Here, leading drive technology specialist NORD Gear examines how more connected and intelligent drive systems are helping to shape modern automation.
Frequency inverters have evolved far beyond simple motor speed control. Today, they play a vital role in industrial automation, providing seamless communication with PLCs, supporting functional safety requirements and helping improve energy efficiency across a wide range of applications.
Modern drive systems can be equipped with Industrial Ethernet connectivity, enabling direct integration into machine and plant-wide control networks. Multi-protocol communication platforms support widely used standards including PROFINET, EtherNet/IP and EtherCAT, allowing the required protocol to be selected through software configuration rather than dedicated hardware. This flexibility simplifies system design and enables a common drive platform to be used across different automation architectures.
Industrial Ethernet enables continuous two-way communication between the PLC and the inverter. Controllers can transmit commands such as start/stop signals, direction, speed and torque setpoints, while inverters return real-time operating data, status information and diagnostics. This ongoing exchange makes the drive an intelligent component within the automation system, improving machine control, troubleshooting and maintenance planning.
The same flexible approach can also be applied to functional safety. A common communication platform allows both standard and safety-related communication to be configured without changing hardware. Depending on the selected Ethernet protocol, corresponding safety protocols such as PROFIsafe, FSoE (Fail Safe over EtherCAT) and CIP Safety can be implemented.
Drive-based safety functions may include Safe Torque Off (STO), Safe Stop 1 (SS1), Safe Limited Speed (SLS), Safe Maximum Speed (SMS) and Safe Speed Monitor (SSM). In many applications, these functions can be achieved without additional motor encoders, helping to reduce system complexity, wiring and installation costs.
Alongside connectivity and safety, energy efficiency remains a major consideration. When paired with high-efficiency motors, modern frequency inverters can deliver excellent performance across a wide operating range while reducing energy consumption and operating costs.
Control Cabinet and Decentralised Solutions
Control cabinet-mounted inverters are available in a broad range of power ratings and can be tailored to application requirements through different performance levels and optional expansion modules. Beyond communication capabilities, many drives offer advanced motor control features such as closed-loop vector control, positioning and synchronisation functions. This allows motion-control tasks to be handled directly within the drive, reducing the need for additional control hardware.
Many inverters also incorporate onboard PLC functionality, enabling application-specific logic to run locally. By distributing control tasks to the drive, processing demands on the central controller can be reduced.
For distributed applications, decentralised inverters can be mounted directly on or close to the motor. This approach reduces cabling, simplifies installation and improves maintenance access, making it particularly attractive for conveyor systems, materials handling equipment and intralogistics operations.
Combined with modern software tools, wireless diagnostics and mobile commissioning capabilities, today’s intelligent drive systems provide the connectivity, flexibility and efficiency required for increasingly automated industrial environments.
