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Beckhoff Automation Ltd.
Effortless access to high-performance CNC solutions for EDM and additive manufacturing
Laser cladding with TwinCAT CNC
for standardized communication with machine tools
The evolving requirements of contemporary machine tool systems emphasize the need for flexibility, high-speed operation with flawless results, energy efficiency, and top-tier connectivity. With PC-based control, we offer a universal tool to effectively meet these diverse challenges. Our high-performance control and drive systems are ideal for all machining processes, as well as for additive processes.
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PC-based control facilitates the significant optimization of machine tools in terms of both productivity and efficiency. Our scalable and efficient portfolio of hardware and software enables customized control solutions – from simple sequence controls through to high-performance CNCs. Scalable industrial PCs form the backbone of the system, complemented by the modular and real-time-capable TwinCAT software architecture, along with EtherCAT as a powerful communication system to all control components. PC-based control provides you with a future-proof solution:
TwinCAT CNC is the automation system optimized for machine tool manufacturing. Extensive software functions tailored to suit typical requirements in machine tool construction serve to streamline your engineering processes and facilitate the implementation of innovative machine concepts. What’s more, the modular TwinCAT concept allows for a wide range of functional expansions, including HMI, robotics, measurement technology, and IoT applications. In addition to all major IEC 61131-3 programming languages, the TwinCAT real-time environment can also run C/C++, MATLAB® and Simulink® modules. Open interfaces and the use of the latest technological standards open up a wide range of options, including integration into existing visualization, control, and database systems, and even cloud communication.
TwinCAT 3 CNC – the universal software for your machine tool:
With TwinCAT 3, we provide you with a modular automation toolkit that you can expand to suit your needs. TcCOM is similar to Microsoft’s COM technology, but adapted to the real-time context. With TcCOM, customer-specific software modules can be securely and flexibly integrated into TwinCAT. TcCOM can also be used to call up a customer-specific method directly from TwinCAT CNC, such as a special axis transformation that is implemented in a module such as C++ or MATLAB® and Simulink®. The software created by the user can be protected with industrially compatible hardware dongles and licensed for the machine.
Highlights of the TwinCAT Component Object Model (TcCOM):
EtherCAT technology was launched by Beckhoff in 2003 and made available as an open automation technology standard. With outstanding performance, flexible topology selection, comprehensive diagnostics, and simple configuration, EtherCAT is also ideally suited for use in machine tools.
EtherCAT highlights for the machine tool industry:
Some applications have extreme requirements for cycle and reaction times, notably in the field of additive manufacturing. In many conventional machine tools, there is a growing demand to deliver the shortest possible cycle times. Beckhoff presented a pioneering solution for this back in 2008 in the form of XFC. With eXtreme Fast Control Technology, it is possible to achieve I/O response times of < 100 μs. This is based on an optimized control and communication architecture comprising modern industrial PCs, ultra-fast I/O terminals with enhanced real-time characteristics, the EtherCAT high-speed Ethernet system, and the TwinCAT automation software.
XFC highlights for the machine tool industry:
The MX-System opens up completely control cabinet-free automation solutions. Combining various baseplates and function modules (IPC, coupler, I/O, drive, relay, and system modules), the modular system encompasses all the functions and properties of a control cabinet: power supply, fuse protection and power 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 internationally certified components reduce the effort required for planning, assembly, machine installation, and maintenance.
Benefits of the MX-System for machine tools:
The TwinCAT 3 CNC Milling Base provides a comprehensive package of cycles for triple-axis milling and drilling machining, which simplifies programming by encapsulating the processes in parameterizable and reusable blocks. A variety of different drilling strategies are supported, ranging from simple centering and deep hole drilling through to tapping and thread milling. The production of slotted holes, grooves, pockets and tenons is also supported. Extensive parameterization options allow all cycles to be adapted to suit different technological requirements, including different machining modes (roughing or finishing) and feed directions (conventional or climb milling).
Advantages at a glance:
TwinSAFE provides a certified safety solution to meet the safety requirements of a machine tool that integrates seamlessly into the Beckhoff control system. The various I/O components are certified for applications up to SIL 3 in accordance with EN 61508:2010 and Cat 4, PL e in accordance with DIN EN ISO 13849-1:2016-06. Numerous drives with safety-related functions are also available. The safety application is configured or programmed in the TwinCAT development environment and then transferred to a TwinSAFE Logic component, which communicates with all safety devices in the system.
TwinSAFE advantages for your machine concept
In addition to our standard panels, we also manufacture customized control panels and panel PCs to suit your requirements. In accordance with the machine tool and CNC standards, customer-specific adaptations such as push button extensions and specific operating elements enable an ergonomic design that is precisely tailored to the application for optimal and intuitive machine operation. An individual housing design – from the company logo and company-specific membrane keyboard to the individual housing construction and flexible color scheme in line with your corporate design – shapes the unmistakable appearance of your brand across all machine series.
Individual panels with standardized features – your options:
The Control Panels in the CP39xx-15xx-00x0 series, featuring an angled push-button extension in a special CNC function design, are control and operating devices specifically designed for CNC applications.
AM8300 servomotors achieve an extremely high power density due to their water cooling system, allowing them to deliver up to 40 kW of rated power. The servomotors also offer maximum dynamics, as the moment of inertia remains constant but much higher currents are possible with water cooling. This also results in a threefold increase in the standstill torque. In terms of technology, the AM8300 series is based on the AM8000 series and its options. Five flange sizes, each with three lengths and standstill torques from 5.1 to 274 Nm, cover a wide range of applications. The water cooling system and high IP65 protection rating of the AM8300 make it particularly suitable for high ambient temperatures.
The advantages of water-cooled motors at a glance:
Instead of using brake choppers to convert the surplus energy from a drive system into heat, you can feed the energy back into the power supply (400 to 480 V AC) at up to 7 kW with the AX8820 universal regenerative unit. Intelligent energy management keeps the voltage in the DC intermediate circuit (up to 848 V DC) in constant balance with the power requirements of the drive axes. Up to 3 AX8820s can be operated in parallel with the AX8000 multi-axis servo system, the AX5000 digital compact servo drives, and third-party devices. No communication via EtherCAT is required for operation.
Advantages of the universal regenerative unit:
