Engineers and machine builders are under constant pressure to deliver reliable, high-precision motion, but without exploding budgets or complexity. That’s exactly where Kollmorgen Essentials can help.
This servo motion system is designed to give you the core performance you need. It is optimized for value, with intuitive commissioning so that you can focus on building your machine, not wrestling with integration.
Here’s a breakdown of what makes Essentials compelling for you, how it solves common pain points, and why it’s positioned as a no-compromise but cost-effective choice.
What is Kollmorgen Essentials?
Kollmorgen Essentials is a motion system that bundles three critical components: a servo drive, a servo motor, and a combined power/data cable. Instead of sourcing disparate parts and piecing them together, you get a system that’s engineered to work seamlessly out of the box.
- The servo drive supports common industrial Ethernet protocols, including EtherCAT, EtherNet/IP, and PROFINET, simplifying fieldbus selection.
- The servo motor covers a broad power range and includes smart feedback.
- The single-cable technology (power + data) simplifies wiring and reduces potential points of failure.
Customer Benefits of Kollmorgen Essentials
The benefits of the Kollmorgen Essentials are as follows:
1. Speed & Simplicity in Commissioning
One of the standout features is the Express Setup in Kollmorgen’s WorkBench software. Even if you’re not a motion-control veteran, you can set up, configure, and tune the drive in under 20 minutes. That means less on-site time, fewer configuration errors, and faster time-to-production.
2. Protocol Flexibility
Because the Essentials drive is a multi-protocol drive that supports multiple industrial Ethernet protocols in the same part number, you aren’t locked into one fieldbus. You can choose EtherCAT, EtherNet/IP, or PROFINET depending on your controller environment.
This flexibility reduces spare complexity. You don’t have to stock separate drives for different buses. Additionally, the drive supports multi-axis synchronization (EtherCAT, CIP Sync, PROFINET IRT), enabling precise coordinated motion when needed.
3. Built-in Safety
Safety isn’t an afterthought. The drive integrates dual-channel Safe Torque Off (STO) functionality, meeting SIL2 / Cat 3 PL d standards. This means you can design safer machines with fewer external safety modules, simplifying architecture and reducing cost.
4. Value Without Sacrificing Performance
Designed for applications such as packaging, material handling, warehousing, and forming, Kollmorgen Essentials delivers strong performance within a standardized product range. The motor offering covers a wide power range of 200 W to 4,000 W across four frame sizes and has standardized IEC mounting, which helps you reduce inventory variants. The result? More flexibility and fewer SKUs to manage.
5. Battery-Free Absolute Feedback
The integrated SFD-M multi-turn absolute encoder provides high-resolution position feedback without requiring a backup battery. It provides 24-bit single-turn and 16-bit multi-turn resolution, but without a backup battery, thanks to energy harvesting. This means:
- No battery maintenance, replacement, or risk of wearing out mid-life.
- The system retains absolute position even after power loss, avoiding homing routines or downtime.
- Plug-and-play parameterization with Kollmorgen drives, reducing setup time.
6. Simplified Cabling & Reliability
By using a single combined cable for both power and data, wiring is simpler, you have fewer connectors, and the system is more robust in industrial environments. This also reduces electromagnetic interference risks and connection errors, which are common sources of downtime.
7. Scalability & Inventory Efficiency
Essentials is designed around curated, high-demand configurations, meaning that most common variants are in stock. For you, this means faster delivery times, less scrambling for parts, and predictable lead times which is all especially valuable when scaling or building machines in series.
Technical Snapshot of Kollmorgen Essentials
To help you evaluate whether Essentials fits your use case, here’s a rundown of key technical specs:
- Motor power & sizes: 200 W to 4,000 W, IEC frame sizes 58 to 138 mm.
- Voltage compatibility: Motors support several windings (120, 240, 400, 480 VAC) for global application.
- Speed: Rated and maximum speeds vary with size, winding, and bus voltage.
- Torque: Continuous stall torque ranges from ~0.74 Nm to ~17.4 Nm, depending on frame and winding.
- Encoder: SFD-M, batteryless, 24-bit single-turn + 16-bit multi-turn.
- Drive current: The largest Essentials drive is rated for 12 A continuous, 30 A peak with a typical shaft power of 2.5 kW.
- Safety: Integrated STO, SIL2 / PL d rated.
- Protocols: Natively supported fieldbuses include EtherCAT, EtherNet/IP, and PROFINET. Sync via CIP Sync or PROFINET IRT.
- Installation: Express Setup via WorkBench, plus full WorkBench suite for advanced tuning.
- Environmental: Motors have IP54 by default, with an optional field-installable IP65 shaft seal kit.
- Accessories: Optional regen resistors, line filters, spare connectors.
Real-World use Cases
Here are some concrete scenarios where Kollmorgen Essentials can bring real value:
1. Warehouse Automation/Intralogistics
In systems like diverter gates, sorters, or retrieval systems, the batteryless absolute feedback means you don’t need to worry about re-homing axes after a power outage.
2. Packaging Machines
For tasks like slicing, cartoning, wrapping, or filling, you need synchronized motion, registration, and high repeatability. Essentials drives feature two high-speed inputs for registration, built-in multi-axis sync, and fast setup.
3. Forming and Cutting Applications
Laser cutting, press forming, or other precision tasks often need tight synchronization. The multi-axis features and real-time protocols make Essentials a solid fit.
4. OEMs / Machine Builders
Smaller or mid-size OEMs who don’t want to over-engineer or pay for ultra-high-end systems can benefit from the value-optimized nature of Essentials.
Why is it a Smart Choice?
Here is why it is best suited for machine builders, design engineers, and systems integrators:
- You save engineering time thanks to pre-matched components and fast commissioning.
- You minimize inventory risk: fewer drive/motor variants to order, fewer SKUs to stock.
- You reduce downtime risk, thanks to absolute feedback that doesn’t need to be re-homed after power loss.
- You simplify wiring and cabling, lowering installation errors and maintenance overhead.
- You build safe machines without adding complex external safety modules because STO is built in.
- The drives supports several fieldbus options, and motors cover a wide power spectrum.
Potential Considerations & Things to Watch for
As strong as Kollmorgen Essentials is, here are some trade-offs and things to think about:
1. Not Ultra-specialized
Essentials is designed for most axes. It may not support ultra-niche, high-performance applications that require custom windings, specialized feedback, or very high currents.
2. Current Limit
Ensure the selected drive model meets your peak and continuous current requirements. Larger or highly demanding loads may require a higher-power drive.
3. Environmental Sealing
The standard motor is rated IP54. Applications requiring wash-down or harsher conditions will need the IP65 shaft-seal kit.
4. Safety Architecture
STO is integrated. However, you must still confirm that it aligns with your overall safety system, including E-stops and safety controllers.
5. Lead Times
Essentials is produced at scale, and common configurations are stocked. For high-volume or specialized orders, verify availability in advance.
Why is Kollmorgen Essentials Best for You?
At its core, Kollmorgen Essentials delivers high-quality motion control without the complexity, cost, or extended lead times often associated with fully customized systems. For you, this results in:
- Faster time to market
- Lower design risk
- Simplified procurement and inventory
- Reliable performance
- Built-in safety
- Minimal maintenance overhead
In short, if you are building machines that need robust, precise motion but don’t necessarily require the absolute top-tier custom servo setup, Essentials is a smart, cost-effective, scalable choice.