Festo extends remote I/O across machine zones with new end plates

Festo recently introduced end plates for its CPX-AP-A remote I/O platform designed to help OEMs expand machine systems without adding gateways or additional network addresses.

The EPLI and EPLI-S end plates extend communication and power across multiple machine zones while keeping systems under a single Ethernet address.

Carlos Carbonell, electric automation product market manager for remote I/O at Festo, says the approach is intended to simplify wiring, reduce cabinet complexity, and support more modular machine layouts. The end plates also eliminate the need for cabinet rewiring when expanding into additional machine zones.

“EPLI and EPLI-S end plates solve a scaling problem,” said Carbonell, during an interview with Packaging OEM. “When OEMs distribute I/O, they typically multiply fieldbus nodes and incur increased wiring complexity. End plates remove the complexity and cost.”

The end plates extend the AP backplane to connect additional modules without introducing new gateways. The EPLI extends communication and system power, while the EPLI-S also provides power to connected modules.

Extending I/O without added cabinet complexity

The design allows I/O, valves, and sensors to be placed closer to the point of use across machine sections. Carbonell outlined additional benefits and integration with a programmable logic controller (PLC).

“Intelligent end plates simplify wiring, reduce cabinet size, lower wiring costs, and commissioning time. They contribute to a less complex system. The OEM is only addressing one device. This arrangement means the PLC requires fewer IP addresses, which enables the OEM to lower cost by right-sizing the PLC,” said Carbonell. 

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Added I/O appears within the existing system rather than as a separate network layer. Festo said that the CPX-AP-A architecture is designed so that distributed modules remain part of a single system view in the PLC as new zones are added.

“Because there are no additional gateway modules and network addresses, the PLC simply shows new zones/positions for the I/O that have been added. The I/O appears as an available position in the PLC software interface,” said Carbonell.

Building across multiple machine zones

Festo said the end plates support distances of up to 50 meters between modules within a segment, allowing machine builders to extend systems across larger machine layouts.

“50 meters is a real, tested maximum, not just a suggestion. Within that limit, it behaves like a design space where performance is assured by cable quality, low electrical noise, and normal power distribution,” said Carbonell.

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That distance limit applies per segment, not per machine.

“Every time an EPLI node is inserted, along with digital I/O, an IO-Link master, or a valve terminal, the OEM effectively starts a new segment. Segment length depends on the application and machine layout,” said Carbonell.