New Beckhoff EP741x motor controllers feature safe torque off function

Beckhoff Automation announced at MODEX 2026 its new EP741x motor-driven roller (MDR) controller modules are available with integrated safety functions.

The trade show was hosted by MHI April 13-16 in Atlanta, Georgia.

Beckhoff said the EP741x IP54-protected EtherCAT I/O controller raises the bar for safety, efficiency, and modularity in automated material handling with powered conveyors.

These compact, conveyor-mounted controllers can be widely-distributed and support 24 and 48 volt brushless DC (BLDC) motors from any manufacturer, including motorized rollers and flat “pancake” motors.

Beckhoff said this design can provide flexibility for equipment manufacturers, simplified wiring, and considerably more data. It also significantly lowers system costs and increases system visibility for predictive maintenance and operational efficiency efforts.

User-defined individually-controlled safety zones

The EP741x features optional safe torque off (STO) safety functionality networked via Safety over EtherCAT (FSoE).

Unlike conventional controllers that meet emergency-stop requirements by shutting down the entire power supply, the EP741x-9071 uses an intelligent design: it safely disconnects the motor power stage internally without having to cut power to the module.

As a result of keeping the control electronics’ logic voltage up, the system retains clear visibility of all input states, motor data, and important safety diagnostics while remaining in a safe state.

A decentralized safety architecture allows users to define individually-controlled safety zones within one EtherCAT network, which Beckhoff said increases the modularity of material transport systems and eliminates the need for additional safety components or complex parallel wiring.

For applications with lower safety requirements, Beckhoff also offers the new MDR controllers as cost-optimized 2-channel and 4-channel variants without the safety functionality (EP741x-0071).

Sensor-less BLDC motor control

Rising automation demands in e-commerce and intralogistics applications require smarter conveyor systems that are more modular, flexible, and reliable. Beckhoff said smart, powered MDR conveyors can deliver major efficiency advantages through zone-based operation, but can be restricted by the limitations of traditional fieldbus systems.

The new EP741x MDR controllers are networked via EtherCAT to allow sub-millisecond update rates and nearly unlimited network size, including no limit on connecting the devices in a line topology and no performance impact on branching - all major weaknesses of other Ethernet networks. This connectivity can enable tightly synchronized routing logic, even with extensive conveyor lines and complex material handling systems.

Built on the established EP7402 EtherCAT MDR Controller Box architecture, the EP741x provides sensor-less control of BLDC motors in the 24 to 48 V voltage range. Using 48 V power permits higher conveyor speeds and longer cable runs without worrying about voltage sag.

Modular design compatible with wide range of motor rollers

Because the modules are compatible with motor rollers from any supplier, engineering can be simplified and spare parts inventories can be significantly reduced. The controllers are available in a 2-channel version (EP7412) and an especially cost-effective 4-channel version (EP7414).

Beckhoff said the fully cascadable IP54+ design with integrated cables and standardized M8 or M12 connectors can reduce costs, eliminate wiring errors, and minimize installation time. A reduced installation depth also facilitates direct, space-saving mounting inside conveyor rail profiles.