The installation and testing for this blog was done on a Windows 10 Pro, 64-bit operating system, Intel Core i7 CPU with 24 GB RAM, Intel UHD 620 graphics card. The performance of this set up is more than sufficient for most simulation projects.

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We combine industry-leading Product Lifecycle Management tools with specialist knowledge, so you can enjoy the journey from product concept to implementation. Our experience makes it possible to keep things simple, personal and accessible so that together we transform your vision into value.

End users and manufacturers of machines for sheet metal working and metal forming are faced with high demands: High productivity must be guaranteed as well as a maximum degree of individualization and high quality standards. In order to be able to produce competitively, the machines must also be optimized with regard to their footprint and energy consumption. In order to meet these requirements, modern automation technology is required, as we offer with PC-based control.

Beyond the high-performance control technology, EtherCAT and EtherCAT P in particular provide for a competitive advantage in press lines. We offer a wide range of CNC functions for cutting and welding plants. Special applications for punching and nibbling are supported by fast signal processing based on EtherCAT and EtherCAT XFC. With the software library TwinCAT 3 Hydraulic Positioning, ready-made function blocks are available for bending processes in folding, roller bending or pipe bending machines. In addition, you can rely on our expertise acquired over many years of cooperation with our customers in the field of sheet metal working and forming. We offer comprehensive application support for both new plants and machine retrofits.

Increasing product diversity, highly fluctuating batch sizes and a strong sense of cost demand maximum flexibility from sheet metal processors. This is precisely where our PC-based control technology offers a decisive competitive advantage: scalable solutions with high performance and precision. With the Beckhoff automation toolkit, control solutions can be configured for the most diverse applications and requirements in sheet metal working: High-performance industrial PCs, multi-touch panels, fast I/O components, EtherCAT as an open and fast fieldbus, dynamic servo drive technology and TwinCAT automation software form the basis for PLC, visualization, motion control, safety and measurement technology. The automation functions are abstracted from the hardware and consistently transformed into software modules. This results in a significantly reduced communication effort, shorter response times and lower costs, both for hardware and for the engineering.

In addition, the standards-based open control architecture with its diverse interfaces in hardware and software offers a high degree of flexibility. Support for common fieldbus systems and software protocols guarantees integrated horizontal and vertical communication: from the networking of individual machines to the IT level and the cloud. The TwinCAT Analytics data analysis software tool can also increase the productivity of the plant: comprehensive condition monitoring allows for predictive maintenance and reduces the downtime of machines and plants.

The EtherCAT technology was launched on the market by us in 2003 and made available as an open standard for automation technology. With outstanding performance, flexible choice of topology, comprehensive diagnostics and simple configuration, EtherCAT is ideally suited for use in sheet metal working machines. We offer the largest number of EtherCAT-compatible automation modules for I/Os and for drive technology. In addition, a large number of EtherCAT-compatible sensors and actuators from third-party manufacturers are also available on the market, thus ensuring a high level of investment security. The fast and highly precise eXtreme Fast Control (XFC) solution with I/O response times of less than 100 s improves the productivity of sheet metal working machines and reduces waste and the consumption of resources.

Punching is a highly dynamic process. Stroke rates of more than 2,000 strokes per minute are not uncommon. At these high speeds, a high-performance control platform and extremely fast communication are required in order to make adjustments to the mechanism in the micron range. In particular with high-speed presses, the dynamic effects resulting from the high centrifugal forces can be compensated. TwinCAT automation software and the EtherCAT high-speed communication system are the basic function blocks for this. Cycle times in the lower millisecond or even sub-millisecond range allow fast reaction and response times. Nevertheless, these times cannot be completely eliminated. XFC helps with its distributed clocks (DC): This technology provides the machine with a nanosecond-precise system time. All signals from the field and calculations within the controller are referenced to this time. Thus, several sensors can be evaluated at the same time, as there is a uniform time base.

Another property of XFC, oversampling, is also used to improve the process. This technology is used whenever it comes to acquiring or outputting signals from the machine with an even higher resolution, despite PLC cycle times that have already been set very short. The trick: in an EtherCAT cycle, up to 100 temporally equidistant values of a signal are transmitted at a stroke; the temporal resolution of the signal is also appropriately increased by this factor. The associated, significantly reduced discretization losses increase the positioning accuracy of drives or the accuracy of the detection of workpieces.

For line systems and modular machine concepts, we offer EtherCAT P, a superior single-cable solution for the field level. EtherCAT P integrates the EtherCAT communication as well as the system and peripheral voltage in one cable. In addition, EtherCAT P enables the direct forwarding of a power supply via the devices. All benefits of EtherCAT are retained, including free choice of topology, high speed, high-precision synchronization, extensive diagnostics. EtherCAT P is the optimum bus system for sensors, actuators and measurement technology in sheet metal processing. In one cable automation, decentralized terminal boxes and individual machine modules are supplied with control data and power via a single cable. The previously familiar, large control cabinets can thus be partly or completely dispensed with, so that the footprint of the plant is significantly reduced.

Thanks to EtherCAT P, it is possible to implement modular machines and system concepts with high flexibility and considerably reduced installation and commissioning effort. Material costs, installation effort and time are saved; the error rate during the installation is reduced. Due to the omission of the power feed it is possible to make sensors and actuators smaller, and the space required in drag chains, control cabinets and in the machine itself is reduced. In other words, EtherCAT P enables above-average performance with low connection costs.

For the first time, the MX-System enables completely control cabinet-free automation solutions in machine and system engineering. The combination of baseplate and function modules resulting from the modular system combines all the tasks and features of a control cabinet: power supply, fuse protection and distribution, generation and monitoring of auxiliary voltages, sequence control with inputs and outputs, control of motors and actuators, and the connection level for the field devices. The full system integration of all machine functionalities is achieved via freely selectable IPC, coupler, I/O, drive, relay, and system modules, which can be configured and combined according to the specific application.

The consistently systemic approach of comprehensively coordinated assemblies, certified to international standards, enormously reduces the effort required for planning, assembly, machine installation, and maintenance. Since considerably fewer components are required than in traditional control cabinet design to implement the same requirements, the entire MX-System is significantly more compact than previous solutions. The system footprint is reduced, and system availability and flexibility are also increased. In each life cycle phase of a control system, the MX-System offers significant advantages over the classic control cabinet.

In TwinSAFE, we have implemented a universal safety concept that integrates safe functionalities into the standard control platform. All safety functions such as emergency stop, safety door monitoring, two-hand operation, safety mat evaluation and muting, safe position and safely limited speed, can be programmed and configured with TwinCAT. Safety technology is seamlessly integrated into the terminal segment via the TwinSAFE I/O modules, allowing safe signals to mix with standard signals as required.

The typical safety functions can be programmed or configured according to the safety requirements in a TwinSAFE Logic Terminal via standard safety function blocks. All Beckhoff safety controllers are suitable for applications up to SIL 3 according to IEC 61508 or PLe of ISO 13849-1. The safety controllers support complex, safe analog evaluations. With the help of the TwinSAFE SC technology, it is possible to qualify standard signals for safety tasks in any network or on any fieldbus. For this purpose, corresponding EtherCAT Terminals are available.

Large networked plants pose major challenges for all parties involved, especially with regard to safety technology. TwinSAFE offers the option to completely or partially decentralize the safety application as required. Each machine or, if necessary, each unit can easily be equipped with its own safety logic. 9d4ff6ea65