Beckhoff TwinCAT The Windows Control and Automation Technology Beckhoff Industrial PC Beckhoff TwinCAT Beckhoff Lightbus Beckhoff Embedded PC Beckhoff Beckhoff Beckhoff PC Fieldbus Cards, Bus Terminal Fieldbus Box Switches Beckhoff Beckhoff EtherCAT Drive Technology 10.02.2009 Beckhoff TwinCAT 1
PC control technology – PLC and NC on a PC 10.02.2009 Beckhoff TwinCAT 2
Contents PC based automation • • TwinCAT • overview • I/O control (plc) • • motion (nc ptp) • interpolated motion (nc-i, cnc) 10.02.2009 Beckhoff TwinCAT 3
PC based automation: development Evolution in control Hardware � � � Software � Mechanic � � Electronic � � IPC IPC Slots/CPUs � � � � Tasks Prog. Prog. par. Connect � � � � Fieldbus HMI HMI Tool Tool Comm. � � direct Access � � Komm. Router RT-Kernel PLC 1 PLC 2 E/A .. NC CPU E/A NC Mapping Fieldbuses 10.02.2009 Beckhoff TwinCAT 4
What is TwinCAT ? TwinCAT is an automation package comprising 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 5
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 6
Platform PC TwinCAT System Usermode Diagnose PLC User User SysMan i.e. Scope Control HMI HMI OPC ADS ADS ADS ADS OCX/Dll OPC TCP/IP ADS Router Windows NT, 2000, XP Realtime Server ADS ADS ADS ADS PLC NC other Kernelmode Server Server i.e. CAM I/O I/O I/O I/O Server I/O Mapping Fieldbus Card Drivers 10.02.2009 Beckhoff TwinCAT 7
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 8
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 9
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 10
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 11
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 12
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 13
Performance Measurements Test 1 : Bit / Byte / Int / Dint / Word / DWord Test 2 : Bit / Byte / Int / Dint / Word / DWord / Real / LReal / String 10.02.2009 Beckhoff TwinCAT 14
TwinCAT I/O System open for all major field buses • • PC hardware supported • easy setup and diagnosis • mapping from logical to physical I/O TwinCAT process image Output Input Input Output Mapping I O I O I O I O I O I O field bus 3 field bus 1 field bus 2 10.02.2009 Beckhoff TwinCAT 15
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, p ower flow, scope • choose the favourite programming language • all IEC61131-3 languages (IL, ST, FBD, LD, SFC) 10.02.2009 Beckhoff TwinCAT 16
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 17
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 18
Hands on 10.02.2009 Beckhoff TwinCAT 19
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 20
TwinCAT NC I Properties TwinCAT NC I Max. number of controlled axes 255 Max. number of independent channels 31 Max. number of simultaneously 3 path axes + 5 auxiliary axes interpolating per channel PLC programming IEC 61131-3 CNC programming DIN 66025 extension High-level language extensions Subroutine techniques CNC function blocks from the PLC Interpolation functions Linear, circular, helical interpolation in the main planes Look Ahead 10.02.2009 Beckhoff TwinCAT 21
TwinCAT NC I Properties TwinCAT NC I Axis functions Path override Axis fault/sag compensation Gantry axes Tracking axes Auxiliary axes Master/Slave coupling variable factor Axis exchange via channels Online changes of configuration of the axes Online axis exchange with PTP axes Real-time transformations Coordinate transformation Axis interface Analog/encoder axis interface via appropriate fieldbus Digital axis interface via Lightbus, Sercos, Profibus DP/MC, CANopen, real-time Ethernet I/O system Lightbus fieldbus system, Profibus DP, CANopen, DeviceNet, Interbus, Sercos, real-time Ethernet, PC interfaces 10.02.2009 Beckhoff TwinCAT 22
TwinCAT CNC � CNC path control for highest demands � complete CNC functionality � 32-axis interpolation � coordinate and kinematik transformation � 5-axis functionality � spline interpolation 10.02.2009 Beckhoff TwinCAT 23
TwinCAT CNC Properties TwinCAT CNC Max. number of controlled 32 axes/spindles 12 Max. number of controlled spindles Max. number of independent 10 channels Max. number of simultaneously 32 path axes/spindles interpolating per channel PLC programming IEC 61131-3 CNC programming DIN 66025 extension High-level language extensions Subroutine techniques User macros Interpolation functions Linear, circular, helical interpolation in the main planes/freely definable planes Look Ahead Spline interpolation Thread functions 10.02.2009 Beckhoff TwinCAT 24
TwinCAT CNC Properties TwinCAT CNC Axis functions Path override Axis fault compensation Gantry axes Tracking axes Auxiliary axes Master/Slave coupling Axis/spindle exchange via channels Spindle synchronisation Real-time transformations Coordinate and kinematic transformation 5-axis functionality Axis interface Analog/encoder axis interface via Lightbus Digital/encoder axis interface via Lightbus, Sercos, Profibus, DP/MC I/O system Lightbus fieldbus system, Profibus DP, CANopen, DeviceNet, Interbus, Sercos, real-time Ethernet, PC interfaces 10.02.2009 Beckhoff TwinCAT 25
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