Headquarters India
Beckhoff Automation Pvt. Ltd.
PC-based control for the process industry
Due to increasing competition, innovative automation solutions are increasingly in demand in the process industry, with a particular focus on quality, safety and efficiency. The development of new technologies opens up possibilities for optimizing production processes, both for modern new plants and for the retrofitting of existing plants.
PC-based control can meet precisely this requirement with the integration of process-specific protocols and interfaces as well as an extended product range for applications in potentially explosive atmospheres. Through the consistent bundling of control intelligence in the software and the use of established standard technologies in the IT and automation world, PC-based control from Beckhoff combines all functions such as PLC, measurement technology and Motion Control in one system. In addition to the industry-proven Control Panels and Panel PCs, Beckhoff offers specific solutions for use in potentially explosive environments in Zone 2/22 with the CPX series. With the Beckhoff EtherCAT Terminals from the ELX series, a wide range of signal terminals is available for use in areas subject to explosion hazard. Up to eight intrinsically safe inputs are integrated in the 12 mm terminal housing, allowing the direct connection of intrinsically safe field devices from Zones 0/20 and 1/21 to the Beckhoff controller. In addition to the Bus Terminals and EtherCAT Terminals in IP 20 for control cabinet mounting, the IP 67 EtherCAT Box modules are also available for direct mounting in the process environment for use in Zone 2/22. Products with an increased temperature range and optional coating are suitable for use in harsh environmental conditions. Thus, the comprehensive portfolio of explosion-proof components enables the realization of holistic solution concepts for barrier-free system integration up to Zone 0/20. In the case of new plants, the explosion protection can be integrated directly into the controller; with existing systems, the PC-based controller can easily be extended. The integrated explosion-proof portfolio also reduces dependencies as PC-based control integrates all essential automation functions in one system. This also applies to the software side: The TwinCAT control software allows HMI integration as well as the use of Industrie 4.0 and IoT applications, takes into account the NAMUR requirements for digital and analog signals and integrates both the HART protocol and FDT/DTM technology.
Intelligent networking improves plant availability in the oil and gas industry
Open up efficiency potentials along the entire value chain of large-scale chemical plants through Industrie 4.0
Increased productivity and enhanced personal safety through digitalization in mining
Flexible and competitive production: process monitoring and networking in the steel mill
Automation and process technology in one system: from machine control to building automation in the paint shop
Future-proof solutions for the energy sector: from biogas plants to smart cities
With a universal component construction kit and profound, cross-industry know-how, Beckhoff realizes open automation systems on the basis of PC-based control technology. Through the consistent bundling of control intelligence in the software and the use of established standard technologies from the worlds of IT and automation, PC-based control combines all functions such as PLC, measurement technology and motion control in a single system. For the process industry, a comprehensive portfolio of explosion-proof components is available for implementing integrated solution concepts for barrier-free communication from Zone 0 to the cloud. These include the EtherCAT Terminals of the ELX series with intrinsically safe interfaces, the Control Panels and Panel PCs of the CPX series with high-quality finish, the TwinCAT control software with specific process technology interfaces, hardware and software modules for simple IoT communication, and the application of cloud-based services and system networking. In the case of new plants, the explosion protection can be integrated directly into the overall controller; in the case of existing plants the Beckhoff PC-based controller can be simply extended.
Automation, process engineering and IoT communication in one system:
One control platform and one high-performance fieldbus for all control tasks. With its PC-based control technology, Beckhoff makes it possible to combine the widest range of I/O components in a single system. With only a single CPU and a single fieldbus, all EtherCAT Terminals for measurement tasks, functional safety and explosion protection can be easily integrated into a comprehensive control system for real-time applications. Users no longer have to rely on multiple standalone solutions, but can benefit from the efficiencies of an integrated solution.
The full integration of the HART functionality into both the I/O system and the TwinCAT engineering environment ensures simple project planning and commissioning. The HART integration allows users to integrate HART field devices directly into the controller. In addition, TwinCAT reduces engineering effort: The TwinCAT FDT container enables the integration of field device DTMs directly into TwinCAT Engineering and thus offers programming and field device configuration in one environment.
Beckhoff ComDTM enables seamless integration of TwinCAT controllers into existing process control systems. DTMs from the field devices connected to the HART-capable EtherCAT Terminals can be integrated in any desired FDT containers with the help of the ComDTM. This allows field devices to be configured and parameterized remotely in the containers without the need for access to the PLC. Thanks to the comprehensive integration of the HART protocol in TwinCAT, the functions from the Engineering interface can be used.
The EtherCAT fieldbus system developed by Beckhoff has been in use around the world since 2003 and is now regarded as the communication standard in many industries: More than 5,535 members* – including over 100 master device manufacturers – have joined forces in the EtherCAT Technology Group, the EtherCAT user organisation. As a universally usable and open high-speed fieldbus for PLC, Motion, I/O sensors, measurement technology and safety technology, EtherCAT is also suitable for explosion-proof connection. In other words, users only need one single communication technology. They can put their trust in the profound know-how of the EtherCAT pioneer Beckhoff and benefit from the safety and flexibility of the universal EtherCAT architecture. EtherCAT-based control systems are flexible and open, permitting the integration of third-party EtherCAT devices as well as many other fieldbus systems. With this openness, EtherCAT optimises existing and new systems alike and ensures investment protection. This is aided by the fact that there is no need to worry about revision control: EtherCAT exists in one version only, which means that new developments based on EtherCAT are always compatible with older device generations.
Users in hazardous areas also benefit from EtherCAT’s time stamp functionality, which guarantees high measuring quality and highly precise synchronization – even in extensive systems. Moreover, the EtherCAT concept with a 100 Mbit data rate and complete diagnostics integrated, enables fast error identification in systems and plants: downtime is minimised, while maintenance is simplified and uptime is increased. Via the ELX modules, the full performance of EtherCAT communication is supported right into each I/O terminal.
With its Extended Distance technology, EtherCAT simplifies the capturing of data in large and distributed installations such as refineries, water treatment or chemical plants. It does this, for example, with two EK1101-0010 EtherCAT Couplers, whose ports support extended distances. They can communicate over distances of up to 300 m without the need for intermediate infrastructure components. The Couplers accept standard EtherCAT Terminal blocks. With the EK1121-0010 terminal module users can also integrate an Extended Distance branch directly into the terminal segment and connect a remote 300 m I/O station. Due to its compatibility with standard EtherCAT devices, the Extended Distance technology does not place any extra demands on the system topology, which makes it possible to configure the EtherCAT network simply based on individual requirements.
With the ELX terminals Beckhoff combines highly compact remote I/O modules with isolating barriers for the direct connection of intrinsically safe field devices. The result: very slim EtherCAT Terminals for direct connection of intrinsically safe sensors and actuators. The high resolution and accuracy of the Beckhoff ELX terminals guarantee the same measuring quality that is familiar from the non-hazardous areas. The compact design of the I/O terminals provides a further advantage: there are up to four intrinsically safe inputs available in the 12 mm housing and up to eight in the24 mm housing. Dispensing with interconnected external barriers leads to a significant reduction in the space requirements inside the control cabinet and thus to cost advantages. With ATEX, IECEx and NEC/CEC certification, the ELX terminals comply with all industry-specific guidelines for explosion protection and can be used in nearly all markets worldwide, which reduces the user’s dependence on different suppliers for different regions. The wide range of uses is also supported by the enormous variety of signals handled by the Beckhoff I/O range: there is a suitable I/O module for every application. Using the ELX terminals, process technology users can realize extremely compact and economical control architectures where the outstanding diagnostic function of EtherCAT helps to minimize system downtimes.
The ELX terminals optimize virtually all process technology applications:
Beckhoff meets the requirements for process control technology with regard to functional safety with the full integration of safety technology into the automation system. Compact and with a modular structure, the TwinSAFE safety solution fits seamlessly into the control platform. PC-based control thus offers a single platform that meets the requirements of both functional safety and explosion protection. The ELX terminals extended with TwinSAFE SC thus enable the direct connection of intrinsically safe field devices up to Zone 0/20 and the attainability of a safety level compliant with PLd/Cat. 3 according to EN ISO 13849-1 or SIL 2 according to EN 62061.
Functional safety and intrinsic safety in one system:
With the CPX Panel series models, the proven multi-touch technology of Beckhoff Control Panels and Panel PCs is available in even more robust versions, complying with the requirements for use in hazardous areas classified Zone 2/22. The high level of functionality and excellent build quality ensure the reliability of CPX panels even under harsh environmental conditions. The capacitive touch technology provides the typical ease of operation found on all Beckhoff multi-touch panels. The aesthetically pleasing appearance of the Beckhoff panels, and the look and feel of the aluminium housing are maintained, making them visual highlights in explosion-proof environments. The comprehensive CPX Panel range includes a large selection of display formats, sizes, installation options and features. Depending on the area of application, both the panels for control cabinet installation and stand-alone panels for flexible installation nearly anywhere in a room are available in the CPX29xx and CPX39xx series. Moreover, the fanless Panel PCs from the CPX27xx and CPX37xx series can be used for highly reliable system control.
Multi-touch panels for process technology:
Powerful Industrial PCs form the basis for a central control station for the management and monitoring of the processes of the entire plant. Sensors and actuators are connected via remote I/Os, which transmit the data from the field to the control station via a fieldbus coupler.
Conversely, with the CX series of Embedded-PC, which are certified according to ATEX and IECEx for use in Zone 2/22, the control of a plant part can run locally in the control cabinet, which opens up potential for more efficient process automation, especially with regard to modularization. In addition, the various functions of TwinCAT automation software are usable directly in the field.
In both cases, the appropriate selection of the controller or coupler can ensure communication to the higher-level system via the required protocol.
In the TwinCAT control software Beckhoff provides a central platform for the control of even highly complex systems. Apart from classic PLC sequences, algorithms written in C++ or MATLAB®/Simulink® can also be executed in real time. Moreover, TwinCAT includes the HMI, the secure cloud connection via TwinCAT IoT and the use of cloud-based analytical functions via TwinCAT Analytics. The field of application of PC based Control is expanded with the extensive integration of specific process technology protocols and interfaces. TwinCAT supports all common protocols such as NAMUR, HART and FDT/DTM, covering all application areas.
Automation and process technology on a single platform:
The modularization of process systems is standardized by the Module Type Package concept (MTP). MTP describes individual modules based on various aspects, including their interfaces and the executable services. The information about the module is stored in an MTP file, which is then imported into a higher-level controller (Process Orchestration Layer, POL). This enables the automated integration of the modules into the POL, so that modules from different manufacturers can be commissioned and linked together efficiently. In addition, MTP increases the flexibility of the system, as the reduced engineering effort allows for rapid changes to be made to the module arrangement.
The integration of the MTP concept into TwinCAT simplifies the guideline-compliant automation of a plant module through automatically generated source code and libraries for PLC programming. As a result, a prefabricated project structure is provided in which the user merely programs the process-specific functions of the service states. Subsequently, an MTP containing the module description can be exported directly from the TwinCAT project.
Benefits of TwinCAT MTP:
In the process industries, forward-looking automation solutions are required to enable transparent digitisation and cross-system connectivity. The traditional divide between discrete and process automation is no longer an obstacle. PC-based automation technology offers all the essential prerequisites for a convergence of technologies in both application areas. It also provides the capability to integrate decentralised systems and enable centralised process control and evaluation at the same time. With its consistency and openness, PC-based control is also the ideal basis for realising networked production in accordance with Industrie 4.0 and IoT concepts: from horizontal integration – even across company boundaries – to vertical integration with production systems to end-to-end engineering throughout the entire product lifecycle.
Beckhoff developed the TwinCAT IoT software library for communication between the machine control system and cloud-based services. The library supports the standardised protocols OPC UA, AMQP and MQTT for communication with popular cloud systems such as Microsoft Azure™, Amazon Web Services, as well as private cloud systems in the local enterprise network.
To create an explosion, a combustible mix of oxygen and fuel must get in contact with an ignition source. Explosion protection involves taking measures that prevent explosions by excluding one of these three risk factors. Since many processes use materials that are flammable and create an explosive atmosphere in combination with air, preventing the atmosphere from becoming potentially explosive is often not feasible. This is why hazardous areas must be marked as such in order to ensure that no electrical equipment will be used that can cause an ignition as a result of factors such as sparks or high surface temperatures, for example.
In compliance with European explosion protectionregulations, such areas are divided into zones that reflect the degree of the explosion hazard. For gases, the Zones are 0, 1, and 2. For dust, they are Zones 20, 21, and 22. Zone 0/20 (gas, dust) describes areas in which an explosive atmosphere exists permanently or frequently or for long periods of time. Areas that are occasionally subject to explosion hazards are marked as Zone 1/21. Zone 2/22 describes areas in which an explosive atmosphere exists never or only for short periods of time.
With its broad portfolio of components, Beckhoff makes it possible to build integrated explosion protection solutions through to Zone 0/20 with EtherCAT Terminals, high-quality Control Panels and Panel PCs, as well as Embedded PCs and Bus Couplers for easy integration with all common fieldbus systems. With Beckhoff, users can implement any explosion protection application involving explosion hazards, including the retrofitting of existing systems.
For systems and equipment in areas exposed to explosion hazards, different standards apply all over the world:
Country-specific approvals such as IA for South Africa may also be required. Users must make sure that their installations meet applicable guidelines and standards. The Ex component portfolio from Beckhoff meets all listed standards and is certified for the intended use in hazardous areas in compliance with applicable regulations.
As a result, PC-based control makes globally uniform solution concepts possible for barrier-free system integration up to Zone 0/20.
The conventional implementation of standardcompliant explosion protection involves connecting field devices from Zone 0 via separate safety barriers. Installing such barriers in the control cabinet, however, requires a relatively high cabling effort and takes up a lot of space. Using highly compact ELX series EtherCAT Terminals eliminates the need for such separate safety barriers, because these I/O modules can be connected directly to intrinsically safe sensors and actuators that are installed in hazardous areas up to Zone 0. In contrast, the cost and space savings made possible by ELX terminals allow users to build machines and systems that are as compact as they are efficient. The bottom line: the control cabinet space requirements along with costsand effort involved can be reduced significantly.
With a control solution from Beckhoff, users choose the comprehensive know-how of a globally successful and reliable partner. With stock levels to cover a period of up to 24 weeks for raw materials and up to six weeks for finished products, Beckhoff guarantees short delivery times and ensures the production reliability of its customers. A thoroughly considered concept for the long-term availability of Beckhoff products means that replacement devices are available in the long term and customers receive with a high level of investment protection.
With an exceptional manufacturing depth at the Verl site, all Beckhoff products meet the highest quality standards, especially for their intended use in potentially explosive atmospheres. The Beckhoff production facilities have been tested in accordance with ATEX and IECEx guidelines for compliance with all necessary standards and ensure a consistently high production quality through continuous quality management and audits. Thanks to a worldwide service network and experienced sales specialists, users of process technology receive fast and competent support on site at all times.
