Technological extension of existing systems with measuring and control systems, drive and safety technology

Digitization, Artificial Intelligence and networked machines: future technologies become usable in existing production environments through the digital upgrading of old machines. Current machine generations already increasingly have the necessary sensors and interfaces to provide the necessary data for these future technologies. In most production facilities, however, there is a mixed portfolio of old and new machines. A consistent digitization initiative must include all machines in the value creation chain in order to identify and exploit optimization potentials.

The potential in the modernization of production processes based on individual machines is particularly high: missing production data and condition information, restricted networking and manual product transport are the rule rather than the exception.

There are various possibilities to upgrade old machines with new technologies:

• Automated supply and discharge synchronize processes with varying speeds and reduce physical effort to a minimum.
• Vision systems help with the identification and quality assurance of the products.
• End-of-line and in-line tests ensure 100 % product quality, e.g. with weighing and press-fit monitoring.
• Fast fieldbus communication optimizes the process times and control loops.
• New safety concepts increase both personal protection and the availability of the machine.
• Power and performance measurement monitors the quality of the supply, records the power consumption and detects anomalies.
• Condition monitoring with adapted sensors enables predictive maintenance concepts and reduces maintenance costs.
• Machine learning in the real-time system identifies anomalies in production operation.

Beckhoff offers machine manufacturers, system integrators and operators a comprehensive modular system:

• Modular and scalable: Drive Technology – from compact servomotors to the XTS linear transport system to floating product transport with XPlanar
• Visual and robust: integrated real-time image processing with TwinCAT Vision and synchronous LED control
• Precise and versatile: integrated manufacturing measurement technology for force and weight, displacement and temperature
• Fast and synchronous: EtherCAT communication for high-performance data exchange and highly dynamic drive and control systems
• Safe and flexible: TwinSAFE integrated safety solution – from the IP20 terminal system to IP67 box modules to safe drive technology, flexible in the architecture with Safety over EtherCAT (FSoE)
• Transparent and distributed: securing the machine against poor grid quality via the Beckhoff Power Quality Factor (PQ). Scalable from the mains monitor to distributed power measurement to the detailed analysis of harmonics and instantaneous values with power monitoring
• Fit and reliable: continuous monitoring of vibrations, speed of rotation and temperatures in the combination of integrated measurement technology and TwinCAT libraries for condition monitoring
• Future proof: execution of machine learning and neuronal networks in the real-time environment with the TwinCAT Inference Engine