3 twincat e - beckhoff new automation...
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10.02.2009 Beckhoff TwinCAT 1
Beckhoff TwinCAT The Windows Control and Automation Technology
Beckhoff Industrial PC
Beckhoff Drive Technology
Beckhoff Lightbus
Beckhoff TwinCAT
Beckhoff Bus Terminal
Beckhoff Fieldbus Box
Beckhoff Embedded PC
Beckhoff PC Fieldbus Cards, Switches
Beckhoff EtherCAT
10.02.2009 Beckhoff TwinCAT 2
PC control technology – PLC and NC on a PC
10.02.2009 Beckhoff TwinCAT 3
Contents
• PC based automation
• TwinCAT
• overview
• I/O
• control (plc)
• motion (nc ptp)
• interpolated motion (nc-i, cnc)
10.02.2009 Beckhoff TwinCAT 4
CP
U
NC
E/A
Evolution in control
Hardware ���� SoftwareMechanic ���� Electronic
Slots/CPUs ����Taskspar. Connect ���� FieldbusComm. ���� direct Access
IPC
Prog.Tool
HMI
IPC
Komm.
Fieldbuses
Prog.Tool
HMI
Router
PL
C 1
NC
E/A
Mapping
..
RT
-Kern
el
PL
C 2
PC based automation: development
10.02.2009 Beckhoff TwinCAT 5
What is TwinCAT ?
TwinCAT is an automation packagecomprising 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.
10.02.2009 Beckhoff TwinCAT 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
10.02.2009 Beckhoff TwinCAT 7
Windows NT, 2000, XP
Fieldbus Card Drivers
ADS Router
I/OServer
I/O Mapping
PLCServer
I/O
NCServer
otheri.e. CAM
SysMan
ADS
PLC Control
Diagnosei.e. Scope
UserHMI
UserHMI
OPCOCX/DllTCP/IP
Kern
elm
od
eU
serm
od
e
ADSADS ADS OPC
ADS ADS ADS ADS
I/O I/O
TwinCAT System
Realt
ime
Serv
er
Platform PC
10.02.2009 Beckhoff TwinCAT 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
10.02.2009 Beckhoff TwinCAT 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
10.02.2009 Beckhoff TwinCAT 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 768
10.02.2009 Beckhoff TwinCAT 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
10.02.2009 Beckhoff TwinCAT 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
10.02.2009 Beckhoff TwinCAT 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
10.02.2009 Beckhoff TwinCAT 14
Test 1 : Bit / Byte / Int / Dint / Word / DWord Test 2 : Bit / Byte / Int / Dint / Word / DWord / Real / LReal / String
Performance Measurements
10.02.2009 Beckhoff TwinCAT 15
TwinCAT I/O System
• open for all major field buses
• PC hardware supported
• easy setup and diagnosis
• mapping from logical tophysical I/O
II OO
InputInput OutputOutput
II OO II OO
TwinCAT process image
field bus 1 field bus 2 field bus 3
Mapping
10.02.2009 Beckhoff TwinCAT 16
TwinCAT Control
modular structure
• max. 4 PLCs on a PC
• 1 PLC on CX1000/BX/BC
timing
• 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 IEC61131-3 languages
(IL, ST, FBD, LD, SFC)
10.02.2009 Beckhoff TwinCAT 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
10.02.2009 Beckhoff TwinCAT 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
10.02.2009 Beckhoff TwinCAT 19
Hands on
10.02.2009 Beckhoff TwinCAT 20
Interpolated movements: TwinCAT NC I
Interpolated movements for 3-
axes plus 5 auxiliary axes
�programming in DIN 66025 Code
�technological features: bottleneck detection
10.02.2009 Beckhoff TwinCAT 21
TwinCAT NC I
Linear, circular, helical interpolation in the main planesLook Ahead
Interpolation functions
DIN 66025 extensionHigh-level language extensionsSubroutine techniquesCNC function blocks from the PLC
CNC programming
IEC 61131-3PLC programming
255313 path axes + 5 auxiliary axes
Max. number of controlled axesMax. number of independent channelsMax. number of simultaneously interpolating per channel
TwinCAT NC IProperties
10.02.2009 Beckhoff TwinCAT 22
TwinCAT NC I
Coordinate transformationReal-time transformations
Analog/encoder axis interface via appropriate fieldbusDigital axis interface via Lightbus, Sercos, Profibus DP/MC,CANopen, real-time Ethernet
Axis interface
Lightbus fieldbus system, Profibus DP, CANopen, DeviceNet, Interbus, Sercos, real-time Ethernet, PC interfaces
I/O system
Path overrideAxis fault/sag compensationGantry axesTracking axesAuxiliary axesMaster/Slave coupling variable factorAxis exchange via channelsOnline changes of configuration of the axesOnline axis exchange with PTP axes
Axis functions
TwinCAT NC IProperties
10.02.2009 Beckhoff TwinCAT 23
TwinCAT CNC
�CNC path control for highest demands
�complete CNC functionality
�32-axis interpolation
�coordinate and kinematiktransformation
�5-axis functionality
�spline interpolation
10.02.2009 Beckhoff TwinCAT 24
TwinCAT CNC
Linear, circular, helical interpolation in the main planes/freely definable planesLook AheadSpline interpolationThread functions
Interpolation functions
DIN 66025 extensionHigh-level language extensionsSubroutine techniquesUser macros
CNC programming
IEC 61131-3PLC programming
3212
10
32 path axes/spindles
Max. number of controlled axes/spindlesMax. number of controlled spindlesMax. number of independent channelsMax. number of simultaneously interpolating per channel
TwinCAT CNCProperties
10.02.2009 Beckhoff TwinCAT 25
TwinCAT CNC
Coordinate and kinematic transformation5-axis functionality
Real-time transformations
Analog/encoder axis interface via LightbusDigital/encoder axis interface via Lightbus,Sercos, Profibus, DP/MC
Axis interface
Lightbus fieldbus system, Profibus DP, CANopen, DeviceNet, Interbus, Sercos, real-time Ethernet, PC interfaces
I/O system
Path overrideAxis fault compensationGantry axesTracking axesAuxiliary axesMaster/Slave couplingAxis/spindle exchange via channelsSpindle synchronisation
Axis functions
TwinCAT CNCProperties
10.02.2009 Beckhoff TwinCAT 26
Performance
BCxxxxBXxxxx
CX1010
PC
Costs
for all Platforms
TwinCAT: One Tool
TwinCAT: PLC
TwinCAT PLC
CX9xxx
CX1020/30
10.02.2009 Beckhoff TwinCAT 27
Performance
BCxxxxBXxxxx
CX1010
PC
Costs
for all Platforms
TwinCAT: One Tool
TwinCAT: NC PTP
TwinCAT NC PTP
CX9xxx
CX1020/30
10.02.2009 Beckhoff TwinCAT 28
Performance
BCxxxxBXxxxx
CX1010
PC
Costs
for all Platforms
TwinCAT: One Tool
TwinCAT: NC I
TwinCAT NC I
CX9xxx
CX1020/30
10.02.2009 Beckhoff TwinCAT 29
Performance
BCxxxxBXxxxx
CX1010
PC
Costs
for all Platforms
TwinCAT: One Tool
TwinCAT: CNC
TwinCAT CNC
CX9xxx
CX1020/30
10.02.2009 Beckhoff TwinCAT 30
Centraal vs Decentrale Motion Control
Centraal
+ 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
Decentraal
- 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 krachtigeCPU nodig
10.02.2009 Beckhoff TwinCAT 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