ACS580 & ACS880 for Servo Motion Control

High-Performance Variable Frequency Drives for Positioning, Indexing, and Electronic Gearing

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Overview

Precise motion control is the backbone of modern automation – from indexing tables and pick-and-place machines to flying shears, rotary cutters, and positioning conveyors. Traditionally, these applications required expensive servo drives and proprietary motors. Now, with ACS580 and ACS880 drives, you can achieve servo-class positioning and electronic cam control using standard induction or permanent magnet motors – at a fraction of the cost.

At Inomax Technology, we leverage Direct Torque Control (DTC) technology (ACS880) and advanced vector control (ACS580) to deliver:

• Position control accuracy – ±1 encoder count

• Electronic gearing – precise master-slave synchronization

• Electronic cam (flying shear) – built-in motion profiles

• Fast positioning – 150 Hz position loop update rate

Whether you are retrofitting an old cam-based machine, building a new rotary table, or implementing a flying shear on a cut-to-length line, our drives provide a cost-effective, high-performance alternative to dedicated servo systems.

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Product Series for Motion Control

Key motion control features (both series):

• Position loop with programmable acceleration/deceleration profiles

• Electronic gear ratio (master-slave with programmable ratio, both directions)

• Position capture using digital input (proximity sensor)

• Position compare output for triggering external actions

• Modbus TCP, Profinet IRT, EtherCAT for real-time position reference

ACS880 adds:

• Electronic cam (flying shear) – built-in cam profile generator for rotary cutters, cross cutters, and reciprocating motions

• Absolute encoder support – EnDat 2.1/2.2, Hiperface, BiSS, SSI

• Positioning with torque limit – ideal for press-fit applications

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Application Case Studies

Case Study 1: Rotary Indexing Table – Replacing Servo with ACS580

Industry: Automotive parts assembly
Machine: 8-station rotary indexing table, 500 kg load, 1.5 second index time
Old system: Servo drive + servo motor (3 kW), expensive and lead time 12 weeks

Solution: ACS580-01-018A-4 (7.5 kW) + standard AC induction motor (3 kW) with 1024 PPR encoder. Configured as position control with pulse train input from PLC.

Results:

• Indexing accuracy ±0.5 mm at 500 mm radius (better than original servo)

• Cost reduced by 60%

• Lead time reduced to 2 weeks

• Payback: 4 months

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Case Study 2: Flying Shear on Cut-to-Length Line – ACS880 Electronic Cam

Industry: Steel service center
Machine: Flying shear cutting 2mm steel plate at 60 m/min, cut length 500–3000 mm
Old system: Complex PLC + servo system, difficult to tune, frequent overshoot

Solution: ACS880-01-045A-3 (22 kW) with built-in electronic cam. Master encoder from measuring roll, slave position control for rotary shear. Configured using PC tool with cam table (synchronization zone 0–180°, return 180–360°).

Results:

• Cut length accuracy ±0.5 mm (previously ±2 mm)

• Tuning time reduced from 2 days to 2 hours

• No external motion controller needed – PLC only sends cut length

• Payback: 6 months

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Case Study 3: Multi-Axis Electronic Gearing – ACS880 Master-Slave

Industry: Paper converting (rewinder with slitter)
Machine: Main rewinder drum (45 kW) + slitter knife roll (7.5 kW) must run at exact 2.345:1 gear ratio
Old system: Mechanical gearbox + line shaft, inflexible, high maintenance

Solution: ACS880-01-090A-3 (45 kW) as master (speed control), ACS880-01-018A-4 (7.5 kW) as slave (electronic gearing). Connected via Profinet IRT with 1 ms cycle.

Results:

• Gear ratio changeable via HMI (no mechanical parts)

• Synchronization error <0.05°

• Maintenance cost reduced by 80%

• Payback: 8 months

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Case Study 4: Pick-and-Place Positioning – ACS580 Pulse Train

Industry: Packaging
Machine: Gantry pick-and-place, 2 kg payload, 60 cycles/minute
Old system: Stepper motor + driver, lost steps, unreliable

Solution: ACS580-01-004A-4 (1.5 kW) + encoder feedback. PLC sends pulse train direction signal. Drive executes positioning with S-curve acceleration.

Results:

• No lost steps, reliable positioning

• Speed increased to 80 cycles/minute

• Cost lower than servo replacement

• Payback: 3 months

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Case Study 5: Rotary Cutter for Corrugated Board – ACS880 Flying Shear

Industry: Corrugated packaging
Machine: Rotary die cutter, cut length 300–2000 mm, board speed 120 m/min
Old system: Mechanical cam + clutch brake, inaccurate, noisy

Solution: ACS880-01-062A-3 (37 kW) with electronic cam. Master encoder from board speed. Built-in cam profile synchronized cutter knife speed with board.

Results:

• Cut accuracy ±1 mm over 2000 mm length

• Noise reduced by 15 dB

• Mechanical clutch eliminated

• Payback: 7 months

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Key Motion Control Specifications

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Frequently Asked Questions

Q1: Can ACS580 replace a servo drive for simple indexing applications?
Yes, for applications requiring positioning accuracy of ±1 encoder count and moderate dynamics (e.g., rotary tables, indexing conveyors, pick-and-place), ACS580 with an encoder and pulse train input works very well. It is significantly cheaper than a servo system and uses standard AC motors. However, for high-speed flying shears or complex cam profiles, ACS880 is recommended.

Q2: What encoder types are supported for position feedback?
ACS580 supports incremental encoders (TTL, HTL, open collector, push-pull). ACS880 supports incremental encoders, resolvers, and absolute encoders including EnDat 2.1/2.2, Hiperface (SICK), BiSS, and SSI protocols. Absolute encoders eliminate homing on power-up.

Q3: Does ACS880 require an encoder for electronic cam (flying shear)?
Yes – for electronic cam, you need an encoder on the master axis (e.g., measuring roll or conveyor) to provide real-time position. The slave axis (cutter) can run with or without its own encoder – with encoder gives higher accuracy. ACS880 can also use motor-mounted encoder for closed-loop position control.

Q4: How do I configure electronic cam on ACS880?
Using our free Drive Composer PC tool. You define a cam table with master position (0–360° or 0–10000 units) vs. slave position (or speed). The drive interpolates between points. Common profiles: synchronization zone (cutter matches line speed), return zone (fast return), and dwell. We provide sample cam tables for rotary cutters, flying shears, and reciprocating feeders.

Q5: Can I use ACS880 for multiple axes synchronized electronically?
Yes. ACS880 supports electronic gearing where multiple follower drives follow a master drive’s position via fieldbus (Profinet IRT or EtherCAT). Synchronization accuracy is <1 μs. You can also set individual gear ratios, offsets, and acceleration limits per axis.

Q6: What is the typical cost saving compared to a servo system?
For a 3–15 kW application, a servo motor + drive costs 2–3× more than an ACS880 + standard AC induction motor with encoder. For larger power (>30 kW), servo systems are rarely available, making ACS880 the only option. Typical savings: 40–60% on hardware, plus reduced spare parts inventory (standard motors are cheaper and available everywhere).

Q7: Does ACS580 support positioning without an encoder?
ACS580 can perform simple positioning using open-loop vector control with a digital input as a proximity switch. The drive accelerates to target speed, decelerates based on calculated ramp, and stops when the sensor triggers. Accuracy is ±10–50 mm depending on speed. For precise positioning (<1 mm), an encoder is required.

Q8: What communication protocols are best for motion control?
For multi-axis synchronized motion, use Profinet IRT (Siemens ecosystem) or EtherCAT (Beckhoff, Omron, or any CODESYS-based PLC). These provide deterministic cycle times down to 250 μs. For simple point-to-point positioning, Modbus TCP or EtherNet/IP (with CIP Motion) works well. We provide GSDML, ESI, and EDS files for all protocols.

Q9: Can ACS880 do torque positioning (press-fit applications)?
Yes. ACS880 has a positioning with torque limit mode. The drive moves to a target position but limits output torque. If torque limit is reached before position, it holds and signals “torque limit reached” – perfect for press-fitting bearings, capping machines, or assembly presses.

Q10: How do I home a rotary table using ACS580/ACS880?
Both drives support homing modes:

• Proximity switch + index pulse (encoder Z channel) – high accuracy

• Proximity switch only – accuracy within 1 encoder count

• Hard limit switch – simple homing

• Current limit homing – drive runs into mechanical stop, detects current increase, sets that as home

Homing parameters are in group 44 (ACS580) or group 25 (ACS880).

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Why Choose Inomax Technology for Motion Control?

• Cost-effective alternative to servo systems – use standard motors

• Built-in motion functions – no external motion controller needed for many applications

• Flexible feedback – incremental or absolute encoders

• Fieldbus integration – Profinet IRT, EtherCAT for real-time synchronized motion

• Global support – application engineering for flying shears, rotary cutters, indexing tables

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Ready to Upgrade Your Motion Control?

Whether you need a simple indexing drive or a high-performance flying shear solution, our engineers are ready to help.

Contact us today for:

• Free application assessment

• Sample cam tables for your cutting line

• Retrofit proposal for replacing servo or cam-based systems

Inomax Technology