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Open automation technology with EtherCAT: perfectly suited to the handling of plastic parts

Automatic part removal and integrated handling are widely used in modern plastics production plants. High flexibility and a short removal time with minimal mounting space are the demands that plastics processors place on the transport and handling systems. On account of its long-standing cooperation with high-performance injection molding machine manufacturers, Beckhoff offers an interesting product range, especially for fast parts removal and in-mold labeling. However, Beckhoff also offers innovative solutions for conventional injection molding: from linear, Cartesian handling to articulated robots. These and other special kinematics can be programmed with the TwinCAT Kinematic Transformation software tool. An extensive portfolio of servomotors and drives with scalable performance and in various form factors provides performance-oriented solutions for the various handling weights with a minimal footprint.

The Beckhoff servomotors from the AM8000 series are based on the One Cable Technology; this simplifies wiring for the machine manufacturer and saves costs for flexible cabling in drag chains. The EtherCAT fast fieldbus technology, combined in a single cable with the power supply of the motors, reduces the control cabinet space requirement to zero.

The EtherCAT Box modules are suitable for decentralized data acquisition on robot arms. Special detection functions, such as pneumatic pressure monitoring for the gripper elements, are optimally tailored to handling applications. For cost-effective applications, Beckhoff offers the EtherCAT Box modules in the version with D-Sub connectors; the cabling for the power supply is additionally saved by using EtherCAT P.

The high requirements for the flexibility of handling equipment, combined with ever-increasing standards for machine safety, are perfectly covered with the Beckhoff safety products. The machine manufacturer benefits from Beckhoff's many years of experience in safety technology. The development of the Safety over EtherCAT (FSoE) protocol dates back to 2005. The decentralized safety components simplify design and commissioning in different machine environments. For example, they are ideal for monitoring protective doors and light barriers. Certified safety function blocks are available with TwinSAFE, the safety technology integrated in the TwinCAT engineering workbench. They enable flexible configuration of the system components on site, adapted to the customer's requirements. TwinSAFE includes all important safety functions for use in handling equipment, such as the Safely Limited Speed or the safe monitoring of the brakes in the drive motors.

Beckhoff offers the well-known Euromap 67 interface for communication with the injection molding machines. For the future OPC UA-based interface Euromap 79 (OPC 40079), Beckhoff offers a powerful engineering tool in TwinCAT; the machine manufacturer can assign the data points quickly and easily to the Euromap objects. In addition to the OPC UA-based Euromap interfaces, Beckhoff strongly recommends the use of EtherCAT as a deterministic fieldbus connection between injection molding machine and handling for time-critical processes such as robot synchronization in high-performance injection molding.

Beckhoff technologies and components optimize handling processes

Linear handling systems are characterized by a sturdy, simple design and are suitable for a wide range of different handling weights. © Engel
Linear handling systems are characterized by a sturdy, simple design and are suitable for a wide range of different handling weights.
© Engel

Optimized handling of plastic parts

Linear handling systems are widely used in particular in combination with injection molding machines. They are characterized by a sturdy, simple design and are suitable for a wide range of different handling weights. The requirements for removal systems on the part of plastics processors are: the lowest possible footprint for control cabinets, simple programming and the integration of the user interfaces of mobile panels into the controller of the injection molding machine. In addition, the machine manufacturer wishes to map its modular design in hardware and software with the help of cost-effective solutions. Standardized Euromap interfaces as well as a fast fieldbus should enable use in the entire range of plastic parts production.

Beckhoff meets these requirements with a wide range of hardware and software products:

  • EtherCAT as a fast Ethernet-based fieldbus for I/Os and drive technology
  • TwinSAFE as a safety-oriented architecture for I/Os and drives: drives are placed in a safe operating state with Safety over EtherCAT. Functions such as safely limited torque or safely limited speed enable setup processes in the working area.
  • EtherCAT Box modules in IP67 with cost-effective D-Sub connection technology
  • EtherCAT Box modules with special functions for robots, such as pressure monitoring on grippers or integrated acceleration measurement
  • EtherCAT P as a single-cable solution for connecting EtherCAT Box modules and motors with an integrated servo drive
  • motors with OCT (One Cable Technology) for reducing the costs of drag chain-compatible cables on the moving axes
  • AX8000 multi-axis servo system supports modular machine concepts for the full range of different handling weights.
  • distributed servo drive from the AMP8000 series for machine designs without a control cabinet
  • compact, distributed servo drive in 48 V technology from the AMI812x series for low handling weights
  • drive technology terminals in an IP20 version for applications with very low part weights or auxiliary axes
  • cost-effective solutions through scalable CPU power: from the Embedded PCs from the CX7000, CX90xx and CX5xxx series for simple applications, e.g., with pneumatic axes, to complex, interpolating systems
  • ultra-compact Industrial PCs from the C60xx series for space-saving installation in the control cabinet
  • programming with TwinCAT, the universal engineering environment, with powerful motion control functions and with support for various cloud protocols
  • Euromap 67 interface for digital signal exchange
  • EtherCAT for fast synchronization with the processing machine
  • TwinCAT HMI for HTML5-based visualization with different end devices

In packaging injection molding it is important to remove parts quickly; short cycle times of machines and removal units are therefore decisive.
In packaging injection molding it is important to remove parts quickly; short cycle times of machines and removal units are therefore decisive.

Short cycle times of machines and removal units

Especially in packaging injection molding, fast parts removal and integrated decoration (in-mold labeling) are a growing market. Productivity, i.e. short cycle times of machines and removal units, is crucial for market success in this processing segment. Beckhoff has been supplying high-performance controls for Husky injection molding machines for many years and thus has extensive experience in high-performance injection molding systems with extremely short cycle times.

Beckhoff meets these requirements with a wide range of hardware and software products:

  • EtherCAT as a fast Ethernet-based fieldbus for I/Os and drive technology
  • EtherCAT P as a single-cable connection for EtherCAT Box modules and motors with integrated drive
  • motors with suitable drive power with up to a standstill torque of 92 Nm
  • motors with OCT (One Cable Technology) for reducing the costs of drag chain-compatible cables on the moving axes
  • drives from the AX5000 series for the main axis and as two-channel drives for the secondary axes in IML applications
  • AX8000 for modular designs in different sizes and performance classes
  • drive technology terminals in an IP20 version for auxiliary axes, e.g., with IML
  • TwinSAFE as a safety-oriented architecture for I/Os and drives
  • powerful PC platforms in the execution as Embedded Controllers from the CX52xx or CX20xx series or the C60xx series of ultra-compact Industrial PCs
  • programming with TwinCAT, the universal engineering environment, with powerful motion control functions and with support for various cloud protocols
  • Euromap 67 interface for the traditional digital signal exchange with the injection molding machine
  • EtherCAT for fast synchronization with the machine in high-performance applications
  • Euromap 79 interface based on OPC UA
  • TwinCAT HMI for HTML5-based visualization with different end devices
Beckhoff supplies the corresponding software interfaces for KUKA and Stäubli robots according to the vendor-specific data exchange procedures based on EtherCAT: mxAutomation for KUKA KR-C4 robots and uniVAL PLC for Stäubli robots.
Beckhoff supplies the corresponding software interfaces for KUKA and Stäubli robots according to the vendor-specific data exchange procedures based on EtherCAT: mxAutomation for KUKA KR-C4 robots and uniVAL PLC for Stäubli robots.

Programming of PLC and robotics in one engineering environment

Articulated robots are used in blow molding machines, among other things, to guide the extruded hose; in injection molding applications they are used, for example, for handling large parts in small workspaces. Since the robots cooperate in the production environment with injection molding machines on the one hand and with other downstream stations on the other, simple integration with fast data communication is crucial for the cell productivity.

EtherCAT is often used in articulated robots as the standard for fast internal communication. This allows the Beckhoff hardware and software to be perfectly integrated into the environment of the articulated robots. Beckhoff supplies the corresponding software interfaces for KUKA and Stäubli robots according to the vendor-specific data exchange procedures based on EtherCAT: mxAutomation for KUKA KR-C4 robots and uniVAL PLC for Stäubli robots.

As a consistent software platform, TwinCAT enables the programming of PLC and robotics in one engineering environment. During operation, travel commands to the robot and actual positions are transmitted in real-time. The entire Beckhoff I/O portfolio is available for the integration of articulated robots into different production environments: from simple digital I/Os and safety-related monitoring to measurement technology or image processing. This makes the articulated robot part of Beckhoff's TwinCAT "ecosystem".

The following products from Beckhoff are particularly interesting for applications in the environment of articulated robots:

  • I/O components in an IP20 or IP67 version
  • TwinSAFE as a safety-oriented architecture for I/Os and drives
  • EtherCAT Box modules with special functions for robots, such as pressure monitoring on grippers or integrated acceleration measurement
  • EtherCAT Box modules with cost-effective D-Sub connection technology
  • Euromap 67 interface for the traditional digital signal exchange with the injection molding machine
  • EtherCAT for fast synchronization with the machine in high-performance applications
  • TwinCAT technology functions according to the mxAutomation standard
  • TwinCAT technology functions according to the uniVAL-PLC standard
  • Euromap 79 interface based on OPC UA

Beckhoff technology highlights for handling

Our scalable product portfolio facilitates the development of cost- and performance-optimized automation solutions for plastics machines.
Our scalable product portfolio facilitates the development of cost- and performance-optimized automation solutions for plastics machines.

The PC-based control principle

With PC-based control technology, we offer comprehensive system solutions in various performance classes for the automation of all types of plastics machines. The basic principle is based on a powerful industrial PC, a high-performance fieldbus connection with the connected peripheral devices for sensors and actuators, and the software for engineering and real-time control. The control platform is supplemented by an extensive portfolio of drive components. TwinCAT automation software bundles all necessary functionalities such as PLC, motion control, robotics, measurement technology, image processing, and HMI. Our technology is based on IT standards and has the necessary openness to implement intelligent production concepts according to Industrie 4.0.

Due to the high performance of modern processors, which we install in all of our PC series, computationally intensive applications can easily be integrated into the control platform. Plastics machine manufacturers benefit from the continuous increase in the performance of PC processors: Shorter sampling times are already increasing the quality of the end product today and will be the requirement for the realization of self-learning machines in the future. The possibility, for example, to completely simulate an injection molding machine in the virtual design process saves time during development and commissioning.

Due to its excellent real-time characteristics and high bandwidth, EtherCAT is ideally suited for controlling the complex processes encountered in plastics machines and serves as a backbone for linking production equipment.
Due to its excellent real-time characteristics and high bandwidth, EtherCAT is ideally suited for controlling the complex processes encountered in plastics machines and serves as a backbone for linking production equipment.

EtherCAT: World standard for plastics machines

The EtherCAT technology was launched on the market by us in 2003 and made available as an open standard for automation technology. With outstanding performance, flexible choice of topology, comprehensive diagnostics and simple configuration, EtherCAT is ideally suited for use in plastics machines. We offer the largest number of EtherCAT-compatible automation modules for I/Os and for drive technology.

EtherCAT is one of the most widely used standards in plastics technology. A large number of EtherCAT-compatible sensors and actuators are available on the market, which guarantees a high level of investment security. Particularly interesting for electrically driven injection molding machines is the problem-free connection of drives from third-party suppliers. Other fieldbus systems can also be integrated as communication layers via EtherCAT.

The fast and high-precision Beckhoff control solution eXtreme Fast Control (XFC) is based on EtherCAT and special I/O modules optimized for XFC that record signals or trigger actions with high accuracy. With I/O response times under 100 μs, XFC enables very fast and extremely deterministic reactions and thus contributes to process optimization.

All safety functions can be integrated into any conceivable machine architecture with TwinSAFE: from the stand-alone solution to the distributed and the software controller, which meets even the most complex requirements. End customers thus get exactly the complete safety package that they need. Unnecessary costs for incorrectly dimensioned safety solutions are avoided.
All safety functions can be integrated into any conceivable machine architecture with TwinSAFE: from the stand-alone solution to the distributed and the software controller, which meets even the most complex requirements. End customers thus get exactly the complete safety package that they need. Unnecessary costs for incorrectly dimensioned safety solutions are avoided.

TwinSAFE: The open and scalable safety technology

With TwinSAFE, we have implemented a consistent safety concept that integrates safe functionalities into the non-safety-related control architecture. Separate safety controllers are thus superfluous. The typical safety functions can be programmed and configured on the EL6910 TwinSAFE Logic or the compact EK1960 safety controller, based on standard safety function blocks according to the safety requirements. The Beckhoff safety solution accelerates the engineering process, as the safety-related requirements of different machine configurations can be realized by software. All our safety controllers are suitable for applications up to SIL 3 according to IEC 61508 or PLe of ISO 13849-1 and meet the EN 201 standard for injection molding machines.

Safety technology seamlessly integrates into the terminal segment via the TwinSAFE I/O modules, whereby safe signals can be mixed with standard signals as required. This benefits, for example, blow molding machines or production cells with control cabinets in different installation locations. Due to its scalability, the Beckhoff safety solution is suitable for expansive, complex systems with distributed I/Os as well as for small injection molding and blow molding machines. One safety logic is sufficient here to realize the complete safety technology. The compact EK1960 safety controller is particularly suitable for injection molding machines with hydraulic and/or electric drives. It allows the direct control of digital switching valves with a load of 2 A, such as those used in core pullers. With the help of the TwinSAFE SC technology, signals with a low safety level can be used redundantly for safety tasks.

Beckhoff product highlights for handling

With the CX series of Embedded PCs, Beckhoff combines PC technology with the modular I/O level on the DIN rail in the control cabinet. Due to the fine scalability of the different device classes, the user can select exactly the right performance category for his application. Even smaller than the compact design of the Embedded PC devices is the series of ultra-compact Industrial PCs, which is therefore suitable as an alternative, especially when it comes to minimizing mounting space.
With the CX series of Embedded PCs, Beckhoff combines PC technology with the modular I/O level on the DIN rail in the control cabinet. Due to the fine scalability of the different device classes, the user can select exactly the right performance category for his application. Even smaller than the compact design of the Embedded PC devices is the series of ultra-compact Industrial PCs, which is therefore suitable as an alternative, especially when it comes to minimizing mounting space.

Modular Industrial PCs for the DIN rail

With the CX series of Embedded PCs, Beckhoff combines PC technology with the modular I/O level on the DIN rail in the control cabinet. By adding or eliminating modules and interfaces, only the components that the user needs for the respective application are installed. In this way, Embedded PCs open up a wide range of applications – for example in the field of plastics machines and production cells.

Due to its sturdiness, the CX is suitable for use as a powerful and reliable controller under harsh industrial conditions, such as vibration or heat. The fine scalability in different device classes allows users to select exactly the right performance category for their applications. The devices from the lower performance class are suitable, for example, for controlling temperature control devices, for dosing applications and for conveyor belts. Powerful control PCs are available for injection molding and blow molding machines in the CX5100 and CX5200. The devices from the CX20x0 and CX20x2 series are high-end controllers that allow for complex user interfaces, the integration of image processing, the realization of machine learning or the aggregation of large quantities of data.

Even smaller than the compact Embedded PC devices is the series of ultra-compact Industrial PCs, which is therefore suitable as an alternative, especially when it comes to minimizing mounting space. While the C6015 is suitable for control tasks in the lower performance category, the C6030 meets the requirements for a standard controller. Another advantage is the flexible mounting: while the CX can only be installed horizontally, the devices from the C60xx series can be installed in any position. Another advantage of the Embedded PCs – as for Beckhoff's entire Industrial PC portfolio – is the long-term availability of spare parts, which offers the customer a high level of investment security.

Suitable EtherCAT Terminals are available for all common digital and analog signal types encountered in the world of automation. Fieldbus devices, e.g. for PROFIBUS, PROFINET, CANopen, DeviceNet, Interbus, IO-Link or Lightbus, are integrated via local fieldbus master/slave terminals. Removal of the fieldbus master saves PCI slots in the PC. Any Ethernet devices can be integrated locally via switch port terminals.
Suitable EtherCAT Terminals are available for all common digital and analog signal types encountered in the world of automation. Fieldbus devices, e.g. for PROFIBUS, PROFINET, CANopen, DeviceNet, Interbus, IO-Link or Lightbus, are integrated via local fieldbus master/slave terminals. Removal of the fieldbus master saves PCI slots in the PC. Any Ethernet devices can be integrated locally via switch port terminals.
With a wide range of TwinSAFE logic-capable components, Beckhoff offers complete freedom in the design of the safety architecture.
With a wide range of TwinSAFE logic-capable components, Beckhoff offers complete freedom in the design of the safety architecture.

EtherCAT I/O modules integrate temperature control, energy measurement and safety technology into the control platform

In 1995, Beckhoff launched the Bus Terminal, which has since become one of the most important technology standards in automation technology. This was followed in 2003 by the development of the EtherCAT fast communication system. Launched by Beckhoff as an open system, it became a global standard in automation within a few years. An extensive EtherCAT I/O Terminal portfolio is available to users that is extremely well suited for automating every functionality in plastics machines and their peripherals in terms of both its performance and variance.

  • EL3318 for temperature measurement
    The EL3318 EtherCAT Terminal is ideal for temperature measurement via thermocouples. The 8-channel input terminal with integrated cold junction compensation is very compact in its design and measures temperatures with high accuracy and high signal-to-noise ratio.
  • EL3403 and EL3446 for power measurement
    The EL3403 three-phase power measurement terminal can be used to measure and optimize the power consumption of a plastics machine. In conjunction with the TwinCAT Plastic Processing Framework, the EL3403 is used for the cost-effective Condition Monitoring of the heating tapes through sequentially alternating testing in operation. In traditional control structures, the power measurement terminal can also be used for current measurement. The EL3446 is available for simple monitoring of the heating tape function. In combination with the voltage measurement in just one power measurement terminal, the power consumption of individual machine components can be recorded cost-effectively by means of current measurement. The Beckhoff SCT current transformers (SCT2xxx, SCT1xxxx) enable assembly of the appropriate combination of sensor and power measuring terminal without requiring detailed knowledge.
  • EL3255 for position detection
    The EL3255 EtherCAT Terminal allows potentiometric position detection. Due to its integrated power supply, the terminal delivers precise results (voltage values) even in environments with high interference fields. The EL3255 is particularly suitable for injection molding and blow molding machines with hydraulic drive technology.
  • EL6224 IO-Link terminal
    IO-Link is an inexpensive fieldbus for the reading of sensors with low real-time requirements. A preferred application, for example in extrusion, is the reading of melt pressure and melt temperature via the EL6224.
  • TwinSAFE terminals for integrating safety technology into the controllerDue to its scalability, the Beckhoff safety solution is suitable for expansive, complex systems with distributed I/Os as well as for small injection molding and blow molding machines. One safety logic is sufficient here to realize the complete safety technology. The compact EK1960 safety controller is particularly suitable for injection molding machines with hydraulic and/or electric drives. It allows the direct control of digital switching valves with a load of 2 A, such as those used in core pullers.

The robust design of the EtherCAT Box modules enables their use directly at the machine. Control cabinets and terminal boxes are now no longer required.
The robust design of the EtherCAT Box modules enables their use directly at the machine. Control cabinets and terminal boxes are now no longer required.

Universal EtherCAT for the IP67 world

With the EtherCAT Box, EtherCAT technology is used without a control cabinet. The modules from the IP67 series have an integrated direct EtherCAT interface, so that the high performance is retained right down to each module. In the IP67 world, this enables fast process data communication with XFC, high-precision measurement technology and integrated drive technology functions directly in the field. The robust design of the EtherCAT Box modules enables them to be used directly at the machine. Control cabinets and terminal boxes are now no longer required. In addition to the sturdy M12 screw connectors, D-Sub connectors, which are perfectly suited for handling applications, are also available for cost-sensitive applications.

  • With the EP3744 EtherCAT Box, pneumatic pressure monitoring for the gripper elements can be implemented in handling applications; at the same time, six digital inputs can be read in.
  • In the EP1816, the acquisition of 16 digital inputs is combined with the measurement of acceleration forces in three axes.
  • The EP3752 enables the measurement of acceleration forces without additional inputs. The measured values of the accelerometers can be used for the acquisition of the mass forces, e.g., on machine bodies or for control concepts with jerk compensation on handling devices.
  • The EP3314 EtherCAT Box is suitable for the acquisition of process temperatures directly at the point where they arise. It increases measuring accuracy and saves having to use compensating cables for the thermocouples.
  • The FM3312 or FM3332 Fieldbus Modules in a sturdy metal housing are particularly suitable for temperature measurement on injection molds or nozzles in extrusion lines. Up to 32 temperature channels can be contained in one industrial connector. Operational reliability is additionally ensured by reverse polarity protection against phase voltage.
  • With the EP3356, the high-precision evaluation of load cells is possible, which is required in extruder applications for dosing and melt throughput measurement.

In combination with the Motion Control solutions of the TwinCAT automation software, the Beckhoff drive technology represents a complete drive system for all applications in plastics technology. Due to its scalability, it enables machine manufacturers to design their drive solution to suit the required performance.
In combination with the Motion Control solutions of the TwinCAT automation software, the Beckhoff drive technology represents a complete drive system for all applications in plastics technology. Due to its scalability, it enables machine manufacturers to design their drive solution to suit the required performance.

Drive systems for highly dynamic positioning tasks

In combination with the motion control solutions in the TwinCAT automation software, Beckhoff drive technology represents a complete drive system for all applications in plastics technology. With EtherCAT as a fast communication system, it is suitable for single and multi-axis positioning tasks with highly dynamic requirements. Due to its scalability, the Beckhoff drive technology enables machine manufacturers to design their drive solution to suit the required performance.

The AX5000 and AX8000 servo drive series offer maximum performance and dynamics with powerful EtherCAT system communication. The integrated, fast control technology of the AX series supports the execution of high-precision positioning tasks, such as those required in the field of film production: The smoothing rollers, which smooth the extruded film before winding, must be adjustable in the submillimeter range. The AX5000 offers the optimal solution for ultra-fast removal processes. The flexible concept of the AX5000 with 1- and 2-channel units as well as the variable motor power ensure a cost-optimized design. The drives from the AX8000 series are predestined for compact, modular drive units and for Cartesian handling devices.

In the lower performance range, the EtherCAT servo terminals, which offer a complete servo drive in the standard terminal housing, represent a drive solution that is both compact and inexpensive for low part weights or for additional units with low power consumption.

Beckhoff drive technology is characterized by its enormous in-house production depth: the servo drives and motors come virtually from a single source. The drives are produced at the production site in Verl, while the motors are developed and produced at a company belonging to the Beckhoff group. Thus, all drive technology components follow a consistent engineering concept. The extensive range of linear and rotary motors is optimally tailored to the Beckhoff servo drives. One result of this successful development collaboration is, for example, the One Cable Technology of the AM8000 motor series, which combines power and feedback systems in one standard cable. This reduces the mounting space on the machine and lowers the commissioning costs. Another technical innovation as a result of this close cooperation is the AMP8000 distributed servo drive system. It integrates the servo drive into the servomotor in a compact design.

The Beckhoff drive components are seamlessly integrated into the TwinCAT engineering tool. The motion control software packages TwinCAT NC-PTP, NC I and TwinCAT Rotobotics are perfectly matched to the servo drives and motors. Thanks to the integrated safety technology the servo drives meet the stringent safety requirements for plastics machines and simplify the configuration of production cells. For the new development of machines, Beckhoff has integrated tools into TwinCAT for the design of motors and gear units. For complex applications or the design of new systems, Beckhoff also offers support in the design of motors and gear units. The customer thus benefits from the many years of expertise of the Beckhoff engineers in various drive applications.

By relocating the power electronics into the machine, the space requirement in the control cabinet is reduced to a single coupling module, which supplies several distributed servo drives with only one cable via a distribution module. Handling devices for injection molding or blow molding machines can be attached with the AMP8000 without an additional control cabinet. This also applies to complete production cells with a typically limited footprint
By relocating the power electronics into the machine, the space requirement in the control cabinet is reduced to a single coupling module, which supplies several distributed servo drives with only one cable via a distribution module. Handling devices for injection molding or blow molding machines can be attached with the AMP8000 without an additional control cabinet. This also applies to complete production cells with a typically limited footprint

Modular design concept for maximum flexibility and space savings

The AMP8000 integrates the servo drive directly into the servomotor in a very compact design. By relocating the power electronics into the machine, the space requirement in the control cabinet is reduced to a single coupling module, which supplies several distributed servo drives with only one cable via a distribution module. A further expansion stage completely eliminates the control cabinet space required for the drive technology. Whereas the connection of the drives to the control cabinet is reduced to only one cable with the coupling modules, it is completely eliminated when using the AMP8620 power supply module.

The AMP8000 is suitable for a wide range of applications in plastics processing. Handling devices for injection molding machines or blow molding machines can be attached with the AMP8000 without an additional control cabinet. This also applies to complete production cells with a typically limited footprint.

The XPlanar is suitable for various transport tasks in a wide range of applications.
The XPlanar is suitable for various transport tasks in a wide range of applications.

Movement with six degrees of freedom ensures maximum flexibility in positioning

With the XPlanar system, Beckhoff opens up new paths in plant design: the planar movers hover jerk-free and contact-free over planar motor tiles in any desired arrangement. They can be moved two-dimensionally at speeds of up to 2 m/s, with 2 g acceleration and 50 µm positioning accuracy, silently and without abrasion.

The planar motor system, which is scalable to suit needs, can significantly simplify the design of machines and plants and enables new freedoms in machine design. Due to the enormously flexible mover positioning and the very high movement dynamics, it is possible, for example, to divide product flows very easily and individually. Where robots or other inflexible mechanical devices have been used up to now, the XPlanar offers an efficient and flexible solution. The non-contact movement of the movers also eliminates wear, emissions and the carry-over of impurities. The XPlanar is therefore also ideally suited for applications with high hygiene standards, such as those that must be adhered to when transporting sensitive workpieces.

TwinCAT integrates all engineering and runtime processes on a central software platform.
TwinCAT integrates all engineering and runtime processes on a central software platform.

TwinCAT: the integrated engineering and control platform

TwinCAT integrates all engineering and runtime processes on a central software platform. This applies to programming, configuration, real-time environment and all runtime modules. By programming in the common IEC PLC dialects and integrating C/C++ algorithms, machine manufacturers can freely choose the most suitable programming method depending on the qualifications of the programmers, the service strategy and the need to protect expertise. With the integration of MATLAB®/Simulink®, controller concepts are developed based on models, thus contributing to virtual machine design. By using Microsoft Visual Studio® as integrated programmer workbench, different version control systems are supported and teamwork is simplified. For series production, TwinCAT offers open interfaces for the integration of commercial IT systems for machine program generation.

  • Extensive TwinCAT libraries for motion control save development time thanks to tested and optimized algorithms. The TwinCAT PTP and TwinCAT NC I supplements are ideally suited for handling applications with Cartesian robots. Ready-to-run solutions are available with TwinCAT Kinematic Transformation for other robot kinematics, such as SCARA, Delta and articulated arm.
  • Commissioning and service processes are accelerated and improved with TwinCAT Scope, a software oscilloscope fully integrated into the TwinCAT system architecture, and thus contribute to increasing machine quality.
  • TwinSAFE software-based safety technology simplifies the wiring of complex systems; variants can be mapped in software. This allows, for example, the modular development and commissioning of production cells. Documentation is also simplified and adaptations to additional customer requirements can be implemented quickly.
  • The integrated, browser-based TwinCAT HMI visualization solution enables convenient development and maintenance of visualization objects. The information is presented either on the machines and systems or via the internet using a web browser.
  • TwinCAT IoT provides the prerequisite for data aggregation in the cloud or locally in the production plant. TwinCAT also includes standardized communication protocols for cloud applications.
  • The collected data can be specifically evaluated using TwinCAT Analytics.
  • The TwinCAT interfaces to machine learning algorithms allow the use of AI methods in the traditional control environment.

Motion Control has been an important part of Beckhoff software engineering tools for many years. With TwinCAT PTP and TwinCAT NC I, the requirements of electric drive technology in plastics machines and their peripherals are perfectly covered.
Motion Control has been an important part of Beckhoff software engineering tools for many years. With TwinCAT PTP and TwinCAT NC I, the requirements of electric drive technology in plastics machines and their peripherals are perfectly covered.

TwinCAT Motion Control: perfectly suited for hydraulic and electric drive technology

Motion Control has been an important part of Beckhoff's software engineering tools for many years. With TwinCAT PTP and TwinCAT NC I, the requirements of electric drive technology in plastics machines and their peripherals are perfectly covered. A wide range of software modules for different tasks such as cam plates, synchronization and interpolating movements of several axes are available. NC PTP is perfectly suited for the widely used Cartesian removal systems; integration into the machine controller of the processing machine is easily feasible. The TwinCAT Plastic Application Components are available for stand-alone handling applications. As an industry-specific extension of the TwinCAT, they support the widely used Euromap interfaces between injection molding machine and robot, either as Euromap 67 or in the future as Euromap 79 (OPC 40079).

Fast removal processes, such as in-mold labeling with the help of side removal handling, are optimized with PC- and EtherCAT-based control technology: EtherCAT as a fieldbus with virtually delay-free synchronization leads to extremely short cycle times. Following the philosophy of open automation technology, TwinCAT Motion Control is a tool for the design of production cells that allows the integration of Beckhoff drive components as well as third-party components. TwinCAT NC-PTP is a suitable engineering tool for a variety of drive concepts: from simple switched axes and stepper motors or frequency converters to servo drives.

Different encoder technologies with fieldbus interfaces or direct connection via I/Os are supported. This makes it possible to design production cells modularly, flexibly and at an optimal cost according to market requirements. In particular, the linking possibilities of master and slave axes in almost any structure as well as the powerful and diverse motion functions of TwinCAT cover wide-ranging applications in outstanding fashion. With the Flying Saw software library, for example, trimming units in extrusion lines can be perfectly synchronized. Powerful tools such as the TwinCAT CAM Design Tool and the TwinCAT Scope support machine design and commissioning. PLC libraries with function blocks according to the PLCopen Motion Control standard facilitate programming and save engineering effort through the reusability of the modules.

The seamless integration of robot kinematics in the control system not only avoids the need for an additional robot CPU, but it also ensures optimum interaction and synchronization with the PLC and the existing motion control functions.
The seamless integration of robot kinematics in the control system not only avoids the need for an additional robot CPU, but it also ensures optimum interaction and synchronization with the PLC and the existing motion control functions.

Flexible and fully integrated robotic solution saves engineering effort

The TwinCAT Kinematic Transformation software integrates the robot controller into the automation software, so that PLC, motion control and robotics can run on one Industrial PC. In TwinCAT, a uniform engineering tool for configuration and programming is available to the user. This saves time and eliminates interface problems while at the same time reducing development costs. In addition to the Cartesian portal, serial 2D kinematics, 2D parallel kinematics and 3D delta kinematics, six-axis kinematics are also easy to implement. The respective kinematics can be selected and parameterized conveniently in the TwinCAT System Manager. The kinematic channel is used to parameterize the type (e.g., delta or SCARA) and the bar lengths and offsets. Mass and mass inertia values can be specified for dynamic pre-control. In addition, the software library also includes tracking functionalities. This means that the robot is synchronized with a moving object, so that it can pick up workpieces from conveyor belts or inclined turntables, for example.

The seamless integration of robot kinematics in the control system not only avoids the need for an additional robot CPU, it also ensures optimum interaction and synchronization with the PLC and the existing motion control functions: direct interfaces replace the complex communication between different controllers and systems. This results in high performance and improved accuracy.

TwinCAT Kinematic Transformation can be used with six-axis robots in plastics technology. As an industry-specific extension of the Beckhoff software platform, the TwinCAT Plastic Application Components support the widely used Euromap interfaces between injection molding machine and robot, either as Euromap 67 or in the future as Euromap 79 (OPC 40079).

The open Beckhoff automation platform with integrated Euromap interface based on OPC UA ensures the secure and reliable M2M communication of heterogeneous plant parts or secure data communication to higher-level systems.
The open Beckhoff automation platform with integrated Euromap interface based on OPC UA ensures the secure and reliable M2M communication of heterogeneous plant parts or secure data communication to higher-level systems.

OPC UA: the platform for all future standards in the plastics industry – essentially driven by Beckhoff

Beckhoff has been a staunch advocate of open standards for many years, from a time when proprietary solutions were still widely used. This also includes great commitment in the field of OPC standardization. Beckhoff customers therefore benefit from a particularly extensive interoperability between Beckhoff products and those of third parties.

Beckhoff is one of the few companies that has its products examined annually for real interoperability and stability in the latest versions and with the latest functions. Companion Specifications are currently being defined in the different domains of mechanical engineering. In plastics technology, this is being driven by the Euromap organization. Beckhoff is actively involved in the Companion Specifications for the plastics industry and can therefore promptly integrate new specifications into its products. Within TwinCAT, an OPC UA interface is optionally available (TF6100) that satisfies the corresponding Euromap Companion Specifications. The Euromap 82 (OPC 40082) has been implemented for machine-to-machine communication; the Euromap 77 (OPC 40077) is available for connection to master computers or to the cloud. In addition to the OPC UA-based Euromap interfaces, Beckhoff strongly recommends the use of EtherCAT as a deterministic fieldbus for time-critical processes such as robot synchronization in high-performance injection molding.