FPR3203526R1002A High Performance Motion Control Processor Module

Description

FPR3203526R1002A Product Description:
FPR3203526R1002A is a high-performance motion control processor module designed specifically for ABB’s IRC5 or OmniCore robot platforms and independent motion control systems. As the computing core of these platforms, it executes control algorithms, manages servo drives, and interfaces with sensors such as encoders and vision systems to achieve precise positioning and speed control. This module supports programming using ABB’s RobotWare language or IEC 61131-3 standard (such as structured text) to make it suitable for robot and general motion control applications.

FPR3203526R1002A

In the system architecture, FPR3203526R1002Aserves as the main controller, communicating with servo drives through high-speed serial links (such as SERCOS, EtherCAT), and connecting to higher-level systems (PLC, SCADA) through industrial Ethernet (PROFINET, EtherNet/IP). Its function is to ensure seamless coordination between up to [X] axes (depending on configuration), enabling complex movements such as linear/circular interpolation or synchronous gear transmission. For system integrators, their modular design and compatibility with ABB’s robot ecosystem simplify the deployment process, whether it’s retrofitting old equipment or implementing new automation projects. The value proposition of this module lies in its ability to strike a balance between computing power and energy efficiency, providing sub millisecond cycle times while supporting real-time diagnostics and predictive maintenance.

FPR3203526R1002A

Main features and advantages:
Multi axis motion control: supports up to [16-32] axes of motion (configurable), with advanced features such as electronic cam, gear transmission, and path planning. The 32-bit RISC processor and dedicated motion coprocessor of this module can quickly calculate trajectory curves, ensuring smooth motion even at high speeds (such as 5 m/s in robot applications).

Real time communication and determinism: Equipped with dual Gigabit Ethernet ports for connecting servo drives and host systems, supporting real-time protocols such as EtherCAT (cycle time ≤ 1 ms) and PROFINET RT. Built in redundancy mechanisms (such as dual core processing and fault injection testing) ensure high availability of critical systems, and the fault switching time of safety critical axes is in microseconds.

Integrated Safety and Diagnosis: Compliant with ISO 10218-1/2 (Robot Safety Standard), and supports functional safety features such as Safe Torque Off (STO), Safe Speed Limit (SLS), and Safe Position Monitoring (SPM). The advanced diagnostic function can monitor the health status of the motor, drive temperature, and communication integrity. The built-in LED indicator light and system log can quickly isolate faults. For example, in pharmaceutical robots, this module may detect abnormal vibration patterns and trigger maintenance alerts before component failures occur.

Industrial grade durability: Reliable operation within a temperature range of 0 ° C to+50 ° C (expandable to harsh environments of -25 ° C to+60 ° C), and can withstand vibrations up to 2 g (IEC 60068-2-6). The compact DIN rail installation (100mm width) and fanless design reduce the space and noise of the control cabinet, while the sturdy metal casing prevents dust and accidental impact (IP20 protection level).

FPR3203526R1002A

Technical specifications:
Model FPR3203526R1002A
Brand ABB
Type: Motion Control Processor Module
System compatibility IRC5, OmniCore, ABB AC 800M (with motion extension)
32-bit RISC CPU (dual core), motion co processor
1 GB RAM, 4 GB Flash
Communication interface 2 x 1 Gbps Ethernet (EtherCAT, PROFINET, EtherNet/IP), 1 x RS-485
Supports up to 32 axes (configurable)
Cycle time ≤ 1 ms (motion control loop)
Power supply 24 V DC (± 10%, supports redundant input)
Working temperature: 0 ° C to+50 ° C (with cooling, expandable to -25 ° C to+60 ° C)
Installation method DIN rail (TS 35/7.5 or TS 35/15)
Dimensions 100 mm (width) x 200 mm (height) x 150 mm (depth)
Weight 1.5 kg
Certified CE, UL, cUL, ISO 10218, IEC 61508 (SIL 2 compatible)
Environmental protection level IP20, IEC 61000-6-2 (electromagnetic compatibility)

Contact Us
Mobile:+86 16626708626
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Email: 3772179818@qq.com

Application areas:
In industrial automation systems that require precise motion control and high-speed data processing, FPR3203526R1002A(typically part of ABB’s robot or motion control product portfolio) is a key processor module used for advanced machine control. This module is designed for harsh environments such as automotive manufacturing, electronic assembly, and pharmaceutical packaging, and can manage complex motion trajectories, real-time feedback loops, and coordinated control between multiple axes. For example, on the semiconductor manufacturing production line, FPR3203526R1002A can control the pick and place robot to process precision components with sub micron precision, ensuring alignment accuracy during chip bonding. In high-speed filling factories, this module can synchronize the movement of conveyor belts, labeling machines, and capping stations, while maintaining a production rate of over 1000 bottles per minute and minimizing mechanical stress.

This module performs excellently in applications that require tight integration of motion control, safety systems, and Industrial Internet of Things (IIoT). Engineers rely on their ability to perform real-time multi axis interpolation, torque control, and collision avoidance algorithms, which are crucial for applications such as robot welding or 3D printing. By combining high-performance processing with deterministic communication protocols, FPR3203526R1002A addresses the core challenges of achieving speed and accuracy in automated manufacturing systems, as even minor errors can result in high defect costs or downtime.

Related products:
DSQC 679- ABB servo drive module, directly controlled by FPR3203526R1002A, used for precise motor control of robot arms.
DSQC 377A – Digital I/O module, used to connect sensors and actuators, providing feedback to the motion controller.
PC520- ABB Industrial PC, as the host system, programs and monitors FPR3203526R1002A through RobotStudio software.
CM578- PROFINET communication module enhances the connectivity between the module and PLC or HMI in hybrid automation systems.
S2C801- Safety controller module, integrated with FPR3203526R1002A, achieves safety level motion control function.
TA541- Servo Motor Cable Terminal Adapter, simplifies wiring between processors and drive units.

Installation and maintenance:
Considerations before installation:
Ensure that the control cabinet has sufficient cooling (such as forced ventilation or heat sinks) to maintain a temperature below 40 ° C when operating multiple axes at full capacity.
Use shielded twisted pair cables for servo communication (such as EtherCAT) and separate power cables from signal cables to reduce electromagnetic interference (EMI).
Use ABB’s RobotStudio or Motion Studio software to configure the IP address and motion parameters of the module, and verify compatibility with the connected servo drives and mechanical systems.
Maintenance suggestion:
Monthly System Health Check: Monitor shaft error rate, processor load, and driver temperature using the manufacturer’s diagnostic tools.
Quarterly firmware updates: Apply validated firmware versions to access new motion curves or security features, and test them in simulated environments (such as virtual debugging) before deployment.
Annual hardware inspection: tighten all terminal connections, clean dust from ventilation ducts, and verify the integrity of safety related wiring (such as STO circuits).
In high load applications such as 24/7 production, predictive maintenance checks on motion curves and drive systems are conducted every six months, using diagnostic data from modules to identify trends such as increased position errors.

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