Applied Motion Products, a recognized leader in high-precision motion control technology, has announced a comprehensive expansion of its automation hardware and software ecosystem. The newly unveiled product lineup—featuring the MCA6 Motion PLC, the MET2 Remote I/O System, and the advanced AK Series StepSERVO Motors and Drives—is engineered to meet the increasingly complex demands of modern machine builders, original equipment manufacturers (OEMs), and automation engineers.
Designed to streamline system integration, simplify multi-axis coordination, and reduce physical footprint inside control cabinets, this new suite of products leverages robust industrial networking standards like EtherCAT. By bridging the gap between high-performance motion and flexible, distributed machine control, Applied Motion Products aims to give engineers a scalable toolset capable of handling everything from compact, standalone machines to highly synchronized, multi-axis automated lines.
Main Facts: A Comprehensive Automation Ecosystem
The centerpiece of this product rollout is a trio of hardware solutions backed by a modern, CODESYS-based development environment. Together, these components address several core bottlenecks in contemporary machine design: reducing panel space, accelerating commissioning, and offering flexible communication protocols.
The MCA6 Motion PLC: A compact, high-performance controller that integrates standard programmable logic controller (PLC) tasks with advanced motion coordination. Powered by an ARM-based processor and operating on IEC 61131-3 and PLCopen standards, the MCA6 supports up to 64 EtherCAT motion axes and 128 total EtherCAT devices. It accommodates demanding motion profiles such as electronic camming, multi-axis interpolation, synchronization, and complex robotic trajectory control.
The MET2 Remote I/O System: A modular, high-density distributed I/O platform designed to extend machine connectivity over EtherCAT. Featuring ultra-slim modules measuring as narrow as 12 mm, the MET2 system allows up to 32 expansion modules (covering digital, analog, and temperature monitoring functions) to be linked from a single coupler, placing data acquisition closer to physical sensors and actuators.
The AK Series StepSERVO Motors and Drives: A versatile motion platform that merges the cost-effectiveness and high low-end torque of stepper technology with the closed-loop precision of servo systems. Available in NEMA 11 through NEMA 34 frame sizes and powered by 24–48 VDC, the series features battery-free 17-bit multi-turn absolute encoders, integrated trajectory planning, and SiL3-certified Safe Torque Off (STO) functionality.
McEngine Pro Software Suite: The centralized engineering environment built on CODESYS. It provides a unified platform for programming logic, configuring motion paths, setting up networks, and simplifying migration paths for legacy control architectures.
Chronology: The Evolution Toward Integrated EtherCAT Architectures
The release of the MCA6, MET2, and AK Series represents the culmination of a multi-year industry shift toward deterministic, high-speed fieldbuses and unified hardware-software platforms.
For decades, machine builders routinely sourced motion controllers from one vendor, drives and motors from a second, and remote I/O blocks from a third. This fragmented approach frequently introduced compatibility hurdles, complicated wiring harnesses, and prolonged the commissioning phase as engineers struggled to synchronize disparate proprietary protocols.
Recognizing these inefficiencies, Applied Motion Products began heavily investing in open-standard architectures, most notably EtherCAT, which offers the high bandwidth and deterministic timing required for synchronized multi-axis automation.
Phase One (Foundational Drives): The company first established its reputation in advanced hybrid motion by refining closed-loop stepper technology (StepSERVO), proving that steppers could achieve servo-like performance without the tuning headaches traditionally associated with high-end AC servos.
Phase Two (Software Convergence): As machines grew more data-intensive, the need for unified programming tools became paramount. The adoption of CODESYS-based platforms allowed Applied Motion Products to align its hardware with globally recognized programming standards (IEC 61131-3), lowering the learning curve for system integrators.
Phase Three (System-Level Integration—Present Day): With the introduction of the MCA6 Motion PLC and MET2 Remote I/O systems, the company transitions from a component supplier to a complete system solution provider. Machine builders can now source a unified, end-to-end automation architecture—from the central PLC and remote field nodes down to the final axis of motion—all optimized to work seamlessly out of the box.
Supporting Data and Technical Specifications
To fully understand the impact of Applied Motion Products’ latest release, it is helpful to examine the granular engineering specifications that govern these devices. The architecture has been built from the ground up to handle high data throughput, harsh industrial environments, and demanding regulatory compliance.
MCA6 Motion PLC Specifications
Processing Core: Advanced ARM-based processor optimized for real-time task execution.
Programming Standards: Fully compliant with IEC 61131-3 and PLCopen Part 1 and Part 2.
Network Capacity: Supports up to 64 synchronized EtherCAT motion axes and a maximum of 128 EtherCAT slave devices.
Communication Protocols: Native support for EtherCAT, EtherNet/IP, Modbus TCP/RTU, CANopen, OPC UA, and UDP. This diverse protocol stack ensures seamless integration with higher-level Supervisory Control and Data Acquisition (SCADA) systems, Manufacturing Execution Systems (MES), and corporate IT networks.
Motion Capabilities: Electronic gearing, electronic camming, multi-dimensional linear and circular interpolation, phased synchronization, and Kinematic transformations for standard robotic topologies (e.g., SCARA, Delta, articulated arms).
Modularity: Up to 32 discrete expansion modules driven from a single bus coupler.
Form Factor: Ultra-compact module widths starting at just 12 mm, dramatically reducing the linear DIN-rail space required inside electrical enclosures.
Signal Diversity: Comprehensive module options including digital inputs/outputs, high-resolution analog inputs/outputs, and specialized temperature monitoring interfaces (thermocouple and RTD).
AK Series StepSERVO Motors and Drives Specifications
Operational Modes: Configurable for open-loop stepper operation, standard closed-loop stepper control, or full closed-loop servo performance.
Feedback Technology: Integrated battery-free 17-bit multi-turn absolute encoder. This eliminates the need for mechanical home switches or optical zero-reference sensors at power-up, significantly reducing machine startup cycles and eliminating battery maintenance issues.
Frame Sizes & Power: Available in standard NEMA frame sizes from NEMA 11 up to NEMA 34, operating on standard 24–48 VDC machine power rails.
Advanced Control Features: Secondary encoder feedback ports for compensating backlash or controlling loads downstream of gearboxes; embedded trajectory planning and Q programming for standalone execution; and USB-C connectivity enabling complete configuration, parameter cloning, and diagnostics even when main DC power is disconnected.
Safety & Connectivity: SiL3-certified Safe Torque Off (STO) for reliable integration into machine safety circuits. Fieldbus options include EtherCAT, EtherNet/IP, CANopen, and Modbus.
Official Responses and Industry Perspectives
Industry analysts and company leadership have highlighted the strategic importance of this product expansion, emphasizing how it directly answers current market pressures facing OEMs, such as component shortages, labor constraints, and the demand for smarter, more modular machinery.
"Machine builders today are caught between two competing forces: they must deliver increasingly sophisticated, high-speed machines with advanced automation features, yet they face severe constraints regarding panel space, engineering hours, and skilled labor availability," noted a senior product development strategist at Applied Motion Products. "By developing an integrated ecosystem built around open standards like EtherCAT and CODESYS, we are removing the friction of system integration. Our customers can now spend less time troubleshooting communication hurdles between different vendors’ hardware and more time focusing on what makes their machines unique."
Independent automation consultants have also praised the inclusion of battery-free absolute encoders across the AK Series. In industries such as packaging, material handling, and electronics assembly, unexpected power outages or routine maintenance shifts can force lengthy re-homing procedures that cost valuable production time. The 17-bit absolute feedback system guarantees that position data is retained instantly upon power restoration, addressing a persistent pain point on the factory floor.
Furthermore, the choice of the CODESYS-based McEngine Pro development environment has been widely welcomed by systems integrators. CODESYS is an established industry standard utilized by dozens of prominent automation brands worldwide. By adopting this environment, Applied Motion Products ensures that engineers migrating from legacy PLC platforms can leverage existing code libraries, drastically reducing software development and validation timelines.
Implications for Machine Builders and Automation Engineers
The introduction of the MCA6, MET2, and AK Series carries several long-term implications for the industrial automation landscape, particularly for small-to-mid-sized OEMs looking to compete against larger multinational conglomerates.
1. Simplification of Machine Architectures
Traditionally, combining the precision of servo motors with the cost efficiency of stepper systems required complex tuning matrices and separate controller loops. The AK Series bridges this gap by unifying open-loop, closed-loop stepper, and servo behaviors into a single device family. Combined with the ultra-compact MET2 remote I/O modules, machine builders can design cleaner, more streamlined electrical cabinets with shorter cable runs and less susceptibility to electromagnetic interference (EMI).
2. Accelerated Time-to-Market
Time is one of the most critical metrics in modern manufacturing. Features such as USB-C configuration without main power, automatic EtherCAT network discovery, and the standardized programming framework of McEngine Pro drastically shorten the window between initial mechanical assembly and final factory acceptance testing (FAT). Engineers can pre-configure drives on a workbench via a simple USB connection before mounting them into the machine frame.
3. Enhanced Safety and Compliance
With global safety standards growing increasingly stringent, the inclusion of SiL3-certified Safe Torque Off (STO) as a standard feature on the AK Series ensures that OEMs can meet high-level machinery directives (such as ISO 13849-1 and IEC 61508) without resorting to expensive, external safety contactors that complicate wiring and consume valuable panel space.
4. Scalability and Future-Proofing
As smart manufacturing and Industrial Internet of Things (IIoT) initiatives continue to penetrate the factory floor, machines must be capable of sharing data effortlessly with enterprise systems. By supporting advanced protocols like OPC UA alongside deterministic fieldbuses like EtherCAT, the new Applied Motion Products portfolio ensures that machines built today will remain compatible with the data architectures of tomorrow.
Conclusion
Applied Motion Products has delivered a timely and comprehensive expansion to its motion control and automation lineup. By addressing the fundamental triad of modern machine design—performance, integration simplicity, and spatial efficiency—the MCA6 Motion PLC, MET2 Remote I/O System, and AK Series StepSERVO ecosystem provide OEMs and automation engineers with the robust tools necessary to build the next generation of smart, high-speed machinery.
For further technical documentation, software downloads, or to explore the full specifications of the new automation lineup, engineers and system integrators are encouraged to visit the official Applied Motion Products website at applied-motion.com.
