Automation & Control Products

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.

The HCS-150-ZEB simplifies camera, light and I/O accessory connectivity by operating as the connection hub between machine vision components. The HCS-150-ZEB is capable of directly powering its connected Zebra camera, while providing essential I/O functionality like triggering and analog dimming control between the connected light head, the Zebra camera and any connected I/O accessories. This SignaTech-enabled controller can supply 4A of continuous output and up to 10A of overdrive strobe. The Light Hub is compatible with any new or existing C1 connection configured light heads. Its IP67-rated enclosure ensures protection from dust and water ingress, and the controller offers multiple mounting options including a DIN rail clip for easy integration into controller cabinets and M4 mounting channels for custom positioning.

Rockwell Automation expands the lineups of both process automation and safety controls with the release of the new Logix SIS platform, which uses the Flex 5000 I/O modules.

Rockwell Automation and Allen Bradley currently have an extensive catalog of safety PLCs, automation controllers, and safety-rated field devices. Recently, Rockwell Automation has expanded its safety component catalog to include the Logix SIS platform, which offers robust communication protocols and system compatibility.
 
Safety Systems In Automation

A solid safety system will protect operators from harm and help keep production running smoothly. Whenever automated equipment moves components, and there is a potential hazard, a safety system needs to be integrated. A solid safety system comprises a safety controller, rated contacts and sensors, and door locks and switches. These components are combined and programmed in the safety controller. The lowest-rated device determines the level of safety. If your controller is rated for SIL 3 but uses SIL 2 door switches, your system is rated for SIL 2.


The entire Logix SIS platform with Flex 5000 I/O safety modules, Image used courtesy of Rockwell Automation

Logix SIS

Built on the same platform as the 5580 process controller, the Logix SIS is an SIL 2 or SIL 3 safety-rated controller. Like the GuardLogix 5580 processors, the Logix SIS is for process safety. The controller uses the popular Flex 5000 I/O modules for safe digital inputs and outputs. Studio 5000 is used to program the entire solution.

With the Logix SIS platform integrated with the Flex 5000 I/O platform, it also works with Rockwell’s PlantPAx, Distributed Control System, and the Basic Process Control System. Both the Logix SIS and 5580 controllers can exist on the rack and can interface with the same Flex 5000 I/O racks.

Just like the GuardLogix, internal redundancy and failover mechanisms are built into the controller to ensure the logic is always running your safety process.

 
Test bench setup of the Flex 5000 I/O modules with safety and standard I/O. Image used courtesy of Rockwell Automation

Flex 5000 I/O Modules

Designed for panel distributed I/O in process automation. The Flex 5000 I/O modules are integrated into Rockwell Automation’s process automation controllers and software. The modules support safety inputs and outputs, as well as standard digital I/O and analog with some communication modules. The Flex 5000 communication supports 1 Gbps of either copper or fiber EtherNet/IP protocol and DLR, star, linear, or PRP network topologies. The Flex 5000 I/O system needs to be mounted in an approved control cabinet as it is only IP20 rated.

Operators controlling an automated process. Image used courtesy of Rockwell Automation

Process Safety

In machine building, we think of hazards as components moving around within a fenced-off area, such as robots and servo gantries; With process automation, the hazards could be static, like a large vessel containing boiling liquids or high-pressure gas lines running throughout the plant.

These safety systems work differently than machine automation safety systems. Instead of monitoring fence door switches in your safety program, you might monitor a valve position or a tank door switch. These devices might also be significantly far away from the PLC, which is why the Logix SIS only supports Flex 5000 I/O modules, which has connections suited for longer distances. The purpose of either safety system is to prevent potential hazards from becoming injuries resulting in loss of production.

The Sentron ECPD (electronic circuit protection device) electronically switches off circuit faults if errors occur and, if necessary, trips the mechanical isolating contact downstream. Sentron ECPD disconnects up to a thousand times faster than the typical two to three milliseconds, minimizing the occurring short-circuit energy. It also offers wear-free switching and an integrated cyclical self-test (including the integrated RCD function). The device comes with a powerconfig app to adjust or add various functions. The device properties can also be adjusted as needed, e.g., rated current or tripping limits. The Sentron ECPD offers transparency on energy consumption in the final circuit through radio-based communication with the Sentron Powercenter 1000 and 3000 gateways. Additionally, it can be integrated into higher level systems using Modbus TCP.

The Flexline 3500 low-voltage motor control center delivers real-time operation and diagnostic data by integrating with smart motor control devices. The modular motor control center design is customizable, and the technology is engineered for a wide range of industries. When Flexline 3500 motor control centers are integrated with smart variable frequency drives, manufacturers can significantly reduce power consumption. Additionally, the motor control center is engineered to integrate motor control and power distribution into one centralized package, meeting IEC 61439-1 and 2 standards for global customers.

NordAC ON/ON+ decentralized variable frequency drives are engineered for the specific requirements of horizontal conveyor technology and feature integrated functions to optimize operation performance, an integrated Ethernet interface, plug-and-play capability and a compact design. These VFDs feature three frame sizes and two base versions: a version designed for combination with IE3 asynchronous motors (NordAC ON) and a version optimized for use with IE5+ synchronous motors (NordAC ON+). Both versions offer compact frame sizes that can be motor- or wall-mounted based on the application and space requirements. NordAC ON supports a power range of 0.50 to 3.00hp while NordAC ON+ supports 0.50 – 4.00hp. The NordAC ON/ON+ is equipped with an internal PLC for drive related functions. The 24V DC supply for control and communication is integrated into the 3-phase 400V supply connected to the drive via a 6-pole connector.

The Klippon Connect W2C and W2T Range signal wiring and signal marshaling terminal blocks are designed for complex production processes. Signal marshaling ensures the connections of complex field signals to I/O systems. The single and double-level arrangement of Weidmuller’s DCS marshaling terminal blocks, combined with the provision of the four basic functions (fuse, feed-through, disconnect and ground), allow for flexibility when connecting field devices. Planning features of the marshaling blocks include data provision, international approvals and space-saving wiring. Installation features include up to three cross section channels, integrated PE contact, an optional shield busbar and various marking options. Operational highlights include signal loop testing with hollow screw heads, last minute function changes, clamping yoke screw technology with a self-locking mechanism and blown fuse indication with low leakage current.

The latest update to the KD2G servo drive features support for Profinet IRT and EtherNet/IP with CIP Sync alongside CANopen, EtherCAT and FSoE time-synchronized communication protocols. The AKD2G servo drive update also allows for synchronized motion between multiple drives using a variety of control architectures. The drive features high power density in a compact package and is easy to mount. Both one- and two-axis variants are available. Engineers can  use a single-cable smart feedback device, Hiperface DSL connections or choose from a range of other feedback devices. The updated drive offers an additional SafeMotion Monitor firmware with a safety level of SIL3/PLe.

The PACSystems IPC 2010 compact industrial PC comes preloaded with the PACEdge industrial edge platform and elements of Movicon.NExT SCADA software, helping users run applications using browser-based configuration. The IPC 2010 runs an industrial version of Linux and includes both serial and Ethernet connectivity, allowing it to be used simultaneously or separately as an edge computing device. Users can also implement the IPC 2010 as a flexible protocol converter. Both the hardware and software are designed to be adaptable and scalable to provide a standardized and unified user experience supported by Emerson’s lifecycle services. The compact IPC 2010 features the widest operating temperature range of any passively cooled IPC, a power consumption of just 4W, and tough packaging so it can be installed virtually anywhere.

The 7L600 is a ModBlox7-based single-pair Ethernet switch that is suitable as a multifunctional gateway in a wide range of IIoT or retrofit applications, but can also serve as an edge computer for (real-time) data pre-processing and data collection thanks to the on-board ARM CPU. The 7L600 is equipped with seven 100 BASE-T1 ports and two 1000BASE-T uplinks in accordance with IEC 63171-6. The SPE ports are hi-pot isolated and fully compatible with the Open Alliance BroadR- Reach standard. Inside the switch is the 88Q5072 Ethernet controller from Marvell, which supports AVB and TSN and also enables uncomplicated configuration via local or remote management functions. Optionally, the switch can be extended by an ARM-based mezzanine controller card, which can transform the switch into an edge computer.