Products
AT2xxx, ATH2xxx | XTS motor modules
In the XTS motor modules, all active components are combined in a compact mounting space.
AT8x00, AT9xxx, ATH9xxx | XTS guide rails and movers
The guide rails and movers form the passive components of the XTS for a linear motion along a track.
XTS software
The TwinCAT 3 XTS extension enables simple configuration, simulation and operation.
XTS starter kits
The all-round package from system assembly to commissioning enables a quick and simple entry.
The linear transport system from Beckhoff
With the XTS linear transport system, Beckhoff offers a proven drive solution in which magnetically driven movers move along a travel path of fully integrated motor modules. An Industrial PC with the TwinCAT automation software enables the independent control of the movers with individual motion profiles. This results in many system-related benefits: The transport system is ready for operation immediately after assembly, as power electronics and displacement measurement are included in the XTS motor modules and the movers are completely passive. Due to different geometries of the motor modules, both an open and a closed travel path can be created and the machine footprint can be reduced by individual track layouts. The XTS not only replaces conventional conveyor belts, but also enables an innovative design of the entire machine. With the flexible motion profiles, simple to highly complex processes can be realized and the entire manufacturing process can thus be optimized.
Software functions enable flexible motion sequences
Each mover can be controlled independently of other movers and with freely movability for individual product transport on the travel path. As a property of the individual mover, the dynamics can thereby change at any time on the fly according to the respective requirement. If necessary, the movers can be synchronized to external process sequences or other movers. Group formation in motion with any number of movers as well as a moving buffer store are also possible. The individual movers are mapped as “normal” servo axes with all common motion control functions such as flying saw, electronic gearing, and cam plate. Functional enhancements in TwinCAT handle typical XTS requirements, such as automatic accumulation, centrifugal force limitation, and collision and jerk avoidance. All of these and other application-specific motion functions can easily be implemented without the complexity of the motion leading to a high complexity in the engineering.
Alternative solutions open up innovation potentials
The innovation potentials of XTS are by no means limited to highly complex motion sequences. In fact, the system offers finely scalable adaptation options with regard to the application requirements, e.g. in relation to the geometry, the number of movers, and the functional scope. This starts with simple applications, such as the purely linear motion of a mover and the extension by a second mover to create an XY motion. With the closing of the modular geometry consisting of motor modules and guide rails, an endless linear system with any installation position is ultimately created. The application possibilities can be further increased through the combination of several XTS systems, the use of comprehensive TwinCAT function blocks and the integration of robotics. If all this is consistently used together with Condition Monitoring and object-oriented controller programming, the result is a highly intelligent machine or production module in the spirit of Industrie 4.0.
The ideal solution for every application
With the AT2200 and AT2202 EcoLine motor modules, the XTS modular system makes intelligent product handling even more economically efficient. The new modules offer 95% of the technical properties of the proven motor modules with the same reliability and robustness. The 500 mm EcoLine motor modules are a cost-effective alternative for processes that do not require minimum values for accuracy or product spacing. Thanks to their full compatibility, it is also possible to combine them with the high-precision motor modules featuring a familiar design – for example, as a way of implementing transport lines alone without process stations.
The XTS EcoLine module type differs slightly with regard to the following technical properties:
- 0.70 mm absolute accuracy and 0.075 mm repeatability
- 70 mm minimum product distance
- up to 30 N nominal force initially and up to 80 N peak force per mover
The addition of No Cable Technology (NCT) to the XTS system forms the basis for another leap forward in machine flexibility. For the first time, a power supply and synchronous real-time data communication are available on the moving XTS movers, allowing the individual movers to be expanded into mobile handling and processing stations. In addition to the previous application that was purely for product transport, NCT also enables process sequences directly on the mover.
XTS with NCT enables new solutions
For the first time, NCT makes it possible to process and check the quality of products on the mover while the process is running. Sufficient power and fast communication with the TwinCAT control system enable easy connection of sensors and actuators. The data communication is real-time capable and can synchronize system-wide events with µs precision in conjunction with EtherCAT. This opens up new solution options for the user, especially when it comes to product handling, machining, and measuring in parallel with product transport – as well as adapting production machines for rapidly changing production batches.
Using the XTS modular system, the XTS system can be perfectly adapted to the machine layout and/or the conditions in the hall. Motor modules with different radii (22.5°, -22.5°, 45°, and 180°) and straight motor modules with different lengths (250 mm, 249 mm, and 233 mm) are available. The customized routes enable more efficient use of the available installation space. This aspect is particularly important when it comes to reducing the plant footprint in cases where production space is limited and increasing the modularity of the plant.
The XTS magnetic plate sets are part of the movers and generate a linear travel movement with the help of the magnetic traveling fields of the fully integrated XTS motor modules. Four performance classes are available, depending on the number of magnetic poles. These enable a minimum mover spacing of 50 mm or a maximum peak force of 210 N. With this peak force, masses of more than 10 kg per mover can be transported. A further increase in performance is possible through the mechanical coupling of several movers. In addition, the dynamics of the movers can be increased by larger forces while the mass remains constant. This leads in turn to an increase in production output.
Optimum time-to-market is becoming increasingly important due to the greater demands facing the plant development process, such as higher variant diversity and increased production output, in combination with ever shorter plant life cycles. It is essential to reduce the individual phases in the plant development process and run them in parallel.
Integrated XTS simulation functions facilitate plant design
The XTS simulation provides users with a software tool capable of achieving significant reductions during the design phase. The simulation enables the configuration of the desired routes from the XTS modular system without hardware and test setups, as well as the validation of the subsequent integration into (existing) plant concepts and verification of application sequences. During the development process, all of the parameters (such as the XTS path and number of XTS movers) can be modified and adapted to achieve the ideal solution.
Parallel software development reduces time-to-market
The complete integration into the TwinCAT automation software provides an additional benefit. Users can work in a familiar development environment, which they can also use for the subsequent implementation work. In addition, the program code developed for the simulation can also be used for the real-life hardware. This reduces costs and enables early implementation of the software without having to complete parts of the hardware. Overall, the time optimization and parallelization of the plant design phases by using the XTS simulation creates a significant competitive advantage.
The eXtended Transport System in the stainless steel XTS Hygienic version has tapped into a wide range of new applications. It offers advantages over classic transportation solutions, especially in the primary area of the food and pharmaceuticals industries, and in manufacturing or bottling liquids. With the high protection rating of IP69K and the hygienic design – with no concealed edges or undercuts – cleaning is easy even in hygienically demanding environments. The electropolished stainless steel 1.4404 AISI 316L with a roughness depth of less than 0.8 µm and the high-pressure cleaner-resistant seals made of VMQ silicone can easily withstand harsh environmental conditions.
As central components of the mechatronic system, the motor modules in the XTS Hygienic can also be quickly mounted and dismounted. Connecting the modules is particularly simple due to the lateral plug contacts for power and communication transmission. The electronic connection contacts are available in versions with or without a power supply cable. The power supply points and even the number of power supplies can be adjusted without dismounting the motor modules.
The modularity of the motor modules is completed by two system solutions for guide rails and movers. Depending on the application requirements, suitable Beckhoff stainless steel guide rails are attached directly to the motor modules with a minimum of mounting effort. This design can then be navigated using two hygienic design mover types: a stainless steel mover for particularly hygienically demanding environmental conditions, and an anodized aluminum mover that can transport larger payloads with higher dynamics than the stainless steel variant. The second system solution consists of a guide rail that is run parallel to the motor modules and a mover. A cover for the mounting surface of the rail interface for the motor modules as well as magnetic plate sets for the movers are available for this.
XTS enables a high degree of flexibility for parts transport in machines and plants through the independent control of movers with different motion profiles. Using different motor module geometries, both an open and a closed travel path can be created.
With the help of the new XTS software function Track Management, an XTS structure can be divided into individual, spatially separated track sections. These can comprise just one or any number of consecutive motor modules. The track sections in turn form building blocks from which a variety of connected travel paths can be defined. By using a suitable mechanism, such as a spindle axle or a linear motor, the track sections can be moved with the movers on it. Movers can be exchanged between different XTS systems. The motor modules and movers retain their full functionality at all times, so that even the moving track sections remain fully usable sections. Track Management is part of the TwinCAT 3 XTS Extension TF5850.
Application examples
- insertion and removal of movers without interrupting the ongoing flow of products
- software-based tool changes
- individual quality control
- integration of optional workstations
- screening out faulty products
- maintenance intervals that are separate from the production process
- manual workplaces
- product buffering through the arrangement of several XTS tracks above one another
- secondary product streams; for example, a coating process in which the workstations can be passed through several times without changing direction thanks to a closed travel path
- A freely configurable product sequence allows different products to be combined into packages, for example.
Individual support for fast project implementation
Beckhoff provides individual support services to implement projects quickly and secure a competitive edge. Local XTS product specialists support the perfect integration of the XTS into innovative plants. Their cross-industry know-how supports the integration on various levels – from conceptual development to implementation and employee training.
Extensive experience enables the perfect integration of XTS
Beckhoff's extensive experience with over a thousand different XTS applications enables the direct and simple implementation of prototypes. Beckhoff already supports its customers during the conceptual design phase with a feasibility assessment and determination of possible cycle times. Optimization approaches are developed jointly to enable users to take full advantage of the benefits of XTS technology. The user can thus concentrate on its core competencies, while at the same time gaining initial experience with XTS technology. The skills acquired in this process can also be the basis for the independent implementation of further projects.
Pre-assembled function modules as plug-and-play solutions
With a pre-assembled function module, customers receive a ready-to-operate and tested XTS system: Motor modules, guide rails and movers are available as a complete unit with a matching control cabinet. The tested overall system significantly reduces potential sources of error. Beckhoff can also assist with on-site electrical installation and the development of application software according to customer specifications. For the user, this results in an easily integrated overall solution with calculable costs.
XTS in practical applications
Tetra Pak Cap Applicator 40 Speed Hyper: The “magic machine”
Tetra Pak's beverage cartons for milk, fruit juices, and more are widely known. These efficient and robust cartons require advanced production technology. In Modena, Italy, Tetra Pak's experts have employed Beckhoff's XTS linear transport system in a new machine for cap application on cartons. The Cap Applicator 40 Speed Hyper has been so successful that Tetra Pak’s pilot customer, impressed by its reliability, performance, and flexibility, has described it as a “magic machine.”
Integration of an L-shaped XTS system for optimum use of existing production spaces
As a specialist for packaging lines, Schubert Packaging Systems relies on the XTS linear transport system for a new solution for packaging vials and ampoules. An L-shaped geometry was particularly helpful here to ensure efficient use of the available hall space. In addition, XTS simulation was used at an early stage of the project so that the key parameters could be checked and optimized.
HOF Sonderanlagenbau: XTS Hygienic for the transport of pharmaceutical products
The XTS Hygienic is the central element of a new system design for the transport of pharmaceutical products at HOF Sonderanlagenbau. The stainless steel version of the intelligent XTS transport system meets all industry standards. It is designed for use in an isolator and can be cleaned with hydrogen peroxide. In addition, XTS enables particularly gentle product transport, which has reduced glass-to-glass contact.
XTS in use for high-performance packaging systems for confectionery products
Syntegon Technology in Beringen is a leading supplier of fully automated packaging systems for confectionery manufacturers around the world. The global confectionery industry is subject to many, sometimes rapidly changing trends. For manufacturers, this means producing many, different products that need to be packed in a wide variety of packages and pack sizes. "The intelligent transport system XTS gives Syntegon the flexibility to optimally solve every task with innovative ideas. In the meantime, we have been able to install around 100 packaging systems with XTS in the market," explains Kurt Gleichauf, Head of Technology & Development at Syntegon Packaging Systems AG in Beringen.
Compact design of the XTS enables highly efficient orientator for bottle
The Spanish company Packfeeder offers a complete series for automatic, robot-based bottle unscrambling with the XTS. With these systems, the particularly compact structure of the XTS enables an inclined installation position, so that bottles can be rotated from a lying to an upright position while in motion. The bottles are clamped between two movers. The changeover to other bottle formats takes place entirely in the software.
Realignment of the production: XTS as the core element of a new solution
L’Oréal is a leading cosmetics manufacturer and has set the strategic goal of making its production operations more agile. In order to achieve this, three production lines have already been equipped with the flexible XTS transport system. The XTS is the core element of the production lines and combines the functionality of five previously separate machines. The same line can now produce lot sizes ranging from a few hundred to millions of pieces as well as seven different format types with only 40 instead of 300 transport containers.
Eliminate standstills in packaging processes with XTS Track Management
XTS makes production fault-free and completely eliminates standstills via two essential functions: firstly, all products are constantly tracked in a system with an XTS, and secondly, XTS Track Management runs through to the next stage of production without any standstills thanks to moving track sections, which are used to eject faulty parts. Track Management sections can be placed at any point in the production process, and the customer can add as many as they wish. Koch PAC’s sealing machine, as shown in this video, contains five Track Management stations.
XTS enables parallel inspection processes for maximum throughput with a minimized footprint
Gefasoft has developed an exceptionally compact installation for the optical inspection of diffusors for airbags. The individual movement of the XTS movers enables individual inspection processes to be duplicated and executed in parallel. As a result, the workstations are utilized optimally and the total number of workstations is reduced. Overall, this leads to a 40 % reduction in the required footprint.
Application reports
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24.09.2015 | Application report
Compact, fast and linear cosmetics filling line with XTS
groninger GmbH & Co. KG, GermanyFor their new cosmetics filling line Groninger utilizes an innovative machine design based on the eXtended Transport System which combines high filling speed with a compact design.
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17.04.2023 | Application report
Linear drive system increases plant efficiency
Marchesini, ItalyEtherCAT and PC-based control has long been used by the Marchesini Group, one of the world’s leading manufacturers of packaging machines and filling lines for the pharmaceutical and cosmetics industries. Nowadays, the Italian machine builder also benefits from Beckhoff’s XTS linear transport system. In a monoblock machine for filling and capping bottles containing tablets, capsules, or pills, XTS makes transport more flexible while reducing setup times and energy requirements.
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17.04.2023 | Application report
Quickly and easily from blister to carton packaging
Elos Medtech, DenmarkElos Medtech from Gørløse, Denmark builds its own machines for the production and packaging of dental components, and aims at standardizing automation throughout. An XTS-based blister packaging machine from 2018 demonstrates the advantages of the platform concept. After expanding the XTS linear transport system, Elos was able to easily add new machine modules for cartoning the blisters.
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04.04.2023 | Application report
Linear transport system eliminates slow pick-and-place process
TU Berlin, GermanyLow-cost lithium-ion battery cells (LIB) are the key to mass electromobility, although the manufacturing process has always been a cost driver – until now. Researchers at TU Berlin are using continuous Z-folding to replace the traditional pick-and-place movements that have been used so far, thus accelerating battery cell production. The XTS linear transport system from Beckhoff has played a crucial role here.
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23.05.2022 | Application report
Modular machine design and highly accurate positioning with XTS
IMS, NetherlandsIn the search for a precise transport system for fully automated electronic module assembly systems, the Dutch company IMS found a fitting solution with Beckhoff. With a repeatability of 10 μm, the linear transport system XTS meets the high requirements for product positioning. In addition, the modular range of XTS components provides the basis for easy system adaptation to changing production requirements.
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13.04.2022 | Application report
Flexible control technology with fast cycle times increases efficiency in hairpin stator production lines
GROB-Werke, GermanyGROB, the machine tool manufacturer, creates high-volume manufacturing and assembly systems to meet the important, rapidly growing requirements for electromobility. The decisive factors here are minimum cycle times and corresponding fast process sequences, as enabled by PC- and EtherCAT-based control and drive technology from Beckhoff. A sophisticated production machine for hairpins, from which the stator winding rims of electric motors are formed, illustrates the advantages of this optimally scalable automation solution. It leverages TwinCAT 3 on a C603x ultra-compact Industrial PC as the central control platform and the XTS transport system.
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14.05.2014 | Application report
XTS revolutionizes machine design in the packaging industry
Technical Development Corporation (TDC)/Gain Automation Technology B.V., NetherlandsWith ‘Doysis’, a machine for forming, filling and sealing stand-up pouches for tobacco packaging, TDC develops one of the first applications on the basis of the eXtended Transport System.
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13.04.2022 | Application report
Flexible transport system makes changeover time plunge from 1 hour to 1 minute
Eclipse Automation, CanadaHow do you design a new assembly line and go on to reduce the footprint of the concept by another quarter? And how can you later increase the productivity of this highly consolidated line even further? Canadian automation expert Eclipse found the answer in the linear XTS transport system from Beckhoff. After the second modernization, the assembly line can produce two different types of pumps on the same small footprint.
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18.11.2021 | Application report
Oval XTS line and PC-based control optimize cutting, winding and assembly of plastic hoses
TEUP, AustriaAustrian custom machine builder TEUP normally adapts its design work to specific customer requirements. The only exception to date: an extremely adaptable assembly line, which the engineers eveloped on their own initiative and which will be available in the future as an individually configurable “standard solution.” The assembly line has a modular design, uses PC-based control and is equipped with the highly flexible eXtended Transport System (XTS) from Beckhoff.
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22.03.2021 | Application report
Integrating fast and flexible digital printing in the packaging process with XTS
Graniten Group, SwedenMaximum flexibility, virtually no changeover times and reduced maintenance and space requirements – this is what the Swedish Graniten Group has achieved with a new digital pad printing machine. This is the world’s first gravure printing system of its kind to be equipped with the XTS intelligent transport system from Beckhoff as the core element. In this way it is able to meet the high requirements of the pharmaceutical industry and can, among other things, convert an uneven product feed into an even product outfeed.
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25.11.2019 | Application report
Efficient PSC production with XTS simplifies access to HIV tests
Roche, GermanyRoche has developed the Cobas Plasma Separation Card (PSC), a new technology that simplifies and improves the examination and monitoring of HIV patients, particularly in remote areas. For the first time, blood plasma samples no longer need to be cooled during transport to the laboratory. The prerequisite for this breakthrough was a flexible, compact and dynamic production technology that allows the PSC to be produced cost-effective. This was realized with the eXtended Transport System (XTS) from Beckhoff, which increases efficiency with its high flexibility.
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01.04.2017 | Application report
XTS at the core of a labeling and grouping unit in a packaging line for toothbrushes delivers quick, software-supported product changeovers
Koch Pac-Systeme, GermanyA total of 24 movers with light, 3 D-printed blister carriers travel along an 11-meter-long XTS circuit between a HSPP system, the laser labeling system, and the second HSPP for removal.
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15.09.2021 | Application report
Pizza case packer with XTS replaces three machines and conventional product transport technology
Brenton, United StatesAmid rapid change in the food and beverage industries accelerated by the COVID-19 pandemic, consumer packaged goods (CPG) manufacturers, contract packagers and their suppliers have to dramatically increase their agility to meet an exponential surge in demand. This prompted U.S. OEM Brenton to equip their side load case packer machine with the XTS. Now, the linear transport system enhances flexibility in product infeed and makes changeovers faster. In addition, the machine offers a significantly reduced footprint after the redesign.
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22.03.2021 | Application report
Intelligent transport system as cost-effective, compact and highly flexible feeder component in cookie packaging
Cavanna Packaging Group, ItalyItaly’s Cavanna Packaging Group is a leading specialist in the flow-pack segment for both food and non-food products. Starting with its cookie packaging segment, Cavanna recently made the strategic decision to equip its flow-pack machines with the intelligent XTS transport system and EtherCAT communication technology from Beckhoff.
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27.04.2018 | Application report
Assembly solution 4.0 – for more efficiency in production down to lot sizes of 1
Smart Factory, ItalyThe “Flexim Open Automation System” combines modularity, flexibility, reconfigurability and connectivity to meet the requirements of small production lots right down to individualized production. At the core of the solution is the XTS linear transport system with the PC-based automation architecture from Beckhoff.
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10.07.2019 | Application report
At the forefront of cosmetics packaging with XTS
Shiseido und Unista, FranceEnd customers in the cosmetics industry require their suppliers to provide them with packaging systems that feature maximum adaptability and flexibility. To meet the needs of cosmetics company Shiseido, equipment manufacturer Unista developed an innovative solution based on the XTS ensuring a short time to market.
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03.09.2017 | Application report
XTS boosts flexibility for a pill bottle cap assembly line
Goldfuß Engineering, GermanyGoldfuß Engineering deployed its first Beckhoff eXtended Transport System (XTS) on a special-purpose machine for medical pill packaging. XTS uses software functionality for flexible buffering to deliver a highly dynamic solution that ideally meets the line’s transport needs and helps to minimize the number of components.