Module Type Package (MTP)
TwinCAT MTP: modular automation with Module Type Package
With modular automation, process technology plants can be flexibly implemented and adapted with little effort. Rigid automation systems that have been operated unchanged for years are increasingly becoming a thing of the past, with individuality and flexibility asserting themselves as the future of the process industry. The Module Type Package (MTP) is a concept that allows process technology plants to leverage maximum potential across the board, from the planning phase through to operation. This makes MTP a crucial component in the development of future modular automation solutions.
One of the emerging challenges for many sectors in the process industry, such as the pharmaceutical sector, is increasing fluctuation across sales markets. This is accompanied by the need for a shorter time-to-market due to accelerated development cycles. Product life cycles are shortened accordingly, and these in particular require economically profitable and simultaneously individualized production of small batches.
An increasingly popular solution is designing plants to be modular, which provides the option to reuse the modules for different purposes. This involves breaking down the plant’s entire process into individual sub-processes and mapping them using modules. Full plant modularity can then be achieved with a separate, decentralized controller for each module. The entire process can be remapped by subsequently integrating the individual modules into a higher-level control system (e.g., a DCS). As a result, the development work shifts from plant engineering to module engineering, enabling the plant to be flexibly modified with little effort, depending on current requirements. Additional modules can be added to the plant and modules that have already been integrated can be rearranged or removed. Complete reprogramming is not required, as most of the logic is in the individual modules. The higher-level controller only handles the orchestration of the modules and the services they offer, and is therefore referred to as the process orchestration layer (POL).
In practice, the concept is implemented by means of a manufacturer-independent standard for the description of process modules: the NAMUR Module Type Package (MTP). The MTP, which is defined in accordance with VDI/VDE/NAMUR 2658, contains all the information necessary to integrate a process module into a modular plant, including functions in the form of services, communication, and an HMI template. Interfaces defined in the MTP guideline enable plug-and-produce behavior, eliminating the work and costs associated with restructuring a plant. This means modules are only developed once and can then be integrated into plants independently of the controller manufacturer and POL.
Advantages of Module Type Package (MTP)
- short time-to-market due to minimized plant engineering
- short time-to-repair due to uniform module interfaces
- individual production of small batches due to reusability of modules
- numbering-up replaces time-consuming scale-up
- uniform look and feel of the visualization system
Advantages and features of TwinCAT MTP
- seamless integration into TwinCAT Engineering
- interface-driven MTP engineering
- option to import and export MTP files before programming
- integrated engineering achieved by importing P&ID information
- automatic PLC code generation based on the module definition
- automatic generation of the local HMI
TwinCAT MTP functionality in detail
The Module Type Package (MTP) concept is integrated into TwinCAT via TwinCAT MTP Runtime and TwinCAT MTP Engineering. TwinCAT Engineering includes a project management system that TwinCAT MTP Engineering is integrated into as its own project type. The project type enables the generic definition of a module, and the MTP file can be generated based on this before programming. Existing information can be processed via an open API, an MTP import, or a DEXPI import. In addition, the information can be used for automated PLC and HMI generation.
Subsequent changes in MTP project management are integrated by means of automatic project synchronization. Only the actual process logic of the functionalities being offered needs to be programmed in the prepared state machine.
Finally, the project can be activated, which automatically makes the variables of the defined interfaces available to the POL via OPC UA.
The following interactive graphic explains the process from the development of the module with TwinCAT MTP to its integration into the plant in individual steps. Then, application scenarios for TwinCAT MTP at the various levels of a process technology system are illustrated with short videos.
MTP application scenarios in green and brownfield environments
MTP makes process technology systems modular and cuts down on both the initial engineering work and the work that goes into reconfiguring a system.
This video shows you how the MTP concept works at plant level. It illustrates how the MTP concept can be applied in both greenfield and brownfield scenarios.
This video shows how the MTP concept works at module level. A distinction can also be made between greenfield and brownfield applications at module level.
Specifically, this video shows how modularity can be implemented within the module using functional units in the greenfield. These functional units are designed dynamically so that they can be integrated flexibly, allowing the module to be customized for the current application.
This video shows how the MTP concept works at module level. A distinction can also be made between greenfield and brownfield applications at module level.
Specifically, this video shows how brownfield modules based on existing skids can be created with the MTP gateway. If several modules need to be implemented on one control unit, the MTP hub is a cost-effective solution.
In practice: Module Type Package (MTP) in industrial use at Ajinomoto Omnichem
In this use case, Ajinomoto Omnichem (an Ajinomoto Group company) and Beckhoff successfully demonstrated how the Module Type Package concept can be used to automate an industrial plant.
A special feature of the plant shown is the use of the MTP hub. In this application, all modules of the plant were implemented on a central Beckhoff control system. The PC-based control technology makes it possible to implement the modules in independent PLC programs and make them available to the POL separately. Through this architecture, the plant structure can be changed without having to adapt the control system – it automatically recognizes which modules are currently connected. The plug-and-produce behavior of the MTP concept enables simple reconfiguration in the POL, which has reduced the changeover time considerably.
FAQs, further information, and contact
TwinCAT allows for straightforward MTP programming without requiring in-depth knowledge of the relevant guidelines: It starts with the definition of the MTP interface, which results in the MTP file. This is then used for automatic code generation for the PLC and the HMI, allowing developers to concentrate primarily on the actual process logic and leave a large part of the programming to TwinCAT.
No, this is not necessary with PC-based control technology. It is also possible to run several MTP modules simultaneously on high-performance Beckhoff Industrial PCs. The resulting MTP hub makes the individual modules available to the control level independently of each other.
Yes, this is possible due to the integrated engineering features in TwinCAT. In addition to the MTP import, it is also possible to read the DEXPI format or proprietary data sources into TwinCAT. This means information from upstream planning steps can be used directly in the engineering environment and passed on to the control level.
Products
TF8400 | TwinCAT 3 MTP Runtime
An MTP (Module Type Package) is a communication interface between a higher-level control system (e.g. process control system) and a modular plant. The MTP describes the interface of visualization, provided services and other features of a module, so that a simple orchestration of the modules to form a complete plant can be done easily and quickly in the higher-level control system.
TF8401 | TwinCAT 3 MTP Engineering
An MTP (Module Type Package) is a communication interface between a higher-level control system (e.g. process control system) and a modular plant. The MTP describes the interface of visualization, provided services and other features of a module, so that a simple orchestration of the modules to form a complete plant can be done easily and quickly in the higher-level control system.
TF6100 | TwinCAT 3 OPC UA
OPC UA is a platform-independent, service-oriented communication architecture for reliable, secure and multisupplier data transport from the production level to the production planning and ERP system or to the cloud.
TF4100 | TwinCAT 3 Controller Toolbox
The TwinCAT Controller Toolbox covers all essential blocks for control applications. All blocks have the same appearance and almost the same properties. Simple parameterization via a structure and the same error handling for all blocks support the application.
Ultra-compact Industrial PCs
The scalable C60xx series combines maximum computing power in what is currently the most compact format with a wide range of options for installation in the control cabinet.
CX5100 Embedded PC series
The DIN-rail-mountable, fanless Embedded PCs from the CX5100 series are equipped with Intel Atom® multi-core processors.
EtherCAT Terminals
The EtherCAT Terminal system provides a comprehensive range of products for all signals in the world of automation.
Control Panels
As the front end of a machine, the Beckhoff Control Panels are its visual and functional business card and allow a wide range of customer-specific adaptations.