What is a high-speed controller?

In industry and automation technology, a high-speed control system is a system that processes signals at high speed and with minimal delay. Conventional control systems (such as classic PLCs) calculate in milliseconds, while high-speed systems often operate in the microsecond (μs) range.

A high-speed control refers to a control system that is capable of enabling very fast responses and precise control in industrial applications or automation systems. This type of control is often used in areas where fast movements, precise positioning, or high data processing speeds are required.

What are the characteristics of a high-speed controller?

Fast response times: They can process inputs and changes in real time, which is important for applications that require immediate adjustments.
High processing power: Our ZX controllers in particular are equipped with powerful FPGAs that can quickly perform complex calculations and algorithms.
Precise control: They enable accurate control of motors, actuators, and other components to achieve the desired movements and positions.
Real-time communication: They often use protocols that enable fast and reliable communication between different components of the system.
High-speed controllers are crucial for efficiency and productivity in modern manufacturing and automation processes

What are the areas of application for high-speed controllers?

• Injection molding machines: The controller monitors the highly dynamic injection process in real time to guarantee consistent material quality with minimum cycle times.
• Cutting machines: In laser, water jet, or knife cutting systems, fast signal processing ensures precise contours even at very high feed rates.
• Labeling systems: The controller precisely synchronizes label dispensing with the speed of the conveyor belt so that labels are perfectly positioned even on thousands of objects per hour.
• Robotics: In high-speed robotics, the controller enables complex path planning and extremely fast pick-and-place cycles without vibration losses.
• Packaging technology: It coordinates the interaction of feeding, filling, and sealing in fractions of a second to maximize the throughput of entire production lines.
• Printing machines: High-speed systems control the register and ink application on paper webs racing through the machine at several meters per second.
• Inspection and sorting systems: In quality assurance, products are scanned and analyzed as they pass by and, if defects are found, are immediately sorted out using compressed air nozzles or slides.

ZX-Controller

Please find the following features of our ZX-Controller:

Digital In- and Outputs:

Connections:

ZX09 Series

For all ZX09 the programming is done via the Ethernet interface; network applications are easily and quickly realized. Of course, you can programm the ZX09 as easily as you are used to in a PLC - with Structured Text (ST) according to IEC 61131-3.

• ZX09 is very fast and cost efficient and offers 10 digital inputs and 4 digital outputs as well as a high speed analog output.
• ZX09A has additionally RS485 / SSI interfaces.
• Analog variants with 6 analog high speed inputs as well as 2 digital inputs and 4 digital outputs are also available (ZX09D, ZX09E).

ZanderLink connects up to three cycle-time free controllers of the ZX09A / ZX09D / ZX09E series in an ultra-fast network.

• Process and network analog and digital sensor signals super-fast
• Guaranteed cycle time in the entire network below 10 µs
• Maximum jitter between controllers below 100 ns
• Simple configuration via predefined function blocks

ZX20 Series

Also for all ZX20 the programming is done via the Ethernet interface; network applications are easily and quickly realized. Of course, you can programm the ZX20 as easily as you are used to in a PLC - with Structured Text (ST) according to IEC 61131-3.

• ZX20T offers more than 20 digital inputs and 16 digital outputs and therefore has more I/Os than the ZX09-series.
• Special bus variants with integrated PROFINET and EtherCAT are also available.
• ZX21TP has a higher chip capacity / processing power for complex, multi networked applications.
• Application examples

Some basic developments in the field of high-speed control systems were funded within the framework of research grants from the German government: