The Vario-X platform replaces the traditional control cabinet with IP65/IP67-rated modules that mount directly on the machine — at the point of action. A rugged backplane carries 48 V DC power (MQ15) and real-time EtherCAT communication between snap-together modules: controller, power supply, safety PLC, I/O blocks, IO-Link masters, switches, and decentralized servo drives.

How does Vario-X eliminate the control cabinet?

Every automation function moves out of the cabinet and onto the machine frame. IP65/IP67 sealed housings withstand direct washdown and mechanical loads. M12 and MQ15 connectors replace hardwired terminal blocks. The backplane distributes both power and EtherCAT communication — plug in a module and it is automatically recognized. Result: up to 40% faster installation, 75% less wiring, and 85% lower energy consumption compared to pneumatic equivalents.

What control and communication capabilities does the Vario-X Controller provide?

The industrial PC runs CODESYS V3 on a quad-core CPU with independent Gigabit Ethernet interfaces. It functions as EtherCAT master for all downstream modules and offers PROFINET Device and EtherNet/IP Device interfaces for integration into higher-level plant networks. CODESYS WebVisu delivers HMI visualization to any device with a browser — panel, tablet, or smartphone.

How does Vario-X support digital transformation?

A full digital twin is created during engineering, enabling kinematic simulation and virtual commissioning before physical hardware ships. Integrated edge gateway functionality streams sensor data to cloud platforms for predictive maintenance. Augmented reality overlays assist with assembly and service — scan a module with a tablet to see its digital twin and status data.