Universal process automation with PC Control

Beckhoff is exhibiting its PC- and EtherCAT-based control solutions for metal forming at EuroBlech 2010, which takes place from 26 to 30 October in Hanover, Germany. The scalable automation solution from Beckhoff is used in almost all sectors of metal forming: from transfer presses and compact high-speed presses to pipe bending machines.

PC-based control technology from Beckhoff can play fully to its strengths in the automation of press lines: all processes can be automated with a universal control platform, from the coil processing, the belt straightening machine, the cutting and punching plants and the actual press, to the transfer facilities and the feeding, loading and unloading station.

Beckhoff covers all control requirements in metal forming and sheet metal working with its extensive product range, which consists of a broad range of scalable Industrial PCs, I/O systems for all common fieldbuses, TwinCAT automation software for PLC and Motion Control, servo drive equipment, the TwinSAFE integrated safety solution and EtherCAT, the fast real-time Ethernet bus system.

EtherCAT for high-precision coordination of manufacturing processes

The Beckhoff Industrial PC and Embedded PC series are equipped with the latest processor technology, from the powerful Intel® Core™ 2 Quad to the energy-saving Intel® Atom™, and offer scalable performance for all machine functions. The controller, which is based on IT standards, additionally features all necessary interfaces such as Ethernet, WLAN or RFID for integrating the machine into higher-level processes.

A fast bus system with short reaction times for tough real-time requirements is available in EtherCAT. All necessary process signals can be integrated simply and inexpensively into the controller via the Beckhoff I/O systems in protection class IP 20 or IP 67: from the digital I/Os, high-precision measuring terminals and safety functions to Condition Monitoring. Gateway terminals enable the integration of PROFIBUS or CANopen components into the EtherCAT Terminal system.

TwinCAT software integrates all necessary functions for the automation of a press line: a development environment for all Beckhoff controllers, IEC 61131 PLC, Motion Control including ‘electronic cam plate’, cam controller and ‘flying saw’, and diagnostic options extending to the software oscilloscope. With TwinCAT the entire spectrum can be solved with one programming environment, from the smallest bus controller to the computer networks of complex manufacturing plants.

TwinCAT 3 opens up new ways in the world of automation

In TwinCAT 3, Beckhoff presents the new software generation for PC-based control technology that will expand the world of automation by many functions. In addition to the object-oriented IEC 61131-3 extensions, the languages of the IT world are available in C and C++. The integration of Matlab®/Simulink® enables the application in scientific fields. The runtime runs under harsh real-time conditions with the use of multi-core technology and the support of 32- or 64-bit operating systems.

Die cushion control: from the black box into the PC

A press controller must precisely coordinate all of the mechanical components involved: in order to be able to start the pre-acceleration of the die cushion in precisely the correct reproducible moment, for example, the position and speed of the plunger must be detected precisely. All inputs and outputs at field level can be read and output synchronously with an accuracy of ~10 ns and provided with a time stamp by means of the distributed clocks of the EtherCAT system. This synchronisation can even go beyond the individual PC and allow a whole production hall to cooperate synchronously.

Presses require control loops with a high control quality. The sampling times of a hydraulic die cushion controller are, for example, around 250 μs, independent of how many axes the die cushion encompasses. The high demands on the availability of a press controller, for example in the press plant of a car manufacturer, are met by the RAID system integrated in the Industrial PC, among other things.

New items in the automation kit

In addition to industry solutions, trade visitors to the Beckhoff booth will find numerous new items: from the Industrial PC and Embedded PC families equipped with the latest processor technology to the HD Bus Terminals, which continue the trend towards compact designs with high packing density. At the centre of attention is TwinCAT 3, the latest version of the Beckhoff automation suite, which opens up new possibilities in modern control technology thanks to its modular structure and multicore support.