Beckhoff Expands TwinCAT 3 with CNC for EDM and Additive Manufacturing

Beckhoff has enhanced its TwinCAT PC-based control software with new functions and additional technology packages designed for additive manufacturing and EDM machine applications.

With the success of its TwinCAT PC-based control software that adds real-time control with multiple PLC, NC, CNC, or robotic runtime systems, the TwinCAT system has evolved into a modular system made of multiple extensions. It has transformed into the TwinCAT 3 system. The TwinCAT 3 CNC will now include access to high-performance CNC solutions for additive manufacturing and wire-erosion/die-sinking EDM machines.

The TwinCAT 3 CNC Family

The upcoming release of TwinCAT 3 will introduce several new features and technology packages. The new functions, including the TF5262 and the TF5263, are designed to support complex additive manufacturing technologies, wire-erosion EDM machines, and die-sinking EDM machines. Additionally, the release will introduce two new technology packages, the TF5291 and the TF5292, to further enhance the capabilities of the TwinCAT 3 family.


The TwinCAT system is Beckhoff’s modular PC-based automation suite. Image used courtesy of Beckhoff
 
Dynamic Contour Control and Tool Radius Compensation

The TwinCAT 3 CNC online adaptation encompasses three distinct functions for influencing dynamic contour control (DCC) to compensate for contour errors by adjusting the tool center point path based on current or previous contour elements. It also includes tool radius compensation (TRC) for online tool radius compensation, path position and tangent, and supports two-path interpolation.

In addition, it involves geometric feed adjustment (GFA) to compute a feed override factor for achieving constant surface speed. TF5262 also enables the integration of customer-specific interpolation functions in C++ into Beckhoff's TwinCAT CNC real-time stack through TcCom interfaces.
 
Extended Interpolation.

The Beckhoff TwinCAT Extended interpolation function, known as TF5263, allows for the simultaneous programming of two separate interpolation paths within a single CNC channel. This feature provides synchronization functions and tool path compensation. Furthermore, TF5263 incorporates conical coupling to synchronize paths 1 and 2 and compensate for additional blocks resulting from tool nose radius compensation.
 
External Process Prediction and Control

This system is designed for additive manufacturing and has advanced features for predicting and controlling external processes. The TF5291 has a PLC and ADS interface to forecast future contour elements and their parameters. It also allows for real-time retrieval of dynamic values for individual axes at any point during the manufacturing process.
 
Specialized Functions for Electrical Discharge Machining

The control system, known as the TF5292, is specifically engineered for PC-based control of intricate wire EDM (Electrical Discharge Machining) systems. It seamlessly integrates the capabilities of the TF5262, TF5263, and TF5291. Additionally, the TF5292 incorporates specialized functions tailored for EDM processes, including retraction strategies and compensation mechanisms essential for wire-erosion and die-sinking systems.