Industrial automation engineers have spent decades looking for ways to simplify machine wiring.

Modern production equipment can contain servo motors, sensors, actuators, industrial computers, I/O modules, safety devices, and communication networks. As machines become more sophisticated, the amount of wiring required to connect these components can also increase.

Beckhoff is addressing this challenge through its One Cable Automation approach and has highlighted its ECP and ENP hybrid connector families as part of an expanded connector portfolio.

The connectors combine industrial power with signal and data communication in a single cabling concept and are designed around the DIN EN IEC 61076-2-118 standard.

The company says hundreds of thousands of ECP and ENP interfaces have already been implemented in the field.

For machine builders and system integrators, the technology addresses a very practical issue: reducing cabling complexity while maintaining the performance required by modern motion and automation systems.

Why Machine Wiring Is Becoming More Complex

Modern automation machines contain more functions than previous generations.

A conventional machine may require separate connections for:

• Motor power
• Encoder feedback
• Digital I/O
• Safety signals
• Communication
• Sensors
• Auxiliary power

When a machine contains multiple servo axes, the number of cables can increase rapidly.

A six-axis machine may require multiple motor cables and feedback connections.

Additional sensors and actuators add further wiring.

Industrial robots create another challenge because cable routing must accommodate continuous movement.

This creates mechanical and electrical engineering problems.

One Cable Automation Changes the Architecture

The concept behind One Cable Automation is relatively simple.

Instead of using separate cables for power and communication, a hybrid connection can combine multiple functions.

The result is fewer physical cables.

In a motion-control application, one cable can potentially carry the electrical power required by the motor together with feedback or communication signals.

This can simplify the connection between a servo drive and motor.

The benefits become more significant as the number of axes increases.

Beckhoff's ECP and ENP Connector Families

Beckhoff's ECP and ENP connectors are designed for this type of hybrid connection.

The company states that the connector families combine industrial power with signal and data communication.

They are compatible with DIN EN IEC 61076-2-118.

Standardization is important because industrial customers want components that can be integrated into broader automation architectures.

A connector should not only work electrically.

It must also provide mechanical reliability, appropriate protection, and compatibility with standardized industrial interfaces.

Reducing the Number of Cables

The most obvious advantage of One Cable Automation is reduced cabling.

Consider a machine with several servo motors.

Traditional architectures may require separate motor power and feedback cables.

A hybrid cable can combine these functions.

This can reduce:

• Cable quantity
• Connector quantity
• Cable trays
• Routing complexity
• Installation time
• Cabinet space requirements

For machine builders, the result can be a more compact machine design.

Cable Reduction Also Affects Engineering

The benefits extend beyond physical installation.

Cable management is an engineering task.

Each cable needs to be selected, routed, labeled, documented, and tested.

Large machines can contain hundreds of cable connections.

Reducing the number of cables can therefore simplify documentation and commissioning.

During troubleshooting, fewer physical connections can also make it easier to identify the relevant cable path.

This can reduce maintenance time.

Servo Automation Is a Major Application

One Cable Automation is particularly relevant to servo systems.

Modern motion applications require both power and feedback.

The motor needs electrical energy.

The controller needs accurate information about position, speed, and other motor conditions.

Traditionally, these functions may require multiple cables.

A hybrid connection can consolidate the physical interface.

This is valuable in applications such as:

• CNC machines
• Packaging machines
• Semiconductor equipment
• Material handling
• Robotics
• Printing machines
• Assembly systems
• Automated production lines

Robotics Creates Additional Cable Challenges

Robots are particularly demanding from a cable-management perspective.

A robot arm can move continuously through multiple axes.

Cables must withstand repeated bending and torsion.

They must also remain within the mechanical envelope of the robot.

Reducing cable count can therefore have mechanical advantages.

A smaller cable package can simplify routing and potentially reduce the physical burden on moving assemblies.

However, cable selection remains critical.

A cable designed for fixed installation may not be suitable for continuous robotic movement.

Engineers still need to consider bending radius, torsion, cycle life, temperature, shielding, and environmental conditions.

Connector Reliability Is Critical

Reducing the number of connectors does not mean connector quality becomes less important.

In fact, the opposite can be true.

If one hybrid connector carries multiple functions, a failure at that connection can affect several systems simultaneously.

The connector therefore needs to provide reliable electrical contact and mechanical integrity.

Environmental protection is also important.

Machine environments can contain:

• Dust
• Oil
• Coolant
• Vibration
• Temperature changes
• Mechanical movement

Industrial connectors need to be designed for these conditions.

Standardization Supports Machine Builders

The compatibility of ECP and ENP connectors with DIN EN IEC 61076-2-118 is important because standardized interfaces can help machine builders avoid overly proprietary architectures.

Standardization can make it easier to source compatible components.

It can also support future maintenance.

A machine may remain in operation for many years.

If the original supplier is no longer available, standardized components can potentially provide more flexibility.

One Cable Automation and EtherCAT

Beckhoff's automation architecture is strongly associated with EtherCAT.

EtherCAT provides high-speed industrial communication for distributed automation systems.

When combined with One Cable Automation, the communication architecture can become closely integrated with the physical machine architecture.

The controller sends motion commands through the industrial network.

The drive executes those commands.

The motor receives power.

Feedback information returns to the controller.

A properly designed one-cable architecture can reduce the physical complexity required to connect these functions.

Impact on Control Cabinets

Cable reduction can also influence control cabinet design.

Traditional machine cabinets can become crowded as the number of drives and I/O connections increases.

Reducing external wiring can simplify cable entry.

It may also reduce the physical space required for terminals and cable-management accessories.

This can support more compact machine designs.

For machine builders, cabinet size can have a direct impact on material cost, enclosure requirements, transportation, and installation.

Faster Machine Assembly

One Cable Automation can also affect manufacturing efficiency.

A machine builder that produces hundreds of similar machines needs repeatable assembly procedures.

Every additional cable connection requires labor.

Every connector needs to be checked.

Every cable needs to be routed.

A simplified connection architecture can reduce assembly effort.

This becomes increasingly valuable in high-volume machine production.

Commissioning Benefits

Commissioning is another area where cable simplification can help.

A large automation system needs to be tested before delivery.

Engineers must verify motor operation, encoder feedback, communication, safety, and I/O.

If the number of physical connections is reduced, the commissioning process can potentially become more straightforward.

However, engineers still need to verify every function.

A simplified physical architecture does not eliminate the need for electrical testing and software validation.

Maintenance and Spare Parts

Machine maintenance can also benefit from standardized hybrid connections.

If a servo motor needs to be replaced, technicians can disconnect the combined cable rather than managing multiple separate interfaces.

This can shorten service procedures.

However, maintenance teams need to understand the cable architecture.

A hybrid cable can carry multiple functions, so improper replacement or incorrect installation can affect more than one system.

Clear labeling and documentation therefore remain important.

The Connection Between Hardware and Software

One Cable Automation also illustrates a broader trend in industrial automation.

Automation systems are increasingly designed as complete architectures rather than collections of independent components.

A modern machine integrates:

• PLC or IPC
• Industrial Ethernet
• Motion control
• Servo drives
• Motors
• I/O
• Safety
• Sensors
• HMI
• Engineering software

The physical connection between these components is becoming increasingly important.

Software may define the machine's behavior, but reliable physical connections allow that software to interact with the machine.

Future Automation Systems Will Need Less Wiring

The broader trend is clear.

Industrial automation is becoming more distributed.

Controllers can be installed closer to machines.

I/O can be decentralized.

Drives can be integrated into machine modules.

Smart sensors can communicate digitally.

Hybrid connectors can combine power and data.

All of these technologies contribute to a reduction in wiring complexity.

This does not mean the factory will become wire-free.

Instead, the wiring architecture will become more integrated.

What This Means for PLC Engineers

For PLC engineers, simplified wiring can change the way automation systems are designed.

I/O mapping may become more distributed.

Drive communication may become more network-centric.

Diagnostic information can be transmitted digitally.

Instead of troubleshooting dozens of individual wires, engineers may increasingly diagnose systems through network information and device-level diagnostics.

This makes industrial networking skills more important.

PLC engineers will increasingly need to understand not only programming but also Ethernet architecture, drive communication, diagnostics, safety networks, and device integration.

Implications for Industrial Automation Suppliers

For suppliers, One Cable Automation creates opportunities in several areas.

Demand may grow for:

• Hybrid connectors
• Industrial cables
• Servo motors
• Servo drives
• EtherCAT devices
• Distributed I/O
• Industrial Ethernet
• Motion controllers
• Robotic cable systems

The value proposition is not simply lower cable quantity.

It is the possibility of reducing the total engineering and lifecycle cost of a machine.