The Windows Control and Automation Technology

Beckhoff TwinCAT 1
Beckhoff New Automation Technology

Beckhoff TwinCAT 2
The Windows Control and Automation Technology

Beckhoff TwinCAT 3
 Contents

 PC-based automation
 TwinCAT
 Architecture
 I/O
 Control (PLC)
 Motion (NC PTP)
 Interpolated motion (NC I, CNC)
 Connectivity

Beckhoff TwinCAT 4
 PC-based automation: development

PC-based automation Evolution in control

TwinCAT
Architecture
I/O Hardware  Software
Control Mechanic  Electronic IPC
IPC
Motion Slots/CPUs Tasks
Interpolated Prog.
Motion HMI par. Connect  Fieldbus Prog.
Tool HMI
connectivity Comm.  direct Access Tool

Komm.
Router

RT-Kernel
PLC 1
PLC 2

NC
..

I/O
CPU

NC
I/O

Mapping

Fieldbuses

Beckhoff TwinCAT 5
 PLC processing times on different platforms

Test 1: Integer operations

3500 16/32 bit
Execution time – linear scale

2898 Test 2: Bit Operations

3000 1/16/32 bit
2515 Test 3: Mixed (incl. REAL
2500 operations)
[µs/5000 code lines

2000 Test 1
1616 Test 2
1500 1443
1500 Test 3
1000

500
93 39,5 14,12 9,84 5,66 5,62 5,2
0
C Hz

C Hz

z
B 00
B LC

C 00

C 00

C 10

C 00
85 10

2, 20

3, 30
H
M
1

P4 X10

P4 X10
90

G
.P

X3

X9

X9

X1

PI X1

0
C

2
nv
co

II

Beckhoff TwinCAT 6
 System overview

PC-based automation
 TwinCAT – integrated engineering and runtime for
TwinCAT
Architecture  control
I/O  motion and
Control  technology
Motion
Interpolated
Motion  TwinCAT – running on different hardware platforms
Connectivity  PC – high performance
 CX – medium performance
 BX – between BC and CX
 BC – low performance/low price

Beckhoff TwinCAT 7
 Beckhoff control devices in 4 performances

performance

IPC
CX highest performance
medium
performance
BX
low performance

BC
lowest
performance

costs
Beckhoff TwinCAT 8
 TwinCAT architecture: platform PC

PC-based automation
TwinCAT
TwinCAT
Architecture  does not modify Windows
I/O  needs no special hardware
Control  turns standard Windows to a real-time OS
Motion
 full access to Windows user interface via OCX, Dll
Interpolated
Motion  remote access via TCP/IP
Connectivity

PC platform
 standard hardware, best performance
 use of PC resources
 use of mainstream operating system (Windows)
 easy integration into office networks
 open fieldbus communication

Beckhoff TwinCAT 9
 TwinCAT architecture: platform PC

TwinCAT System

Usermode
Diagnose PLC User User
SysMan
i.e. Scope Control HMI HMI
ADS ADS ADS OCX/Dll OPC

ADS ADS
TCP/IP
ADS Router
Windows
ADS
NT,
ADS
2000,
ADS
XP
ADS
Realtime Server

PLC NC other

Kernelmode
Server Server i.e. CAM
I/O I/O I/O I/O
Server

I/O Mapping
Fieldbus Card Drivers

Beckhoff TwinCAT 10
 TwinCAT architecture: platform PC

TwinCAT real-time
 cycle times down to 50 µs
 latency time < 5 µs (P4)
 adjustable ratio real-time to Windows
 message when latency time is to high

Base-time Base-time Base-time

Max. 80% 20% 80% 20% 80% 20%

Actual 40% 60% 80% 20% 60% 40%

TwinCAT NT TwinCAT RT
on on
Windows

Beckhoff TwinCAT 11
 TwinCAT architecture: platform PC

Switch from office PC to a IPC with PLC and Motion Control

Safe operation Hard real-time

motherboard Jitter < 5 µs
diagnosis min. task 50 µs
retain data

Integration
of PLC
Motion Control Connectivity
eventlogging ADS
diagnosis OPC

Beckhoff TwinCAT 12
 TwinCAT architecture: platform CX

PC-based automation
TwinCAT
TwinCAT
Architecture  pure software solution
I/O  uses Windows CE real-time
Control  remote configuration, setup,
Motion
programming
Interpolated
Motion
Connectivity CX
 embedded hardware
 OS: Windows CE or Windows XP embedded
 no rotating media, fanless
 direct access to terminal I/O
 more than one fieldbus
 master and/or slave

Beckhoff TwinCAT 13
 TwinCAT architecture: platform CX

Switch from Embedded PC to a IPC/PLC

Safe operation Hard real-time

retain data min. task 50 µs
NovRam
access

Integration
of PLC Connectivity
Motion Control ADS
eventlogging OPC
diagnosis

Beckhoff TwinCAT 14
 TwinCAT architecture: platform BX/BC

PC-based automation
TwinCAT
TwinCAT
Architecture  downloads program
I/O  online debugging
Control  remote configuration, setup
Motion
programming
Interpolated
Motion  remote access via fieldbus
Connectivity
BX/BC
 embedded hardware
 embedded operating system
 direct access to terminal I/O

Beckhoff TwinCAT 15
 TwinCAT and standards

PC-based automation
TwinCAT implements and uses established
TwinCAT
Architecture industrial standards for automation
I/O  operating system: Windows NT4.0, 2000, XP, CE
Control  programming: IEC 61131
Motion
 Motion Control: PLCopen Motion Control function
Interpolated
Motion blocks
Connectivity  vertical integration: OPC
 connectivity: fieldbuses

Benefit to customer
 quick orientation: same look and feel
 less training costs
 less maintenance costs
 reuse of software modules

Summary
 shorter time to market, decreased costs

Beckhoff TwinCAT 16
 TwinCAT architecture

PC-based automation
TwinCAT I/O system
TwinCAT
Architecture  open for all major fieldbuses
I/O  support of PC hardware interfaces
Control  easy setup and diagnosis
Motion
 mapping from logical to physical I/O
Interpolated
Motion
Connectivity

TwinCAT process image

Input Output

Mapping

I O I O I O
fieldbus 1 fieldbus 2 fieldbus 3
Beckhoff TwinCAT 17
 TwinCAT control

PC-based automation
Modular structure
TwinCAT
Architecture  max. 4 PLCs on a PC
I/O
Control Timing
Motion
 max. 4 tasks in one PLC
Interpolated
Motion
Connectivity Easy setup and maintenance
 online program change
 full debugging features:
 breakpoint, monitoring,
powerflow
 scope

Choose the favourite programming language

 all IEC61131-3 languages (IL, ST, FBD, LD, SFC)

Beckhoff TwinCAT 18
 TwinCAT motion

PC-based automation
Shift from mechanical to electronical system
TwinCAT
Architecture  mechanical cam → electronic cam
I/O  mechanical gear → electronic gear
Control  mechanical clutch → electronic clutch
Motion
 mechanical cam shaft → electronic cam shaft
Interpolated
Motion  “flying saw”
Connectivity
Benefit
 greater flexibility
 increased machine output
 reduced setup time – no mechanical modification
 decreased stock – no different mechanical parts

Summary
 shorten delivery/development time, decreased costs
 TwinCAT supplies all of this in one tool/runtime

Beckhoff TwinCAT 19
 TwinCAT motion: NC PTP

PC-based automation
 easy setup and maintenance
TwinCAT
Architecture  open for all axis types
I/O  servos
Control  stepper
Motion
 DC motors
Interpolated
Motion  switching axes
Connectivity  hydraulic axes
 several encoder
 digital encoders: Sercos, SSI
 analog: +/-10 V
 several controller:
 P, PI, PID
 additional functions:
 digital cam switch,
flying saw, superposition

Beckhoff TwinCAT 20
 TwinCAT motion: NC PTP

PC-based automation
TwinCAT
Architecture
 Point-to-point movement
I/O
Control
Motion  Gearing
Interpolated
Motion
Connectivity
 Digital cam switch

 Camming

 Superposition

 Flying saw

Beckhoff TwinCAT 21
 TwinCAT interpolated motion: NC I

PC-based automation
Interaction with PTP-movements
TwinCAT
Architecture  interpolated movements for 3 axes plus
I/O 5 auxiliary axes
Control  programming in DIN 66025 code
Motion
 technological features
Interpolated
Motion  easy access to PTP axes
Connectivity  easy to use FB interface

Beckhoff TwinCAT 22
 TwinCAT interpolated motion: CNC
N00 #KIN ID [1]
PC-based automation
Interaction with PTP-movements N10 #RTCP ON
N20 G01 G18 X0 Y0 Z0 B90 F500
TwinCAT
Architecture  interpolated movements for up to 32 N30 X-4
N40 G02 X-20 I-40 B-90 F2000
I/O axes in one channel N50 .................
........................
Control  programming in DIN 66025 code
Motion
 different transformations
Interpolated
Motion
Connectivity
Path of
rotation point
of rotatory axis

Z
Path of
tool centre
point
X
0

Beckhoff TwinCAT 23
 TwinCAT Connectivity

PC-based automation
Easy to use communication standard:
TwinCAT
Architecture ADS (Automation Device Specification)
I/O Access to ADS with standard Windows mechanism:
Control  ActiveX control, DII, .Net, ASP, OPC
Motion
Interpolated
Motion
Connectivity
ADS over TCP/IP
ADS over serial
connection

ADS over TCP/IP ADS over HTTP/SOAP

ADS over Fieldbus

Beckhoff TwinCAT 24
 TwinCAT communication

Beckhoff ADS interface

 open, simple, for free, documented
 many Scada providers
 standard interface OPC
 DA/AE/XML

C#, Delphi Explorer VB, C#

VB Third party Third party
VB.Net C++ Third party Delphi/C++

Internet

OCX .Net ASP XML Wrapper

ADS Dll TwinCAT OPC Server
ADS Router
Beckhoff TwinCAT 25
Beckhoff TwinCAT - the universal software
platform for all control requirements

Beckhoff TwinCAT 26