High-performance automation solutions for the automotive industry

Flexible control technology for a dynamic industry

An average car consists of around 10,000 individual parts. This calls for extensive production processes and machinery within the automotive industry, which all require equally diverse and sophisticated control solutions. At the same time, ever shorter product life cycles demand a high degree of flexibility. This is where PC-based control from Beckhoff provides crucial benefits, as the modular control technology offers scalable options based on specific needs. By incorporating retrofits, it safeguards investments in proven systems while also facilitating the production of cutting-edge technology through innovative solutions. The integration of all control functions into a single PC platform makes for highly precise and efficient production processes.

The core advantages of PC-based control:

• PLC, motion control, robotics, safety and measurement technology, HMI, IoT, and image processing integrated into a single PC platform
• straightforward modification and extension of functionalities
• fast software-based machine conversion
• perfect synchronization of all processes for maximum precision
• high speed and repeatability

Fast, open, and ideal for the automotive industry: the EtherCAT high-speed fieldbus

EtherCAT technology was launched by Beckhoff in 2003 and made available as an open automation technology standard. With outstanding performance, flexible topology selection, comprehensive diagnostics, and simple configuration, EtherCAT is ideally suited for use in production plants. This is why the world’s largest automotive manufacturers are already members of EtherCAT Technology Group (ETG).

Primary benefits of EtherCAT:

• extremely fast cycle times for precise and efficient processes
• perfect synchronization of all plant processes
• wide selection of EtherCAT-compatible sensors and actuators on the market
• flexible connection of other fieldbus systems, such as CANopen, IO-Link, PROFIBUS, PROFINET, EtherNet/IP™, Modbus/TCP, TSN, and OPC
• reduced cabling work thanks to the EtherCAT P one-cable solution
• maximum performance with speeds of 1 Gbit/s or 10 Gbit/s with EtherCAT G

Simplifies and accelerates engineering

TwinCAT 3 automation software integrates all engineering and runtime processes and features a consistent development environment for implementing all control tasks in the automotive industry. Programming is carried out using the most appropriate method for the application, including IEC 61131-3, high-level languages such as C/C++, MATLAB^®, and Simulink^®. Microsoft Visual Studio is used as the standard programming workbench, since it not only supports version management, but also simplifies teamwork. Ready-made software blocks facilitate engineering and shorten development and commissioning times. As the latest innovation, TwinCAT PLC++ enables significant improvements in engineering and runtime performance. With the focus placed on DevOps principles such as continuous integration and continuous deployment, we are consistently pursuing our philosophy of merging automation and IT.

TwinCAT benefits include:

• libraries for motion control and supplements for robot kinematics
• accelerated commissioning and maintenance with TwinCAT Scope
• simplified implementation of functional safety with TwinSAFE
• cloud communication in common protocols with TwinCAT IoT

Save resources with a virtual PLC

Working on the basis of PC-based control with TwinCAT for Linux^®, Beckhoff opens up additional application possibilities: By using containers, the TwinCAT PLC runtime and TwinCAT functions can be operated as a virtual PLC.

Production facilities in the automotive industry often require rapid adjustments and changes in order to keep pace with the requirements of different vehicle models and series production. With a virtual PLC, control software updates and changes can be carried out centrally and automatically, which significantly reduces the need for manual work and saves resources. The ability to carry out control tasks in a data center also makes it easier to integrate sophisticated simulation and test procedures, which are essential for quality assurance in automotive production.

The most important advantages of TwinCAT for Linux^® and virtual PLC:

• increased flexibility: virtual control systems can be easily scaled and adapted to different requirements
• lower costs: there is less need for physical hardware in the field, reducing the associated costs
• simplified maintenance: maintenance and software upgrades are easier to carry out as no physical hardware is affected

Innovative approaches to drive technology with XTS and XPlanar

Our drive solutions cover a wide range of applications, ranging from rotary and translatory servomotors to compact servo drives in terminal format to the high-performance servo drives in the AX series. With perfect scalability in terms of design and performance, they pave the way for optimized drive concepts.

The intelligent and flexible XTS and XPlanar transport systems open up completely new application scenarios. Their individually controllable movers revolutionize the rigidly timed product transport found in conventional conveyor systems. With free-floating movers that travel across arbitrarily arranged planar tiles, the XPlanar planar motor system facilitates outstanding product handling flexibility with up to six degrees of freedom. The XTS linear transport system uses the movers to transport products along an open or closed track of motor modules. What’s more, the XTS movers even become end effectors with the contactless energy and data transmission of the No Cable Technology.

XPlanar and XTS benefits:

• individually controllable movers for flexible material flows in the plant
• rapid conversions thanks to software-based adjustments
• higher productivity due to minimized downtimes
• compact footprint thanks to individual plant layout

Paves the way to control cabinet-free automation

For the first time, the MX-System enables completely control cabinet-free automation solutions in machine and system engineering. The combination of baseplate and function modules combines all the tasks and properties of a control cabinet: power supply, fuse protection and power distribution, generation and monitoring of auxiliary voltages, sequence control, control of motors and actuators, and the connection level for the field devices. Based on coordinated assemblies and certified to international standards, this approach enormously reduces the work required for planning, assembly, machine installation, and maintenance.

Benefits of the MX-System for the automotive industry:

• exact scalability to individual automotive applications
• modular and highly flexible design to save on installation space
• extensive diagnostics integrated into each module for high machine availability
• minimal downtime due to hot-swap functionality
• IP67 protection rating for demanding environmental conditions
• reduced work for engineering, installation, commissioning, and maintenance

Operation, control, and monitoring directly on the machine

A panel PC combines all the benefits of a high-performance industrial PC with the touch technology of a modern control panel. In its attractive, high-quality housing, the device becomes the central operating and control element on the machine. The product range includes a wide variety of sizes and formats in built-in or portable versions. In addition to further options, such as special equipment with operating elements or visual adaptations in customer-specific corporate designs, our in-house production capabilities mean we can also accommodate entirely custom designs.

Panel PCs as the visual hallmark of a plant:

• state-of-the-art touch technologies for industrial requirements
• integrated, power-scalable industrial PC
• extensive portfolio with various standard options
• various options for customer-specific modifications
• entirely customized designs available on request

The basic building block of automation: The extensive I/O portfolio

With around 1000 I/Os for more than 100 signal types, Beckhoff’s modular automation toolkit is well equipped to cater to a whole host of requirements. An extensive range of housings, a variety of channel densities, and flexible interfaces ensure that the ideal product is available for every application scenario.

In addition to standard functions, our I/O portfolio includes products for specialist applications, such as safety technology, explosion protection, measurement technology, and the control of small drive technology motors. Communication and power measurement terminals for charging infrastructure are also available. A large number of EtherCAT-compatible sensors and actuators are available thanks to their high level of acceptance on the market. Support for common communication protocols, such as CANopen, IO-Link, PROFINET, and Modbus, offers our customers maximum freedom in terms of control design – even when it comes to retrofits or conversions of existing systems.

Seamless integration of machine vision

With Beckhoff Vision, real-time image processing can be easily integrated into both new and existing control environments, and can be optimally synchronized with all machine and plant processes. The system integration approach effectively bridges the historical division between vision and automation technology. At the same time, Beckhoff Vision components impress with their robust, attractive design, as well as high scalability and long-term availability.

Benefits of vision integration in EtherCAT:

• direct synchronization and linking with control processes
• simplified and synchronized trigger generation for image capture and exposure
• shortened response times, higher cycle rates, and accelerated processing
• reduced hardware, wiring, waiting time, installation space, and footprint
• simplified diagnostics