A machine controller can be physically small and still sit at the heart of the complete system. Vectioneer uses a compact FITLET2 supplied by MiniDis to run Motorcortex, its software platform for hard real-time control, EtherCAT communication and browser-based engineering tools. The result is a PC-based motion-control platform that brings machine control, data access and visualisation together without requiring a large conventional industrial PC.
A compact industrial PC for EtherCAT motion control
Vectioneer has worked on complex control, robotics and system-engineering projects since 2010. The company created Motorcortex to give machine builders and robotics developers a more open way to build real-time control applications.
The interesting part of this use case is not simply that software runs on a small computer. The FITLET2 has to support several roles at once. It runs the Motorcortex control environment, communicates with EtherCAT drives and I/O, and makes system data available to engineering and visualisation tools.
That makes hardware selection part of the control architecture. Processor performance matters, but so do the Ethernet controllers, operating-system image, thermal design, storage, BIOS configuration and long-term availability of the chosen system.
What Motorcortex brings together
Motorcortex is a Linux-based framework for building hard real-time control systems. In practical terms, hard real-time means that critical control tasks must execute within predictable timing limits. Motorcortex also provides interfaces for industrial EtherCAT hardware and makes application data available to browser-based and external tools.
Real-time control application
The controller runs the application logic, control loops and state machines that coordinate the machine or robot.
EtherCAT drives and I/O
A dedicated industrial network connects the controller to compatible servo drives, sensors, actuators and remote I/O.
Engineering and visualisation
Browser-based Motorcortex tools can expose parameters, signals, traces and application-specific user interfaces to authorised users.
Motorcortex also provides client libraries for languages including JavaScript, Python, C++ and C#. This gives developers room to connect the control system to visualisation, data logging, analysis tools or higher-level applications without moving the real-time control task away from the controller.
Where the FITLET2 fits into the architecture
In this MiniDis case, the FITLET2 provides the x86 computing platform on which Motorcortex runs. The system is compact, fanless and based on an Intel Atom platform. Its enclosure measures approximately 112 Ć 84 Ć 34 mm, making it practical for control cases, compact cabinets and embedded machine spaces.
The platform includes two Ethernet ports as standard and can be configured with additional interfaces. Depending on the validated design, one network connection can be dedicated to EtherCAT while another supports engineering access or communication with a higher-level network.
Fanless construction removes a moving cooling fan, but it does not remove the need for thermal engineering. The complete controller still has to be assessed inside its final enclosure, with realistic ambient temperature, mounting orientation and processor load.
Hardware and software have to be validated as one control platform
A fanless industrial computer does not automatically become a deterministic motion controller. Real-time performance depends on the selected hardware, operating system, network interface, Motorcortex configuration and EtherCAT topology. Functional safety also remains a separate system-level responsibility.
Why this approach is useful to machine builders
PC-based motion control can combine functions that would otherwise be spread across a dedicated controller, separate engineering software, an HMI and additional data interfaces. For the right project, that can create a cleaner and more flexible architecture.
The browser-based workflow is particularly useful during commissioning and service. Engineers can inspect signals, tune parameters and analyse system behaviour through Motorcortex tools. A project-specific interface can also make selected information available to an operator without exposing the complete engineering environment.
The trade-off is that the engineering team must take responsibility for the complete platform. Network separation, user access, software updates, cybersecurity, recovery procedures and component changes should all be planned before series deployment.
What should be checked before selecting a PC-based motion controller?
- Real-time requirements: required task timing, jitter limits and worst-case processor load.
- EtherCAT interface: supported network controller, dedicated port and verified slave-device topology.
- Software image: Motorcortex version, operating-system image, drivers and BIOS settings.
- Thermal design: enclosure temperature, mounting position, airflow and sustained workload.
- Safety architecture: emergency stop, safe torque off and functional-safety components outside the standard PC.
- Lifecycle: expected project duration, configuration control and replacement strategy.
- Service access: secure engineering connection, backups, logs and remote-support policy.
- Series preparation: repeatable memory, storage, labelling, assembly and software deployment.
The role of MiniDis in the Vectioneer solution
Vectioneer develops Motorcortex and the control-system expertise around it. MiniDis supplies the compact FITLET2 hardware used as the computing platform and supports the practical configuration of the system.
For an OEM or machine builder, this division of responsibilities is important. The control specialist validates the application, EtherCAT devices and machine behaviour. MiniDis helps make sure the selected computer can be supplied with the agreed processor, memory, storage, networking and operating-system preparation.
A documented hardware configuration reduces avoidable changes after software validation. MiniDis can also support in-house assembly, customer software images, kitting and planning for repeat orders.
Configure the FITLET2 for your application ā
What this use case demonstrates
The Vectioneer project shows how a compact industrial PC can become a capable motion-control platform when the hardware and real-time software are designed together. It also shows why industrial computing is not only about choosing a CPU. Interfaces, thermal behaviour, software consistency and supply continuity all influence whether the controller remains practical throughout development and deployment.
Similar considerations apply to robotics, test systems, machine retrofits, research equipment and other EtherCAT-based automation projects. The correct platform depends on the control workload and environment, not on a universal specification.
Planning an EtherCAT or machine-control project?
Share the control software, required network interfaces, cabinet conditions, real-time requirements and expected rollout volume. MiniDis can help compare suitable industrial computers and prepare a repeatable configuration for validation.
Discuss your control applicationFrequently asked questions
What is PC-based motion control?
PC-based motion control uses an industrial or embedded computer to run motion-control software. The platform can combine real-time control, EtherCAT communication, visualisation and higher-level software interfaces, provided the complete system is validated for the application.
What does EtherCAT do in a motion-control system?
EtherCAT is the industrial Ethernet network used between the controller and compatible drives, I/O modules, sensors and actuators. It supports the fast and synchronised exchange of process data required by many machine and robotics applications.
Why use a fanless industrial PC instead of an office PC?
A fanless industrial PC is designed for embedded installation and can offer a compact enclosure, DC power input, multiple network interfaces and project-oriented lifecycle options. Suitability still depends on temperature, vibration, electrical integration and software validation.