‘Game-changing’ servo systems simplify motion control and cut costs
29 September 2025 
The motion control and automation supplier Kollmorgen has announced a range of servo products designed to simplify high-performance motion control and make it more affordable for almost any axis of motion. The pre-configured Kollmorgen Essentials system allows simple sizing and selection, while a choice of onboard communication protocols ensure integration with common controller environments.
The system is said to offer “unmatched ease of installation and commissioning,” and to ensure reliable performance across applications from packaging and warehouse automation, to material handling and forming. This is achieved while reducing engineering times and system costs.
Each Kollmorgen Essentials motion system consists of a matched combination of a servodrive, servomotor with absolute multi-turn feedback, and a combined power/data cable.
The drives support multiple protocol options, allowing users to choose between EtherCat, EtherNet/IP or Profinet at the time of installation. Synchronisation capabilities give designers precise control of multi-axis systems via a choice of CIP Sync, Profinet IRT or EtherCat. This flexibility gives users access to high-performance motion in their existing environments, without high system costs. It also simplifies ordering and inventory management for machine-builders, allowing them to support different communication protocols for customers around the world. Functional safety is provided via integrated dual-channel STO, SIL2/Cat 3 PLd capabilities.
The compact drives are easy to install and commission using the Express Setup function built into Kollmorgen’s WorkBench software. Drive setup, configuration and tuning has been simplified, even for engineers with little motion experience. A graphical configuration tool supports them throughout the commissioning process. The full suite of WorkBench tools is included for more advanced motion programming and tuning tasks.
The Kollmorgen Essentials servodrives are available for 120–240V or 240–480V AC supply voltages and can deliver continuous power up to 4kW, at 3, 6 or 12A.
The matching Essentials servomotors are rated at 120, 240, 400 or 480V AC and are designed for power requirements from 200W to 4kW. Each delivers a rated speed of 3,000 rpm, with peaks of up to 6,000 rpm. An integrated 24V DC brake is available as an option.
Standard mountings reduce the need for excess inventory and improve field flexibility. With a simple shaft key kit, users can adapt the shaft configuration to any type of coupling.
The servomotors incorporate Kollmorgen’s SFD-M multi-turn absolute encoders, which provide a 24-bit single-turn resolution and 16-bit multi-turn resolution. A power-harvesting technology eliminates the need for batteries or the risk of battery failures. The encoder retains absolute positioning information even when the system is powered down or during a power failure.
Kollmorgen says that users can expect positioning performance comparable to Hiperface or EnDat feedback systems. The high-performance encoders cost no more than an equivalent motor with resolver feedback.
A single-cable technology that combines power and data is offered as standard with the Kollmorgen Essentials motion system. It allows fast installation, with just one cable to route and just one connection at the drive and motor ends. It also enhances reliability with a strong immunity to electromagnetic noise and fewer connection errors. The combined power/data cables are available in lengths up to 25m.
The system is also optionally available with regen resistors, line filters and spare drive-side connectors. It supports DC bus-sharing, which balances energy between the connected drives, helping to save energy, and a more constant DC link voltage for better control performance.
“Kollmorgen has always been the motion leader for torque density, responsiveness and control in compact systems that offer the flexibility and features to suit practically any application,” says Chris Cooper, the company’s global director of product management. “We’re pleased to now offer all these advantages in complete, optimised systems that allow design engineers to more easily and affordably integrate Kollmorgen high-performance motion across all axes of their machines, with easy connectivity to their existing PLC environments.
“The new Kollmorgen Essentials motion system is truly a game-changer for our business and the essential industries we serve.”
