MORGAN HILL, Calif. — In a significant expansion of its industrial automation portfolio, Applied Motion Products has announced the launch of a robust new suite of hardware and software designed to streamline machine control, enhance motion coordination, and simplify system integration. The newly introduced lineup—featuring the MCA6 Motion PLC, the MET2 Remote I/O System, and the AK Series StepSERVO Motors and Drives—directly targets the evolving demands of original equipment manufacturers (OEMs), machine builders, and automation engineers.
Built on high-performance EtherCAT architecture and backed by open programming standards, this integrated ecosystem addresses some of the most persistent bottlenecks in modern machine design: multi-axis synchronization, distributed field wiring, complex panel space constraints, and lengthy commissioning cycles.
Main Facts: A New Era of Integrated Motion and Control
The rollout from Applied Motion Products represents a unified approach to automation engineering. Rather than treating control, I/O, and actuation as isolated components, the company has engineered a cohesive architecture where high-density controllers, modular I/O, and flexible drive technologies communicate seamlessly across standard industrial networks.
At the heart of the hardware release are three flagship introductions:
- The MCA6 Motion PLC: A compact, ARM processor-driven controller combining traditional programmable logic controller (PLC) tasks with advanced, synchronized multi-axis motion control. Supporting up to 64 EtherCAT axes and 128 EtherCAT devices, it is programmed using IEC 61131-3 and PLCopen standards via the CODESYS-based McEngine Pro environment.
- The MET2 Remote I/O System: A high-density, modular remote I/O platform featuring a single coupler capable of managing up to 32 expansion modules. With ultra-slim profiles starting at 12 mm wide, the MET2 system minimizes electrical enclosure footprints while placing digital, analog, and temperature-monitoring nodes directly at the point of action.
- The AK Series StepSERVO Motors and Drives: An adaptable motion platform supporting open-loop stepper, closed-loop stepper, and closed-loop servo operation. Equipped with a battery-free 17-bit multi-turn absolute encoder, secondary feedback options, and SIL3-certified Safe Torque Off (STO), the AK series bridges the gap between traditional cost-effective stepper setups and high-performance servo systems.
Chronology: Development, Integration, and Market Release
The introduction of the MCA6, MET2, and AK Series is the culmination of years of strategic development focused on standardizing industrial communication and reducing total system costs for machine builders.
Phase 1: The Shift Toward EtherCAT and Open Standards
Over the past decade, the automation industry has witnessed a steady migration away from proprietary fieldbuses toward high-speed, deterministic Ethernet protocols, most notably EtherCAT. Recognizing this shift, Applied Motion Products began developing hardware capable of native, high-speed network communication. The engineering roadmap prioritized open programming environments—specifically IEC 61131-3 and PLCopen—to ensure that OEMs could easily migrate legacy codebases without locking into proprietary ecosystems.
Phase 2: Prototyping and Compact Form-Factor Engineering
As machine footprints shrink and modular machine design grows in popularity, the physical size of control hardware has become a major pain point for panel builders. During the development of the MCA6 Motion PLC and MET2 Remote I/O systems, design teams focused on thermal efficiency and high-density packaging. By utilizing advanced ARM processors for the MCA6 and engineering the MET2 expansion modules down to a 12-millimeter width, the company successfully minimized physical enclosure requirements.
Phase 3: Perfecting Hybrid Motion Technology
Concurrently, the engineering division refined the StepSERVO technology found in the AK Series. By integrating high-resolution, battery-free absolute encoders into NEMA 11 through NEMA 34 frame sizes, the development team sought to eliminate the time-consuming homing sequences traditionally required at machine startup. Integrating USB-C connectivity for out-of-box configuration without requiring main AC/DC power further streamlined the prototyping and debugging phases for field engineers.
Phase 4: Official Market Launch and Software Integration
The release culminates with the pairing of these hardware platforms with McEngine Pro, a comprehensive CODESYS-based development environment. This software suite ties the MCA6, MET2, and AK Series together, giving machine builders a singular workspace for hardware configuration, trajectory planning, and diagnostic monitoring.
Supporting Data: Technical Specifications and Performance Metrics
A closer examination of the engineering specifications reveals a high-performance feature set designed to meet the rigorous demands of modern factory automation, packaging lines, material handling, and robotic cells.
The MCA6 Motion PLC
- Processor Architecture: High-performance ARM-based processor.
- Programming Standards: IEC 61131-3 and PLCopen compliance via McEngine Pro (CODESYS).
- Capacity: Supports up to 64 EtherCAT motion axes and a total of 128 EtherCAT nodes.
- Motion Capabilities: Advanced interpolation, electronic camming, master-slave synchronization, and multi-axis coordinated robotic motion control.
- Communication Protocols: Native EtherCAT, EtherNet/IP, Modbus TCP/RTU, CANopen, OPC UA, and UDP.
The MET2 Remote I/O System
- Bus Architecture: EtherCAT-based high-speed backplane.
- Scalability: Up to 32 expansion modules connected to a single bus coupler.
- Module Variety: Comprehensive options including digital inputs/outputs, analog inputs/outputs, and specialized temperature-monitoring modules.
- Physical Footprint: Ultra-compact module widths starting at 12 mm, significantly reducing DIN-rail space inside control cabinets.
The AK Series StepSERVO Motors and Drives
- Operating Modes: Open-loop stepper, closed-loop stepper, and closed-loop servo operation.
- Feedback System: Battery-free 17-bit multi-turn absolute encoder (retains position across power cycles, eliminating homing routines) plus secondary encoder support for closed-loop load control.
- Frame Sizes: NEMA 11, NEMA 17, NEMA 23, and NEMA 34.
- Operating Voltage: 24–48 VDC power input.
- Safety Features: SIL3-certified Safe Torque Off (STO).
- Advanced Features: Embedded trajectory planning, Q programming language support, and USB-C configuration port for parameterization without applying main power.
- Network Connectivity: EtherCAT, EtherNet/IP, CANopen, and Modbus.
Official Responses and Industry Perspectives
Industry analysts and engineering leadership have pointed out that this multi-product rollout addresses a critical market need: the convergence of machine control and precision motion into simplified, highly connected architectures.
According to technical representatives at Applied Motion Products, the driving philosophy behind the new release is "architectural simplification." Modern machine builders are often forced to stitch together controllers, remote I/O blocks, and drives from multiple disparate vendors, leading to complex commissioning processes, fragmented software toolchains, and bloated control panels.
"By providing a unified ecosystem built around standard protocols like EtherCAT and programming platforms like CODESYS, we are removing the friction traditionally associated with system integration," noted a company spokesperson during the product launch. "Whether an OEM is building a standalone pick-and-place gantry or a sprawling, multi-axis automated assembly line, the MCA6, MET2, and AK Series provide the scalability and speed required without unnecessary complexity."
Early beta testers and automation engineers have praised the inclusion of features like battery-free absolute encoders and USB-C unpowered configuration. In manufacturing environments where downtime carries a massive financial penalty, the ability to hot-swap components, eliminate homing routines after a power interruption, and configure drives safely on a workbench before cabinet installation represents a major operational advantage.
Implications: What This Means for Machine Builders and OEMs
The introduction of Applied Motion Products’ new automation suite carries significant implications for the competitive landscape of machine design and industrial automation.
1. Reduced Time-to-Market
By consolidating programming into the CODESYS-based McEngine Pro environment and utilizing standardized PLCopen motion blocks, development teams can drastically cut down on software development time. Furthermore, features like embedded trajectory planning on the AK Series drives shift computational burdens away from the main PLC, optimizing overall system performance.
2. Minimized Physical Footprint
Control cabinet real estate is at a premium in modern industrial machinery. The combination of the compact MCA6 controller, the 12-mm wide MET2 I/O modules, and the space-saving StepSERVO motors allows OEMs to design smaller, lighter enclosures or integrate controls directly onto the machine chassis. This reduces cabling costs, lowers installation labor, and simplifies shipping logistics.
3. Enhanced Flexibility and Scalability
The broad spectrum of supported communication protocols (EtherCAT, EtherNet/IP, Modbus, CANopen, OPC UA) ensures that machines equipped with Applied Motion Products hardware can easily interface with higher-level Manufacturing Execution Systems (MES) and supervisory control and data acquisition (SCADA) networks. This makes the new lineup well-positioned for Smart Factory and Industry 4.0 implementations.
4. Lower Cost of Ownership for End Users
For the end-users operating these machines on factory floors, the benefits manifest as increased uptime and simplified maintenance. Eliminating homing routines via absolute encoder technology prevents startup alignment errors, while SIL3-certified Safe Torque Off ensures that safety compliance is met without compromising productivity.
As machine builders continue to face pressures to deliver smarter, faster, and more modular equipment, integrated solutions like the MCA6 Motion PLC, MET2 I/O, and AK Series StepSERVO systems illustrate the clear industry trajectory toward unified, network-centric automation.
For further technical specifications, documentation, and software download details regarding the new automation suite, machine builders and automation engineers can visit the official Applied Motion Products website at applied-motion.com.
