| |
| TS: 2-wire → E1 Drive TS1/TS2 |
| Hall: A/B/C/5V/GND → E1 Drive Hall Port |
| Power: U/V/W → E1 Drive 3-Phase |
+------------------------------------------------------+
Travel: 4200mm max
Speed: 9.7 m/s max
Acceleration: ≥29.4 m/s² (for 1m constant velocity zone)
EtherCAT Topology
C6030 (Master)
│
└── EK1100 (Coupler)
│
├── EL1008 (8DI)
├── EL2004 (4DO)
├── EL6900 (TwinSAFE Logic)
├── EL1904 (Safety DI)
├── EL2904 (Safety DO)
└── EL9011 (End Terminal)
│
└── E1 Drive Axis A
│
└── E1 Drive Axis B
│
└── NQ-EC8L (IO-Link Master)
Resistor Configuration (Per Axis)
Regenerative Resistors (BR+/BR-)
- Quantity: 3× parallel
- Requirement: < 417.3Ω (per LMSA13L report)
- Connection: E1 Drive BR+ / BR-
Brake Resistors (Dynamic)
- Quantity: 3× parallel
- Purpose: Dynamic braking during stop
- Connection: Brake Input terminals
Power Supply Requirements
| Supply | Voltage | Notes |
|---|---|---|
| Main Power | 380VAC 3-phase | E1 Drive main circuit |
| Control | 24VDC | I/O, sensors, logic |
| Safety | 24VDC | TwinSAFE circuits |
Cable Specifications
| Signal Type | Cable Spec | Max Length |
|---|---|---|
| EtherCAT | CAT6/6A Shielded | 50m |
| Motor Power | 4-6mm² Shielded | As required |
| Hall/Encoder | Shielded Twisted Pair | <10m |
| Safety (STO) | Safety-rated cable | As required |
Control Cabinet (UL508A)
The control cabinet follows UL508A standards for industrial control panel design:
Key Components
- Main disconnect switch
- Motor contactors
- 24VDC power supply
- Terminal blocks
- EtherCAT coupler and terminals
Wiring Guidelines
- Separate power and signal wiring
- Shield grounding at cabinet side
- Proper cable management and labeling
Available References
references/ascii-blueprint.md- Complete engineering ASCII blueprint (2025-11-16)references/cabinet-wiring.md- Control cabinet wiring diagram (2025-10-30)references/lab-assembly.md- Lab 149 actual assembly configurationreferences/procurement-list.md- Hardware procurement checklistreferences/c6030-wiring.md- C6030 physical connection guide