Description

The UFC718AE01 (ABB order code HIEE300936R0001) is a high-performance embedded controller from ABB’s AC 800PEC family, engineered for applications demanding extreme speed, deterministic response, and tight integration between motion, logic, and process control. Built around a powerful dual-core CPU and a reconfigurable FPGA for ultra-fast I/O handling, the UFC718AE01 delivers scan cycles as low as 1 microsecond, making it ideal for robotics, high-speed packaging, test benches, and synchronized multi-axis drive systems.

Application Scenarios

At a European automotive battery cell production line, engineers struggled to synchronize 24 servo axes during electrode slitting and stacking—jitter above 50 µs caused misalignment and scrap rates exceeding 8%. They replaced conventional PLCs with the UFC718AE01. leveraging its FPGA-based I/O processor to achieve <5 µs jitter across all axes via EtherCAT. The UFC718AE01 executed complex cam profiling and real-time tension control in a single 50 µs cycle, reducing scrap to 0.3% and increasing throughput by 22%. Operators noted, “It doesn’t just control machines—it anticipates them.”

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Technical Principles and Innovative Values

Innovation Point 1: FPGA-Based I/O Bypasses OS Latency – Unlike standard PLCs where I/O must pass through the OS stack, the UFC718AE01 routes signals directly to the FPGA, enabling true hardware-level response—critical for emergency stop, laser triggering, or high-frequency PWM.

Innovation Point 2: Unified Engineering in Automation Builder – Motion, logic, safety, and HMI are programmed in a single environment using IEC 61131-3 and C/C++, eliminating integration gaps and version mismatches.

Innovation Point 3: Native EtherCAT Master with DC Synchronization – The UFC718AE01 acts as a full EtherCAT master with distributed clock support, synchronizing hundreds of drives and I/O terminals to within ±100 ns—ideal for printing, converting, or semiconductor equipment.

Innovation Point 4: Open Architecture for Custom Algorithms – Engineers can deploy proprietary C/C++ or Simulink-generated code directly on the FPGA or CPU, enabling AI-based predictive control, custom filters, or real-time analytics without external co-processors.

Application Cases and Industry Value

A global manufacturer of lithium-ion battery dryers deployed the ABB UFC718AE01 to control 16-zone thermal profiles with millisecond-level feedback from IR sensors. The system adjusted heater power in real time based on web speed and moisture content—previously impossible with 10 ms PLC cycles. Over six months, energy consumption dropped by 18%, and coating uniformity improved by 35%. The customer later reused the same UFC718AE01 platform for their electrode calendering line, citing “unmatched flexibility and performance per watt” as key ROI drivers.

Related Product Combination Solutions

CI874: EtherCAT communication module – extends UFC718AE01 connectivity to redundant EtherCAT networks.

DI840 / DO840: High-speed digital I/O modules – connect via backplane for FPGA-accelerated signal handling.

AC 800M PM866A: Standard DCS controller – used alongside UFC718AE01 in hybrid architectures (e.g., machine + plant control).

ABB Ability™ Manufacturing Operations Management: Integrates production data from UFC718AE01 for OEE and traceability.

Automation Builder: Unified engineering suite – fully supports UFC718AE01 configuration, FPGA logic, and motion tuning.

TU854: Profibus baseplate – enables legacy fieldbus integration in UFC718AE01-centric test cells.

HIEE300937R0001: Optional SSD upgrade kit – expands storage for high-frequency data logging on UFC718AE01.

Installation, Maintenance, and Full-Cycle Support

Installing the UFC718AE01 requires secure panel mounting with adequate airflow (no fanless operation at full load). Connect power (24 VDC), link to industrial Ethernet switches, and attach I/O modules or EtherCAT slaves. Commissioning is performed in Automation Builder, which auto-detects the unit, validates FPGA bitstreams, and enables real-time oscilloscope-like debugging of I/O signals.

Maintenance is simplified by comprehensive self-diagnostics: the UFC718AE01 monitors CPU load, FPGA temperature, SSD health, and network latency—reporting anomalies via OPC UA or email alerts. Firmware and FPGA images can be updated remotely without physical access. We provide full lifecycle services: from FPGA logic validation and cybersecurity hardening to long-term spare parts availability and migration paths to next-gen platforms.

Contact us for a customized solution—whether you’re building next-generation machinery, pushing the limits of motion synchronization, or integrating AI at the edge of automation, the ABB UFC718AE01(HIEE300936R0001) delivers the speed, openness, and intelligence to turn breakthrough concepts into industrial reality.