Modular drive system

Overview
Lenze FAST Robotics is a modular, PLC-based drive and software platform for robotic applications. It enables integration of diverse robot kinematics directly into the controller environment (IEC 61131-3), delivering synchronized motion and machine functions without a separate robot controller. The architecture focuses on parameterization for fast commissioning, reusable software modules, digital twin support, condition monitoring and system services to reduce time-to-production and increase availability.

Key benefits

• Integrated robotics: robot movements and machine functions are implemented and synchronized on the PLC and executed via EtherCAT.
• Modular software: PLCopen-based technology blocks and predefined robot types accelerate development and reuse.
• Parameterization-first approach: configure technology modules instead of writing code to shorten development and commissioning.
• Digital twin: simulate, test and validate software and mechanics without hardware; controller motion matches simulation.
• Condition monitoring & AI: sensor evaluation and machine learning for early anomaly detection and optimized maintenance planning.
• Single-source solution: coordinated hardware, software and services supporting up to 6 degrees of freedom and multiple auxiliary axes.

Supported kinematics and application types

• Delta (Delta 2, Delta 3, Delta 4) for high-speed pick & place and end-of-line packaging.
• Scara for precise planar assembly and handling.
• Articulated arm kinematics (Articulated, Articulated P) for flexible workspace applications.
• Portal and Belt-Portal gantries for extended linear work areas.
• Linear Delta and customized kinematics for specialized solutions.
• Typical applications: packaging, cartoning, pick & place, gantry positioning and logistics/end-of-line processes.

Software & system capabilities

• Lenze FAST Robotics: modular technology blocks, auxiliary functions and system services (asset management, condition monitoring, OEE tracking).
• PLC-based path planning and coordinated motion control; jobs/recipes to adapt application behavior.
• Predefined robot types and reusable modules reduce integration effort and accelerate first implementation.
• Commissioning tools and training designed for usability to enable integration without deep specialist knowledge.

AI, monitoring and lifecycle
AI and machine learning support condition monitoring and service planning by analyzing drive and sensor data to detect deviations early without requiring additional sensors. Data-driven evaluation improves maintenance scheduling and machine availability.

Integrated digital twin
The integrated digital twin enables programming, simulation and commissioning without physical hardware. Simulations run directly on the controller and mirror real system motion to allow safe testing, optimization and low-risk updates.

Technical specifications

• Platform: Lenze FAST Robotics — modular PLC-based software, PLCopen-based.
• Controller integration: robot motion generated and executed on IEC 61131-3 PLC; EtherCAT for devices and sensors.
• Degrees of freedom: supports robots up to 6 DOF plus auxiliary axes.
• Commissioning: parameterization-first workflow to reduce commissioning time.
• Supported kinematics: Delta (multiple variants), Scara, Articulated, Portal, Belt-Portal, Linear Delta, custom kinematics.
• Simulation: integrated digital twin for testing, optimization and validation without hardware.
• Condition monitoring: sensor-based evaluation and data analysis; AI/ML for anomaly detection and service planning.
• System services: asset management, condition monitoring, OEE tracking and modular extensibility for customer-specific functions.