Solving the Custom Machine Builder’s Dilemma: Standardization vs. Flexibility

For Berran Industrial Group, a Custom Machine Builder (CMB), the engineering reality is that no two machines are exactly the same. This inherent variability creates a conflict: custom mechanics usually require custom controls, but efficiency demands a standardized architecture.

David Black, a Controls Engineer at Berran, needed a motion control platform versatile enough to handle diverse kinematics yet rigid enough to integrate seamlessly with their standard Allen-Bradley CompactLogix PLCs. His search for a solution that didn't require complex third-party workarounds led him to Teknic’s ecosystem of ClearPath EtherNet/IP servos and associated I/O and motion control hubs.

Berran’s primary requirement was tight integration with their existing Rockwell Automation architecture. David notes that previous experiences with other vendors were often frustrating, citing competing products that were "difficult to integrate" and offered "very little diagnostic information."

Teknic’s approach to EtherNet/IP integration provided an immediate improvement. By utilizing Electronic Data Sheet (EDS) files designed to mirror familiar Rockwell workflows, the learning curve was practically eliminated.

"The EDS files provided by Teknic emulate the Studio 5000 instructions so well that there is virtually no learning curve for our engineers. This was a great relief to the team, as it significantly reduced the time required to successfully integrate motion into our builds," says David. In addition to the EDS files, users of Allen Bradley ControlLogix, GuardLogix, or CompactLogix PLCs, benefit from ClearPath’s comprehensive motion AOIs (Add-On Instructions). AOIs allow engineers to issue a single Allen Bradley-type command, like “Motion Axis Move”, and the AOI will issue the move, confirm acceptance, monitor execution, handle interruptions or faults, and detect when the move has settled.

Beyond ease of use, the architecture addresses a costly constraint for Rockwell users: node limits. Standard EtherNet/IP PLCs strictly limit the number of allowed IP addresses; exceeding this limit forces builders to purchase significantly more expensive PLCs.

Teknic’s ClearPath-IP system solves this using 4-axis “sync hubs”. These hubs allow up to four motors (and extensive I/O devices) to connect to the network while appearing as a single node to the PLC. This allows builders to control each motor individually while using only one-quarter as many IP addresses. The hubs also synchronize the attached motors to better than 200 nanoseconds.

"We especially like that the node requirements are reduced to a single node for up to four axis of motion. That, and when implementing the Teknic ClearLink or IO-Hub controllers, there is no requirement to use a motion-capable PLC," David explains.

To handle the custom nature of their projects, Berran utilizes the IO-HUB-4E enhanced version. While the standard ClearPath-IP hubs handle motion synchronization and motion-related I/O, the enhanced version ($249) offers the full potential of the hub’s 13 I/O points.

Engineers can configure the I/O points on the enhanced hub as general-purpose digital inputs, digital outputs, or analog inputs (for potentiometers or transducers). One output can be an analog output (0-10 V or 4-20 mA), and there’s also a dedicated high-speed quadrature encoder input with courtesy 5-volt power. This flexibility allows Berran to adapt to unforeseen sensor or feedback requirements without adding external I/O cards. Regarding the diagnostic feedback provided by this system, David notes, "It offers everything we're looking for and then some."

Hardware durability is critical for machines deployed into industrial environments. Berran had previously struggled with a competitor's motors where "equipment did not function as advertised, if at all" and "quality control was not up to par and would fail."

Since switching, Berran has found Teknic’s quality to be "far superior," and backed by a standard 3-year warranty. This reliability is paired with responsive engineering support, which is vital when custom projects face tight deadlines.

"Teknic is top-notch when it comes to service and support," David says. "They are always very quick."