plc and motion control on the pc -...

T W I N C AT ®

PLC and Motion Control on the PC

Twin

CAT

961

The Windows Control and

Automation Technology

New Automation TechnologyBECKHOFF

Twin

CAT

962

Product overview

PC-based control technology

PLC and Motion Control

on the PC

TwinCAT PLC

TwinCAT NC PTP

TwinCAT NC I

TwinCAT CNC

TwinCAT I/O

TwinCAT CP

TwinCAT PLC Libraries

TwinCAT PLC Controller Toolbox

TwinCAT PLC

Temperature Controller

TwinCAT PLC

Hydraulic Positioning

TwinCAT PLC Modbus RTU

TwinCAT PLC Serial

Communication

TwinCAT PLC Serial

Communication 3964R / RK512

TwinCAT PLC Serial

Communication EnOcean

TwinCAT PLC

Building Automation

TwinCAT PLC

Building Automation DALI

TwinCAT PLC

IEC 60870-5-101 Slave /

IEC 60870-5-104 Slave

TwinCAT PLC

IEC 60870-5-104 Master

TwinCAT PLC

IEC 60870-5-101 Master /

IEC 60870-5-103 Master

TwinCAT NC PTP Libraries

TwinCAT NC Camming

TwinCAT NC FIFO Axes

TwinCAT NC Flying Saw

TwinCAT PLC

Remote Synchronisation

TwinCAT System Software

TwinCAT ECAD Import

TwinCAT Engineering

Interface Server

TwinCAT Eventlogger

TwinCAT XML Data Server

TwinCAT Backup

TwinCAT Simulation Manager

TwinCAT Database Server CE

TwinCAT PLC HMI

TwinCAT Building Automation

Framework


Motion

TwinCAT Cam Design Tool

TwinCAT Digital Cam Server

TwinCAT DriveTop Server

TwinCAT DriveCom OPC Server

TwinCAT Valve Diagram Editor


Connectivity

TwinCAT ADS

TwinCAT OPC Server

TwinCAT OPC UA Server

TwinCAT SMTP/SMS Server

TwinCAT Modbus TCP Server

TwinCAT TCP Server

TwinCAT

964

967

969

972

983

984

984

985

992

992

974

976

978

980

982

985

985

986

986

987

987

988

989

990

990

990

991

992

993

993

994

994

997

997

998

998

999

999

1000

1000

1001

1002

1002

1003

995

1003

988

996

991

995

New Automation TechnologyBECKHOFF

Twin

CAT

963

TwinCAT System

TwinCAT CP

TwinCAT I/O

TwinCAT PLC

TwinCAT NC PTP

System Manager

Syst

em S

oftw

are

NC L

ibra

ries

PLC

Libr

arie

s

TwinCATSupplement

TwinCAT NC I

TwinCAT CNC

TwinCAT PLC

PC hardware standard PC/IPC hardware, no extras

Operating systems Windows NT/2000/XP/Vista, NT/XP Embedded, CE

Real-time Beckhoff real-time kernel

I/O system EtherCAT, Lightbus, PROFIBUS DP/MC, Interbus,

CANopen, DeviceNet, SERCOS, Ethernet and PC

hardware

Run-time system 4 multi-tasking PLCs each with 4 tasks in each PLC

run-time system, development and run-time systems

on one PC or separately (CE: only run-time)

Memory process image size, fl ags area, program size,

POU size, number of variables only limited by

the size of the user memory (max. 2 GB with

NT/ 2000 / XP/Vista)

Cycle time adjustable from 50 µs

Link-time 1 µs (Pentium® 4 2.8 GHz) for 1,000 PLC

commands

Programming IEC 61131-3: IL, FBD, LD, SFC, ST, powerful

library management, convenient debugging

TwinCAT PLC Libraries

Libraries TwinCAT PLC Controller Toolbox

TwinCAT PLC Temperature Controller

TwinCAT PLC Hydraulic Positioning

TwinCAT PLC Modbus RTU

TwinCAT PLC Serial Communication

TwinCAT PLC Building Automation

TwinCAT PLC IEC 60870-5-101/4

TwinCAT NC PTP

TwinCAT PLC inclusive






hardware

Programming performed using function blocks for TwinCAT PLC

according to IEC 61131-3 (standardised PLCopen

Motion Control libraries), convenient axis commis-

sioning menus in the System Manager

Run-time system NC point-to-point including TwinCAT PLC

Number of axes up to 255

Axis types electrical and hydraulic servo drives, frequency

converter drives, stepper motor drives, switched

drives (fast/crawl axes)

Cycle time 50 µs upwards, typically 1 ms (selectable)

Axis functions standard axis functions: start / stop / reset /

reference, speed override,

special functions: master/slave cascading,

cam plates, electronic gearings, online distance

compensation of segments, “fl ying saw”

TwinCAT NC PTP Libraries

Libraries TwinCAT NC Camming

TwinCAT NC FIFO Axes

TwinCAT NC Flying Saw

TwinCAT PLC Remote Synchronisation

Software NC PTP Software PLC

985

985

987

988

985

984

984

990

990

991

991

974

972

972

New Automation Technology We reserve the right to make technical changes.BECKHOFF

Twin

CAT

964

P R O D U C T O V E R V I E W T W I N C AT

TwinCAT NC I


TwinCAT NC PTP inclusive






hardware

Programming DIN 66025 programs for NC interpolation,

access via function blocks from TwinCAT PLC

according to IEC 61131-3

Run-time system NC interpolation, including TwinCAT NC PTP

and PLC

Number of axes max. 3 axes and up to 5 auxiliary axes per group,

1 group per channel, max. 31 channels

Axis types electrical servo axes, stepper motor drives

Interpreter subroutines and jumps, programmable loops,

functions zeroshifts, tool compensations, M and H functions

Geometries straight lines and circular paths in 3-D space,

circular paths in all main planes, helixes with base

circles in all main planes

Axis functions online reconfi guration of axes in groups, path

override, slave coupling to path axes, auxiliary axes

TwinCAT CNC


TwinCAT NC PTP inclusive

TwinCAT NC I inclusive


Operating systems Windows NT/2000/XP/Vista, Windows NT/XP

Embedded




hardware

Programming DIN 66025 programming language with

high-level language extensions, mathematical

functions, programming of parameters/variables,

user macros, subroutine techniques, spindle and

help functions, tool functions, zero offset shifts

Run-time system CNC, including TwinCAT NC I, NC PTP, PLC

Number of axes / 8 path axes / 6 controlled spindles, max. of

spindles 64 axes / 12 controlled spindles (optional)

Axis types electrical servo-axes, analog/encoder interface

via fi eldbus, digital interface via fi eldbus

(EtherCAT, Lightbus, PROFIBUS MC, SERCOS)

Geometries linear, circular, helical interpolation in the main

planes and freely defi nable planes, 8 interpolating

path axes per channel, look-ahead function

Axis functions coupling and gantry axis function, override, axis

error and sag compensation, measuring functions

Operation automatic operation, manual operation (jog /

inching), single block operation, referencing,

block search, handwheel operation (motion /

superposition)

TwinCAT CNC Options

Options TwinCAT CNC Axes Pack

TwinCAT CNC Channel Pack

TwinCAT CNC Transformation

TwinCAT CNC Spline-Interpolation

Software NC I Software CNC

979

979

979

979

978

972

976

972

974 974

976

New Automation TechnologyBECKHOFFWe reserve the right to make technical changes.

Twin

CAT

965

P R O D U C T O V E R V I E W T W I N C AT

TwinCAT I/O



(only run-time)


TwinCAT CP


Operating systems Windows NT/2000/XP/Vista, NT/XP Embedded


TwinCAT Level System software | Motion

TwinCAT ADS

set of different ADS communication components

TwinCAT OPC Server

for access to TwinCAT variables in accordance with the OPC DA/XML-DA

specifi cation

TwinCAT OPC UA Server

for access to TwinCAT variables in accordance with the OPC UA

specifi cation

TwinCAT SMTP/SMS Server

enables sending of SMS messages from the TwinCAT PLC to

a mobile phone

TwinCAT Modbus TCP Server

for communication with Modbus TCP devices

(server and client functionality)

TwinCAT TCP Server

server and PLC library for communication via generic TCP server

(client functionalities included)

TwinCAT ECAD Import

tool for importing XML fi les from ECAD systems

TwinCAT Engineering Interface Server

for coordination of programming tasks via a source code management

system

TwinCAT Eventlogger

Alarm and diagnosis system that can be used in all TwinCAT controllers

with very little programming effort.

TwinCAT XML Data Server

PLC data can be written directly into an XML fi le or read from an XML fi le.

TwinCAT Backup

tool for backing up and restoring of fi les, operating system and TwinCAT

settings

TwinCAT Simulation Manager

simplifi es preparation and confi guration of a simulation environment

TwinCAT Database Server CE

for bi-directional access to the PLC database

TwinCAT Building Automation Framework

for easy confi guration of building automation applications

Multi-purpose I/O interface for all common fi eldbus systems, PC Fieldbus Cards and interfaces with integrated real-time driver

Windows driver for Beckhoff Control Panel

System software | ConnectivitySystem software

TwinCAT Cam Design Tool

tool for designing electronic cam plates, fully integrated in the TwinCAT

System Manager

TwinCAT Digital Cam Server

fast camshaft controller as software implementation in TwinCAT,

freely confi gurable via the TwinCAT System Manager

TwinCAT DriveTop Server

communication server for connecting the Indramat DriveTop tool with

TwinCAT

TwinCAT DriveCom OPC Server

for communication of drive setup tools right into DriveCom compatible

drives

TwinCAT Valve Diagram Editor

graphics-oriented editor for designing the characteristic curves of

a hydraulic valve

980

982

997

998

998

999

999

1000

1001

1002

1003

1003

992

992

993

993

994

994

995

1002

996


Twin

CAT

966

Comparison: execution times for 1,000 PLC commands by a hardware PLC

and by TwinCAT PLC

TwinCAT – PC-based control technologybehaviour is achieved in this way. TwinCAT indicates the system load for programs that are running. A load threshold can be set in order to assure a defi ned computing capacity for the operating programs and for Windows NT/2000/XP/Vista. If this threshold is exceeded, a system message is generated.

TwinCAT supports system diagnosisThe general use of hardware and software from the open PC world requires some checking: Unsuitable components can upset the PC system. Beckhoff has integrated a practical indica-tor of the real-time jitter, giving administrators an easy way to evaluate the hardware and soft-ware. A system message during operation can draw attention to incorrect states.

Start/stop behaviourDepending on the setting, TwinCAT is started and stopped manually or automatically. Since TwinCAT is integrated into Windows NT/2000/XP/Vista as a service, an operator is not needed to start the sys -tem: switching on is enough.

Restarting and data backupWhen a program is started or restarted, TwinCAT loads pro-grams and remanent data. To back up data and to shut down Windows NT/2000/XP/Vista cor-rectly, a UPS (uninterruptible power supply) is of great value.

TwinCAT and “Blue Screen”The TwinCAT system can be confi gured such that real-time

capability is maintained in the event of a BSOD (Blue Screen of Death) operating system crash. Real-time tasks such as PLC and NC can therefore continue to run and bring the controlled process into a safe state. Ultimately, it is the decision of the programmer whether or not to utilise this fea-ture, bearing in mind that data or programs may already have been destroyed by the BSOD.

World-wide connection through message routing – “remote” connection is inherent to the systemAccording to the requirement for operating resources, the TwinCAT software devices can be distrib-uted: TwinCAT PLC programs can run on the PCs or on Beckhoff

The Windows Control and Automation TechnologyThe TwinCAT Software System turns any compatible PC into a real-time controller with a multi-PLC system and NC/CNC axis control. At the same time, TwinCAT integrates the pro-gramming environment for all Beckhoff controllers: from high-end Industrial PC control to embedded controller.

TwinCAT architectureTwinCAT consists of run-time systems that execute control programs in real-time and the development environments for programming, diagnostics and confi guration. Any Windows pro-grams, for instance visualisation programs or Offi ce programs, can access TwinCAT data via Microsoft interfaces, or can execute commands.

A practically oriented software solutionTwinCAT offers a precise time-base in which programs are executed with the highest deter-ministic features, independently of other processor tasks. The real-time load on a PC is set with TwinCAT; defi ned operating


Twin

CAT

967

TCP/ IP | serial

ADS interface

System Manager

Real-time server

I/O mapping

I/O: All fieldbuses and PC interfaces

ADS

Message router

Message router

I/O

ADS interface

I/O serverI/O run-time

I/O

ADS interface

PLC serverPLC run-time

I/O

ADS interface

NC PTP serverNC PTP run- time

I/O

ADS interface

NC I serverNC I run-time

I/O

ADS interface

CNC serverCNC run-time

System Manager

configuration,service,monitoring

ADS

PLC control

PLCprogramming

ADS ADS

Motion Control

TwinCAT NC PTPTwinCAT NC ITwinCAT CNC

ADS OCX/DLL

Scada,Visual Basic,Delphi, VisualC++, .NET, C#,VB.NET, …

OPC client

Scada,Visual Basic,Delphi

ADS Web service

ADS-http://

Internet /Intranet

TwinCAT OPC server

DAXMLUA A&E

PLC cycle PLC cycle

Read

inpu

ts

Ope

rate

pro

gram

Writ

e ou

tput

s

Read

inpu

ts

Ope

rate

pro

gram

Writ

e ou

tput

s

t

Real-time operation of PLC software in a classic PLC

Real-time operation of PLC software on a PC

Real-time operation of software for a PLC and NC (Motion Control) on a PC

The Windows Control and Automation Technology

The Beckhoff TwinCAT software system turns any compatible PC into a real-time controller with a multi-PLC system, NC axis con-trol, programming environment and operating station. TwinCAT replaces conventional PLC and NC/CNC controllers as well as operating devices with: – open, compatible PC hardware– embedded IEC 61131-3 software PLC, software NC and

software CNC in Windows NT/2000/XP/Vista, NT/ XP Embedded, CE

– programming and run-time systems optionally together on one PC or separated

– connection to all common fi eldbuses– PC interfaces are supported – data communication with user interfaces and other programs

by means of open Microsoft standards (OPC, OCX, DLL, etc.)

PLC cycle PLC cycle

Read

inpu

ts

Ope

rate

pro

gram

Writ

e ou

tput

s

Win

dow

s N

Tan

d HM

I

Read

inpu

ts

Writ

e ou

tput

s

Ope

rate

pro

gram

Read

inpu

ts

Ope

rate

pro

gram

t

PLC Server Windows NTand HMI

NC Serverfor Motion Control

t1 ms

PLC cycle (e.g. 2 ms) PLC cycle t

NC cycle (e.g. 1 ms) NC cycle t

2 ms 3 ms 4 ms 5 mse.g.

NC cycle NC cycle

Load threshold and jitter online

Bus Terminal Controllers. A “mes-sage router” manages and dis-tributes all the messages, both in the system and via TCP/IP connections. PC systems can be connected with each other via TCP/IP; Bus Terminal Controllers are integrated via serial inter-faces and fi eldbuses (Lightbus, PROFIBUS DP, CANopen, RS232, RS485, Ethernet TCP/IP).

World-wide accessSince standard TCP/IP services of NT/2000/XP/Vista can be used, this data can be exchanged across the world. The system offers scalable communication

capacity and timeout periods for the supervision of communi-cations. OPC provides a stand-ardised means for accessing many different SCADA packets. The SOAP (Simple Object Access Protocol) enables a connection between two computers to be established by means of an inter -net connection via standard HTTP. A TwinCAT component is available for this purpose.


Twin

CAT

968

TwinCAT I/O – universal I/O interface for all common fi eldbusesMany PC fi eldbus cards from various manufacturers are sup-ported. It is possible to operate more than one fi eldbus card per PC. Master and slave function-ality is supported, depending on the selected fi eldbus card. The fi eldbus cards can be confi gured and diagnosed conveniently via the TwinCAT System Manager. TwinCAT I/O includes the TwinCAT real-time system for operating the fi eldbuses and a DLL inter-face to application programs.

TwinCAT PLC – the central pillar of automation softwareConceived as a pure software PLC, TwinCAT PLC allows up to four virtual “PLC CPUs”, each running up to four user tasks, on one PC. The PLC program can be written in one or more of the languages provided for in the IEC 61131-3 standard:– IL (Instruction List),– LD (Ladder Diagram),– FBD/CFC (Function Block

Diagram),– SFC (Sequential Function

Chart) and– ST (Structured Text).

PLC and Motion Control on the PCTwinCAT PLC running under the Windows NT/2000/XP/Vista operating systems includes both the programming environment and the run-time system, so that an additional programming device is not required. Under the CE operating system and the embedded operating systems for the series BX and BC control-lers, only TwinCAT run-time is available. Program modifi cations are implemented via network-capable powerful communica-tion with the run-time system. Programming can be done– locally,– via TCP/IP or– via the fi eldbus

(BXxxxx and BCxxxx).

IEC 61131-3 – advanced programming standard for all Beckhoff controllersThe TwinCAT PLC is programmed in accordance with IEC 61131-3 independently of the manufac-turer. TwinCAT supports all the IEC 61131-3 programming lan-guages with convenient editors and a fast, effective compiler, so that the development cycle for the creation even of large PLC programs of several mega-bytes can be short. Incremental

compilation prevents long turnaround times. Only genu-inely new sections are compiled. Powerful editor features, such as “autoformat”, “autodeclare” or “fi nd” and “replace” enable fast programming. For all program-ming languages, the project comparison function facilitates differences to be identifi ed and accepted if appropriate. If a project (comments, directories, etc.) is to be translated into a language other than the origi-nal language, all terms can be exported into a table, translated and re-imported. If a team is dealing with the development, all objects (blocks, data types, lists) can be managed within a source code management tool via the TwinCAT Engineering Interface. This enables changes to be traced back and differences between individual versions to be displayed.

The concept of the “instan-tiation” of function blocks, in which each instance is associ-ated with its own data, leads naturally to object-oriented and structured programming styles. All common data types specifi ed in IEC 61131-3 are supported. Multi-dimensional fi elds and

structures are possible, as are enumeration and subrange types.

TwinCAT PLC is certifi ed for the languages IL and ST (base level). The online change function can be used for code and/or data modifi cations while the PLC is running, providing maximum data retention. Source code can be stored in the target system (except for BCxxxx series controllers). The criteria analysis function is very helpful for the detection of process errors.

Code can very easily be reused via the convenient library manager. For know-how pro-tection, multi-stage password protection can be applied to programs and libraries.

Many target platforms – one toolThe PLC programs created with TwinCAT PLC can be executed on a number of target platforms. Apart from Industrial PCs and the Embedded PCs, the PLC project can also be loaded into the BC and BX series fi eldbus controllers from Beckhoff. Pro gram devel-opment and debugging proceed in the same working environ-ment, regardless of which unit is executing the program.


Twin

CAT

969

Hierarchical controller architecture: central or distributed

TwinCAT NC – Motion Control on the PCA software NC consists of:– positioning (set value gen-

eration and position control)– integrated PLC with NC

interface– operating programs for

commissioning purposes– I/O connection for axes via

fi eldbusWith TwinCAT NC, the position controller is calculated on the PC processor as standard. It exchanges data cyclically with drives and measurement systems via the fi eldbus.

Central NC positioning on the PCThe computing capacity of a PC enables axis motion simulta-neously with the PLC, whereby the position controller is usually calculated on the PC: The com-puting capacity of a PC enables many axes to be positioned simultaneously.

TwinCAT enables a PC to pro cess the operating pro-grams, the PLC and the NC at the same time. The division of the system load is supported by TwinCAT with appropriate functions.

Analytical path calculationThe algorithms that TwinCAT NC/NC I/CNC uses to control axes take account of the dynamic parameters of the axis: speed, acceleration and jerk. In this way, the axes are moved at any time within the limits of what is dynamically possible, and are precisely analytically coordinated. A range of different regulation algorithms are available in order to reduce the deviations from the ideal trajectory that will occur in practice.

Individual or jointBased on the normal methods for positioning an individual electrical axis, moving from its starting point to its destination (point-to-point positioning), TwinCAT NC also allows the coordinated movement of a number of axes in multi-stage master-slave operation (e.g. gearing functions or cam plates) to be executed. TwinCAT NC I further allows the interpolated path sequencing described in accordance with DIN 66025 to be carried out involving up to three axes.

Extensive supplementary librariesAs an extension to the blocks defi ned by the IEC language standard, Beckhoff offers a wide range of supplementary libraries for the execution of tasks typical in automation technology: e.g. libraries for controlling electrical and hydraulic axes via TwinCAT NC, serial communication librar-ies, system libraries for message outputs, write/read fi les, control technology blocks, etc.

Helpful practice toolsExtensive faultfi nding functions in TwinCAT PLC facilitate the solu-tion of problems either on site or via remote maintenance. For this purpose, the PLC programming environment in TwinCAT offers:– monitoring,– powerfl ow (fl ow control),– break point,– sampling trace of PLC

variables,– single step,– watchlist,– call hierarchy and– forcing of variables.In addition, the TwinCAT Scope-View (a software oscilloscope) can be used to record one or several variables simultaneously.

Supervisory system

TwinCAT

PC Control

TwinCAT

PC Control

TwinCAT

PLC I/O

LANCommunication


Twin

CAT

970

PTP positioning procedure

0

20

40

100

80

60

-22-20-18

-12-14-16

-10-8-6

0-2-4

24

86

1210

0.0 0.2 0.4 0.6 0.8

0

200

400

1000

800

600

0

-2

2

time (s)

velocity (m/min)

acceleration (m/s2)

jerk (scaled to -1.0, +1)

position (mm)

enables the dynamic parameters of an axis to be determined.

TwinCAT NC I – axis interpolation in three dimensionsTwinCAT NC I (interpolation) is the NC system for linear and circular interpolated path movements of axis groups each involving two or three drives. The system includes interpreter, set value generation and posi-tion controller. PLC functionality is integrated, as is the connec-tion of the axes with the fi eld-bus.

The interpreter interprets the code described in DIN 66025. Comprehensive PLC libraries enable interaction between NC and PLC. NC programs, for example, can be loaded directly from the PLC program into the interpreter.

TwinCAT CNC – the software CNC for toughest requirementsTwinCAT CNC expands TwinCAT NC I with classic CNC features: Up to 32 interpolating axes and comprehensive coordinate and kinematic transformations are possible. Parts programming

is carried out according to DIN 66025 using high-level language extensions. TwinCAT CNC can operate with up to 64 axes or 32 path axes and controlled spindles that can be distributed across up to twelve CNC channels. In a CNC chan -nel, up to 32 axes can be inter-polated simultaneously, enabling even the most diffi cult motion tasks to be solved. Apart from the classic linear, circular and helical interpolations, TwinCAT CNC offers convenient spline interpolation, optionally based on Akima or B-splines. Real-time transformations enable complex machine kinematics to be real-ised without problem.

Software PLC includedTwinCAT combines software NC and software PLC to form a powerful controller. The commu-nication between the two pack-ages is a pure software/software channel with minimum delay times. The NC functionalities are called from the PLC program via standardised, PLCopen-certifi ed function blocks.

Axis movements can be simulated without hardware; the actual value is instructed to ideally track the set value, and the complete machine fl ow is checked. TwinCAT ScopeView is helpful for commissioning and maintenance. It records all axis variables such as position, speed, acceleration and jerk.

Convenient commissioningCommissioning is simplifi ed signifi cantly by the confi guration and diagnostic dialogs offered in the TwinCAT System Manager. For each axis, all main data are displayed at a glance. The axes can be moved via function keys. Special functions such as cou-plings, cam plates or distance compensation can be triggered and observed via the System Manager. A convenient dialog


Twin

CAT

971

plc and motion control on the pc -...

Documents