Beckhoff TwinCAT The Windows Control and Automation Technology

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Beckhoff TwinCAT The Windows Control and Automation Technology Beckhoff Industrial PC Beckhoff Lightbus Beckhoff TwinCAT Beckhoff Embedded PC

1 Beckhoff TwinCAT The Windows Control and Automation Technology Beckhoff Industrial PC Beckhoff Lightbus Beckhoff TwinCAT Beckhoff Embedded PC Beckhoff Bus Terminal Beckhoff Fieldbus Box Beckhoff PC Fieldbus Cards, Switches Beckhoff EtherCAT Beckhoff Drive Technology Beckhoff TwinCAT 1

2 PC control technology PLC and NC on a PC Beckhoff TwinCAT 2

3 Contents PC based automation TwinCAT overview I/O control (plc) motion (nc ptp) interpolated motion (nc-i, cnc) Beckhoff TwinCAT 3

4 PC based automation: development Evolution in control IPC Prog. Tool Komm. HMI Hardware Software Mechanic Electronic Slots/CPUs Tasks par. Connect Fieldbus Comm. direct Access Prog. Tool IPC HMI Router CPU E/A NC PLC 1 PLC 2.. E/A NC Mapping RT-Kernel Fieldbuses Beckhoff TwinCAT 4

5 What is TwinCAT? TwinCAT is an automation package comprising engineering and runtime software for sequence control (Software PLC), motion (Software Motion Control), communication over all components (ADS), technological function (controllers, communication, OS functions, etc...) and all this in HARD REALTIME on Windows NT/2000/XP as well as on Windows NT/XP Embedded and CE.NET Beckhoff TwinCAT 5

6 TwinCAT architecture TwinCAT on a PC platform TwinCAT does not modify Windows needs no special hardware turns standard Windows to a real-time OS Floating Point Unit (FPU) fully supported full access to Windows user interface via OCX, Dll remote access via TCP/IP PC platform standard hardware, best performance use of PC resources use of mainstream operating system (Windows) easy integration into office networks open field bus communication Beckhoff TwinCAT 6

7 Platform PC Diagnose PLC User User SysMan i.e. Scope Control HMI HMI ADS ADS ADS ADS OPC Realtime Server TwinCAT System ADS Router OCX/Dll Windows NT, 2000, XP ADS ADS ADS ADS PLC NC other Server Server i.e. CAM I/O I/O I/O I/O Server I/O Mapping Fieldbus Card Drivers OPC Kernelmode Usermode TCP/IP Beckhoff TwinCAT 7

8 TwinCAT real-time developed by Beckhoff needs no extra hardware other than PC cycle times as low as 50 µs preemptive scheduling latency time < 15 µs (PIII) adjustable real time ratio to Windows (patented) message if latency time is too high Beckhoff TwinCAT 8

TwinCAT PC system key features Safe operation TwinCAT real-time systems survive a BSOD (blue screen of death) motherboard diagnosis for fan/temperature Performance fast closed loop control, cycle

9 TwinCAT PC system key features Safe operation TwinCAT real-time systems survive a BSOD (blue screen of death) motherboard diagnosis for fan/temperature Performance fast closed loop control, cycle time down to 50 µs Vertical and horizontal integration ADS routing (local or via TCP/IP) Retain data/restart behaviour UPS support (serial and Beckhoff) Event tracking Beckhoff TwinCAT 9

TwinCAT on a CX1000/CX1020/CX9000 platform TwinCAT pure software solution uses Windows CE real-time cyclic storage of Retain Data programming display CX10xx/CX9000 embedded HW: 32-bit x86 comp.

10 TwinCAT on a CX1000/CX1020/CX9000 platform TwinCAT pure software solution uses Windows CE real-time cyclic storage of Retain Data programming display CX10xx/CX9000 embedded HW: 32-bit x86 comp. CPU 266 MHz OS: Windows CE or Windows XP embedded (CX10xx) no rotating media, fan less direct access to terminal I/O more than one field bus master and/or slave resolution from 320 x 240 to 1024 x Beckhoff TwinCAT 10

TwinCAT CE system key features Safe operation TwinCAT real-time systems survive a BSOD (blue screen of death) Motherboard diagnosis for fan/temperature Performance fast closed loop control, cycle

11 TwinCAT CE system key features Safe operation TwinCAT real-time systems survive a BSOD (blue screen of death) Motherboard diagnosis for fan/temperature Performance fast closed loop control, cycle time down to 50µs Vertical and horizontal integration ADS Routing (local or via TCP/IP) Retain data/restart behaviour UPS support (serial and Beckhoff) Event tracking language independent messages Beckhoff TwinCAT 11

TwinCAT on a BXxxxx platform TwinCAT downloads program source code up/download online debugging/online change remote access via field bus BXxxxx embedded

12 TwinCAT on a BXxxxx platform TwinCAT downloads program source code up/download online debugging/online change remote access via field bus BXxxxx embedded hardware Smart System Bus (CANopen based) display navigation switches embedded operating system direct access to terminal I/O Beckhoff TwinCAT 12

13 TwinCAT on a BCxxxx platform TwinCAT downloads program online debugging remote access via field bus BCxxxx embedded hardware embedded operating system direct access to terminal I/O Beckhoff TwinCAT 13

14 Performance Measurements Test 1 : Bit / Byte / Int / Dint / Word / DWord Test 2 : Bit / Byte / Int / Dint / Word / DWord / Real / LReal / String Beckhoff TwinCAT 14

15 TwinCAT I/O System open for all major field buses PC hardware supported easy setup and diagnosis mapping from logical to physical I/O TwinCAT process image Input Output Mapping II O II O II O field bus 1 field bus 2 field bus Beckhoff TwinCAT 15

16 TwinCAT Control modular structure timing max. 4 PLCs on a PC 1 PLC on CX1000/BX/BC max. 4 task in one PLC easy set up and maintenance online program change full debugging features: breakpoint, monitoring, power flow, scope choose the favourite programming language all IEC languages (IL, ST, FBD, LD, SFC) Beckhoff TwinCAT 16

17 TwinCAT Motion Migration from mechanical to electronic system mechanical cam electronic cam mechanical gear electronic gear mechanical clutch electronic coupling mechanical cam shaft electronic cam shaft flying saw Benefit greater flexibility when changing the finished product increase machine output reduce set up time no mechanical modification decrease stock no different mechanical parts Summary shorten delivery/development time, decrease costs Beckhoff TwinCAT 17

interfaces: Lightbus, Sercos, Profibus DP/MC, SSI, pulse train analogue: +-10V

18 TwinCAT NC PTP up to 255 axes easy set up and maintenance open for all axis types servos stepper switching axes hydraulic axes interfacing to drives via digital interfaces: Lightbus, Sercos, Profibus DP/MC, SSI, pulse train analogue: +-10V additional functionality: camming, gearing, flying shear, superposition Beckhoff TwinCAT 18

19 Hands on Beckhoff TwinCAT 19

20 Interpolated movements: TwinCAT NC I Interpolated movements for 3- axes plus 5 auxiliary axes programming in DIN Code technological features: bottleneck detection Beckhoff TwinCAT 20

21 TwinCAT NC I Properties Max. number of controlled axes Max. number of independent channels Max. number of simultaneously interpolating per channel PLC programming CNC programming Interpolation functions TwinCAT NC I path axes + 5 auxiliary axes IEC DIN extension High-level language extensions Subroutine techniques CNC function blocks from the PLC Linear, circular, helical interpolation in the main planes Look Ahead Beckhoff TwinCAT 21

22 TwinCAT NC I Properties Axis functions Real-time transformations Axis interface I/O system TwinCAT NC I Path override Axis fault/sag compensation Gantry axes Tracking axes Auxiliary axes Master/Slave coupling variable factor Axis exchange via channels Online changes of configuration of the axes Online axis exchange with PTP axes Coordinate transformation Analog/encoder axis interface via appropriate fieldbus Digital axis interface via Lightbus, Sercos, Profibus DP/MC, CANopen, real-time Ethernet Lightbus fieldbus system, Profibus DP, CANopen, DeviceNet, Interbus, Sercos, real-time Ethernet, PC interfaces Beckhoff TwinCAT 22

23 TwinCAT CNC CNC path control for highest demands complete CNC functionality 32-axis interpolation coordinate and kinematik transformation 5-axis functionality spline interpolation Beckhoff TwinCAT 23

24 TwinCAT CNC Properties Max. number of controlled axes/spindles Max. number of controlled spindles Max. number of independent channels Max. number of simultaneously interpolating per channel PLC programming CNC programming Interpolation functions TwinCAT CNC path axes/spindles IEC DIN extension High-level language extensions Subroutine techniques User macros Linear, circular, helical interpolation in the main planes/freely definable planes Look Ahead Spline interpolation Thread functions Beckhoff TwinCAT 24

25 TwinCAT CNC Properties Axis functions TwinCAT CNC Path override Axis fault compensation Gantry axes Tracking axes Auxiliary axes Master/Slave coupling Axis/spindle exchange via channels Spindle synchronisation Real-time transformations Axis interface I/O system Coordinate and kinematic transformation 5-axis functionality Analog/encoder axis interface via Lightbus Digital/encoder axis interface via Lightbus, Sercos, Profibus, DP/MC Lightbus fieldbus system, Profibus DP, CANopen, DeviceNet, Interbus, Sercos, real-time Ethernet, PC interfaces Beckhoff TwinCAT 25

26 TwinCAT PLC Performance f O : T A C n i Tw n Pl l l or a s m r atfo C L P T: A C n i Tw l o o et CX1020/30 PC CX1010 CX9xxx BCxxxx BXxxxx Costs Beckhoff TwinCAT 26

27 TwinCAT NC PTP Performance f T: A C n i Tw On l o o et Pl l l or a N : T A C n i Tw s m r atfo TP P C CX1020/30 PC CX1010 CX9xxx BCxxxx BXxxxx Costs Beckhoff TwinCAT 27

28 TwinCAT NC I Performance f O : T A C n i Tw n Pl l l or a s m r atfo I C N : T A C n i Tw l o o et CX1020/30 PC CX1010 CX9xxx BCxxxx BXxxxx Costs Beckhoff TwinCAT 28

29 TwinCAT CNC Performance f O : T A C n i Tw n Pl l l or a s m r atfo C N C T: A C n i Tw l o o et CX1020/30 PC CX1010 CX9xxx BCxxxx BXxxxx Costs Beckhoff TwinCAT 29

30 Centraal vs Decentrale Motion Control Centraal Decentraal + Alle data (instellingen, status) op één locatie + Meerdere assen zijn eenvoudig te coördineren + Applicaties zijn eenvoudiger te multipliceren + Backups zijn eenvoudig te maken + Minder spareparts - Er is een krachtige CPU nodig - Alle data (instellingen, status) verspreid over de diverse controllers - Meerdere assen zijn moeilijk te coördineren - Applicaties zijn lastig te multipliceren - Backups zijn lastig te maken - Meer spareparts + Er is niet zo n krachtige CPU nodig Beckhoff TwinCAT 30

31 Voordelen Motion Control met TwinCAT Geen dure hardware motion controller nodig Alle informatie op één plek Krachtige Scoop functie Nagenoeg veldbus onafhankelijk Geïntegreerde PLC (zelfs 4 PLC s op één PC) Motion Control Library volgens PLCopen Software kan al met standaard PC ontwikkeld en getest worden Extreem flexibel Van NC PTP via NCI naar CNC Beckhoff TwinCAT 31

TF5xxx TwinCAT 3 Motion Control

TF5xxx TwinCAT 3 Motion Control TF5xxx Motion Control TC3 NC PTP 10 Axes TC3 NC PTP Axes Pack 25 TC3 NC PTP Axes Pack unlimited Technical data TF5000-00pp TF5010-00pp TF5020-00pp TC3 NC PTP 10 Axes implements Motion Control for pointto-point