ELAU MAX-4

Core Technical Performance Parameters

1. Control Hardware Core: 32-bit high-speed RISC processor, angular positioning resolution up to 0.001°
2. Real-Time OS: VxWorks hard real-time system, motion cycle jitter ≤100 ns for EtherCAT bus linkage
3. Axis Control Capacity: Base unit integrated 4-axis drive output; expandable to max 99 axes via MC series servo drive modules
4. Power Specifications
   • Control Logic Supply: 24 VDC, max current draw 10 A
   • Main Drive Three-phase Input: 220 VAC three-phase industrial power
   • Output Frequency Range: 0 Hz – 500 Hz
5. I/O Channel Configuration
   • Analog Inputs: 3 channels
   • Digital Inputs: 16 channels
   • Digital Outputs: 16 channels
   • Encoder Feedback Inputs: 10 channels
   • Safety Stop I/O: 1 safety input, 1 safety relay output
6. Environmental & Mechanical Specs
   • Operating Temperature: 0 °C ~ +50 °C
   • Storage Temperature: -40 °C ~ +85 °C
   • Protection Class: IP54 enclosure with PCB conformal coating
   • Product Dimensions: 156 mm (W) × 67 mm (D) × 161 mm (H)
   • Net Weight: 1.5 kg

Material Composition

• Main Housing: Galvanized steel sheet with black anti-oil electrostatic coating
• Terminal Block Base: Glass fiber reinforced PA66 high-temperature plastic
• Internal Power Heat Sink: Extruded aluminum alloy oxidation anti-corrosion radiator
• Main Control PCB: Multi-layer FR4 circuit board with full acrylic conformal coating for washdown environment resistance
• Communication Port Interface Shell: Nickel-plated zinc alloy anti-interference shielding housing

Structural Characteristics

1. Vertical DIN rail mounting modular compact design, small footprint for machine integrated control cabinet layout
2. Front panel layered layout: Green spring-cage digital/analog I/O terminal blocks, DB9 RS232/RS485 serial ports, RJ45 EtherCAT Ethernet port, status diagnostic LED array
3. Independent power drive compartment separated from logic control compartment via metal shielding partition to eliminate power circuit electromagnetic interference
4. Built-in safety relay circuit for Category 3 machine safety stop function, compliant with EN ISO 13849-1 machinery safety standard
5. Multi-bus integrated communication interface: SERCOS, EtherCAT, CANopen, PROFIBUS DP for flexible upper system interconnection

Working Principle

1. Machine logic program written under IEC 61131-3 standard programming environment downloaded to MAX-4 onboard flash memory.
2. VxWorks real-time OS executes logic tasks and motion control tasks with strict nanosecond scheduling cycle, processing electronic cam, electronic gear, linear/circular interpolation motion trajectory algorithms.
3. High-speed EtherCAT/SERCOS bus transmits synchronized position commands to connected ELAU MC series servo drives, collecting encoder position feedback signals in real time to form full closed-loop multi-axis coordination control.
4. Digital/analog I/O channels receive sensor trigger signals and output actuator drive signals for machine auxiliary pneumatic/hydraulic components.
5. Adaptive vibration suppression algorithm dynamically adjusts servo gain to offset mechanical resonance generated by high-speed reciprocating machine movement, reducing positioning vibration error.

Installation Requirements

1. Mount on standard TS35 DIN rail inside machine control cabinet; maintain 20 mm vertical spacing between adjacent MAX-4 units for heat dissipation
2. Separate power wiring and signal wiring into isolated cable ducts; shielded twisted-pair cable mandatory for EtherCAT servo bus communication
3. 24 VDC control power supply equipped with anti-surge filter module to suppress machine switching electromagnetic surge
4. All communication cable shielding layers single-point grounded at cabinet PE protective earth bar
5. Cabinet cooling fan required for continuous full-load multi-axis operation to keep internal temperature below 50°C
6. Install away from high-power contactors, frequency converters to avoid strong electromagnetic field interference

Function & Feature Highlights

1. All-in-one integrated controller: PLC logic + multi-axis servo motion control + local I/O eliminates separate PLC and motion card hardware
2. Ultra-precise multi-axis synchronization with <100 ns bus jitter, stable high-speed electronic cam & flying shear motion control
3. IP54 conformal coated PCB design adapts to food, dairy production line high-pressure washdown environments
4. IEC 61131-3 full standard programming support (ST, LD, FBD, SFC structured programming languages)
5. Built-in machinery Category 3 safety stop circuit without external safety relay expansion
6. Multi-protocol industrial bus compatibility for seamless connection with HMI, upper monitoring systems, third-party servo motors
7. Adaptive resonance suppression algorithm automatically eliminates mechanical vibration of high-speed automated equipment

Typical Application Scenarios

• Pharmaceutical blister packaging, carton folding & filling high-speed packaging machinery
• Confectionery, snack food wrapping, bottle filling automated production lines
• Label printing, flexible packaging rotary printing multi-axis register control equipment
• Robotic palletizing, carton handling automated material conveying lines
• Cosmetic filling, bottle capping precision positioning packaging machines
• Textile printing, slitting high-speed roll-to-roll converting machinery

Operation & Maintenance Precautions

1. Cut off both 220 VAC drive power and 24 VDC control power before disassembly or wiring modification
2. Do not touch communication port shielding housing with bare hands during live wiring, electrostatic discharge damages internal communication chips
3. Quarterly blow dust from heat sink and terminal blocks with dry compressed air, dust accumulation causes over-temperature alarm
4. Avoid direct high-pressure water wash onto controller housing even with IP54 rating; water penetrates terminal gaps under high pressure
5. After mechanical equipment overhaul, re-tune servo gain and vibration suppression parameters to match new mechanical resonance characteristics
6. Store spare controllers in dry anti-static packaging with desiccant bags to prevent PCB moisture corrosion
7. Prohibit operation beyond maximum 99-axis expansion limit; overload bus communication causes motion synchronization loss