PC-based control becomes the standard for sheet extrusion applications
Graham Engineering, Pennsylvania, USA
It's impossible to imagine the world without plastic products and demand continues to rise. Even the ongoing discussions around resource conservation and sustainability have not initiated a U-turn – plastics processing continues to gain in importance globally. However, demands for the sustainable production of plastics and a circular economy are increasingly becoming drivers of innovative technologies and processes in the industry. The requirements for plastics machines with regard to high product quality and productivity, but at the same time with a reduction in resource consumption, are met in all applications with innovative control technology from Beckhoff: from injection molding and blow molding to extrusion and thermoforming.
Your head start in the plastics industry with Beckhoff:
- competitive advantages through innovative technology and industry-specific product developments
- end-to-end solution for all plastics applications
- competent advice thanks to in-depth industry expertise
- seamless integration of industry-typical standards according to Euromap and OPC UA
Modular software solution for the plastics industry: TwinCAT 3 Plastic Framework
With the TwinCAT 3 Plastic Framework, we offer a modular software solution for controlling plastics machinery that minimizes development work and maintains the open nature of Beckhoff architecture. The TwinCAT 3 Plastic Framework brings together our many years of expertise in plastics, seamlessly integrating important industry-specific functions into the established TwinCAT environment. As a result, plastics machinery can be programmed, visualized, and controlled on a single platform.
The TwinCAT 3 Plastic Framework offers both software packages and application solutions for PLC and HMI which act as a launchpad for developing a specific application solution. The Plastic Processing Framework (TF8540) offers comprehensive software-based temperature control, the Plastic Technology Functions (TF8560) provide motion function blocks, and the Plastic HMI Framework (TF8550) consists of elements and functions that allow a machine to be mapped out visually. All software packages are specifically developed for use on plastics machinery and can be seamlessly integrated into TwinCAT 3. The TwinCAT 3 Plastic Application project, consisting of a PLC and HMI, combines all software packages into the ideal application solution for plastics machinery. Application-specific templates already included in the HMI project, sample code in the PLC project, and the TwinCAT 3 Plastic Base Application library offer free sample integration and facilitate project planning and programming for various plastics applications.
TF8540: Plastic Processing Framework
- software temperature control supports almost any number of controlled systems
- optimal process adaptation through auto-tuning for thermally coupled heating zones
- intelligent band heater monitoring by current or power measurement with minimized number of sensors
TF8550: Plastic HMI Framework
- a wide range of user-friendly functions, controls, and icons for specific plastics processes
- cuts down on development work with pre-developed, tried-and-tested software modules
TF8560: Plastic Technology Functions
- software system structures can be adapted to machine concept
- reduction of development and commissioning times through pre-developed standard blocks
- field-proven typical motion functions for plastics machinery
- software solution independent of the selected drive concept (hydraulic/electric/hybrid)
- intelligent commissioning support for axes
- support of virtual commissioning through integrated simulations
TwinCAT 3 Plastic Application
HMI project:
- web-based user interface (HTML5) with the option of customer-specific design customization, can be extended to mobile devices
- flexible, intuitive user guidance and configuration of user-specific favorite pages
- temperature zone configuration during runtime, recipe management, user management and logging, unit switching
- wall thickness control can be adjusted via multi-touch function (WTC)
- energy measurement for process optimization
PLC project:
- suitable for hydraulic, servo-electric, and hybrid machinery
- standardized programming interface that can fit any axis technology and additional axis functionality specifically for plastics processes
- object-oriented programming architecture, can be combined with classic programming languages (e.g., FBD, LAD)
- prepared for Euromap/OPC UA integration
Our technologies for your plastics machine
The PC-based control principle
With our PC-based control technology, we offer comprehensive system solutions in various performance classes for all areas of automation in plastics machinery. The basic principle is based on a high-performance industrial PC, a high-performance fieldbus connection with the connected peripheral devices for sensors and actuators, and the TwinCAT software for engineering and real-time control. The control platform is supplemented by an extensive portfolio of drive components. TwinCAT bundles all necessary functionalities such as PLC, motion control, robotics, measurement technology, image processing, and HMI into one software package. Our control system is based on IT standards and has the necessary openness to implement intelligent production concepts according to Industry 4.0.
Due to the high performance of modern processors, which we install in all of our PC series, computationally intensive applications can be easily integrated into the control platform. Plastics machinery manufacturers benefit from the continuous increase in the performance of processors: Shorter sample times are already increasing the quality of the end product today and will be the requirement for the implementation of self-learning machines in the future. The possibility, for example, to completely simulate an injection molding machine in the virtual design process saves time during development and commissioning.
EtherCAT: global standard for plastics machinery
We launched EtherCAT technology in 2003 and made it available as an open automation technology standard. With outstanding performance, flexible topology selection, comprehensive diagnostics, and simple configuration, EtherCAT is ideally suited to use in plastics machinery. We supply the largest number of EtherCAT-compatible automation modules for both I/Os and drive technology.
EtherCAT is one of the most widely used standards in plastics technology. A large number of EtherCAT-compatible sensors and actuators are available on the market, which guarantees a high level of investment security. Easy integration of third-party drives is particularly useful for electrically driven injection molding machinery. Other fieldbus systems can also be integrated as communication layers via EtherCAT.
The speedy and highly precise eXtreme Fast Control (XFC) technology is based on EtherCAT and special, XFC-optimized I/O modules that accept signals and/or trigger actions with a high degree of precision. With I/O response times of less than 100 μs, XFC enables very fast and deterministic responses and helps to optimize processes.
TwinCAT: the integrated engineering and control platform
TwinCAT integrates all engineering and runtime processes on one central software platform. This applies to programming, configuration, real-time environment, and all runtime modules. Programming in the common IEC PLC dialects and the integration of C/C++ algorithms enables the machine builder to freely choose the most suitable programming method, depending on the programmers’ qualifications, the service strategy, and the know-how protection. With the integration of MATLAB® and Simulink®, controller concepts are developed on a model basis and thus make their contribution to virtual machine design. Through the use of Microsoft Visual Studio as a uniform programmer workbench, different versioning systems are supported and team work is simplified. With the Automation Interface, TwinCAT features open interfaces for integrating commercial IT systems into the machine program generation process in high-volume production applications.
- Extensive TwinCAT libraries for motion control save on development time thanks to tested and optimized algorithms. The TwinCAT NC PTP and TwinCAT NC I supplements are ideally suited to handling applications with Cartesian robots. With TwinCAT Kinematic Transformation, ready-to-run solutions are available for other robot kinematics, such as SCARA, delta, and articulated arm.
- Commissioning and service processes are accelerated and improved using TwinCAT Scope, a software oscilloscope fully integrated in the TwinCAT system architecture, thus contributing to the improvement of machine quality.
- The software-based TwinSAFE safety technology simplifies the wiring of sophisticated systems because variants can be mapped in software. This allows production cells to be developed and commissioned module by module, to name just one example. Documentation is also simplified and adaptations to additional customer requirements can be implemented quickly.
- The integrated, browser-based visualization solution TwinCAT HMI enables the convenient development and maintenance of visualization objects. The information is presented on the machinery and systems or in a web browser over the internet.
- TwinCAT IoT provides the prerequisite for data aggregation in the cloud or locally at the production site itself. For this purpose, TwinCAT includes standardized communication protocols for cloud applications.
- The collected data can then be analyzed specifically with the help of TwinCAT Analytics.
- The TwinCAT interfaces to machine learning algorithms allow the use of AI methods in the traditional control environment.
Our product highlights for your plastics machine
Modular software solution for the plastics industry
With the TwinCAT 3 Plastic Framework, we offer a modular software solution for the control of plastics machinery that minimizes development work and maintains the open nature of Beckhoff architecture. The TwinCAT 3 Plastic Framework brings together our many years of expertise in plastics, seamlessly integrating important industry-specific functions into the established TwinCAT Engineering environment. As a result, plastics machines can be programmed, visualized, and controlled on a standardized platform.
The TwinCAT 3 Plastic Framework contains three software libraries: TF8540 enables comprehensive software-based temperature control in plastics processing. TF8560 is a technology package that provides all the components for controlling motion functions in plastics machinery. TF8550 is an HMI package specially developed for the plastics industry that enables the visualization of typical processes with minimal engineering work and integrates seamlessly into the other technology packages. Integrated, application-specific templates and sample code for various plastics applications facilitate project planning and programming, and are made available free of charge via the TwinCAT 3 Plastic Application. Of course, existing templates can also be used and your own process expertise can be integrated.
Multi-touch panel PC for your plastics machine
The CP2219-1025-0030 multi-touch built-in Panel PC is the perfect complement to the TwinCAT 3 Plastic Framework. The 19-inch display offers you enough space to control your plastics machine. The freely configurable push button extension, the integrated control wheel, and the large number of LEDs offer a high degree of flexibility for controlling the machine. The emergency stop switch provides the necessary safety. User management can be implemented via the built-in RFID reader to make it easier to log in to the controller. To configure the device, you can choose between different Intel® processor performance classes, a main memory of up to 64 GB DDR4 RAM, and a CFast card with up to 320 GB, as well as an integrated uninterruptible power supply (UPS).
Features at a glance:
- Intel® Celeron® G4900 3.1 GHz, 2 cores (TC3:50)
- 3½-inch motherboard for Intel® Celeron®
- 4 GB DDR4 RAM, expandable to 64 GB
- 40 GB CFast card, 3D flash
- on-board dual Ethernet adapter with 2 x 100/1000 BASE-T connector
- file exchange via USB 3.0 interface
Industry 4.0 for the plastics industry
As a major supporter of the OPC UA organization, we are committed to open standards and provide corresponding interfaces in our control system as standard. Our customers therefore benefit from a particularly high level of interoperability. We are actively involved in the Euromap Companion Specifications for the plastics industry and can therefore promptly integrate new specifications into our products.
PC-based control enables IoT scenarios to be implemented easily and safely. Open interfaces, in conjunction with support for all common fieldbus systems and software protocols, enable seamless communication from the field level to the cloud. The TwinCAT IoT software library was developed for secure communication between the machine control system and cloud-based services.
The TwinCAT Analytics software library aggregates process data synchronously with the machine cycle. The stored data can be evaluated with appropriate analysis tools to derive all the necessary information about the processing operation and the machine condition in order to optimize production efficiency and energy consumption. TwinCAT Cloud Engineering also allows existing TwinCAT Engineering and Runtime products to be instantiated and used directly in the cloud.
Scalable industrial PC series
With the CX Embedded PC series, Beckhoff combines PC technology with the modular I/O level on the DIN rail in the control cabinet. By adding or eliminating modules and interfaces, only the components that the user needs for the respective application are installed. In this way, embedded PCs open up a wide range of applications – for example in the field of plastics machinery and production cells. The fine scalability in different device classes allows users to select exactly the right performance category for their applications. The devices from the lower performance class are suitable, for example, for controlling temperature control devices, for dosing applications, and for conveyor belts. Powerful control PCs in the form of the CX5100 and CX5200 are available for injection molding and blow molding machinery. The devices from the CX20x2 series are high-end controllers that allow for complex user interfaces, the integration of image processing, and the implementation of machine learning.
Even smaller than the compact design of the embedded PC devices is the series of ultra-compact industrial PCs, which is therefore suitable as an alternative, especially when it comes to minimizing installation space. While the C6015 is suitable for control tasks in the lower performance category, the C6030 meets the requirements for a standard controller. The flexible mounting options are also advantageous: while the CX can only be installed horizontally, the devices from the C60xx series can be installed in any position. Another advantage of the embedded PCs – as with Beckhoff’s entire industrial PC portfolio – is the long-term availability of spare parts, which offers the customer a high level of investment security.
EtherCAT I/O modules integrate temperature control, energy measurement, and safety technology into the control platform
In 1995, Beckhoff launched the Bus Terminal, which has since become one of the most important technology standards in automation technology. That was followed in 2003 by the development of the EtherCAT fast communication system. Launched by Beckhoff as an open system, it became a global standard in automation within a few years. An extensive EtherCAT I/O Terminal portfolio is available to users that is extremely well suited to automating every functionality in plastics machinery and their peripherals in terms of both its performance and variance.
- EL3318 for temperature measurement: The EL3318 EtherCAT Terminal is ideal for temperature measurement via thermocouples. The 8-channel input terminal with integrated cold junction compensation is very compact in its design and measures temperatures with high accuracy and high signal-to-noise ratio.
- EL3403 and EL3446 for energy measurement: The EL3403 power measurement terminal can be used to measure and optimize the energy consumption of a plastics machine. In conjunction with the TwinCAT Plastic Processing Framework, the EL3403 is used for the cost-effective condition monitoring of the band heaters through sequentially alternating testing in operation. The EL3446 is available for simple monitoring of the band heater function. In combination with the voltage measurement in just one power measurement terminal, the power consumption of individual machine components can be recorded cost-effectively by means of current measurement. The Beckhoff SCT current transformers enable assembly of the appropriate combination of sensor and power measurement terminal.
- EL3255 for position detection: The EL3255 EtherCAT Terminal allows potentiometric position detection. Due to its integrated power supply, the terminal delivers precise results (voltage values) even in environments with high interference fields. The EL3255 is particularly suitable for injection molding and blow molding machinery with hydraulic drive technology.
- IO-Link terminal: IO-Link is an inexpensive fieldbus for the reading of sensors with low real-time requirements. A preferred application, for example in extrusion, is the reading of melt pressure and melt temperature via the EL6224.
- FM33xx Thermocouple Fieldbus Modules: The fieldbus modules with EtherCAT fieldbus connection allow the safe and accurate reading of thermocouples on injection molds, for example in injection mold making. The fieldbus modules have back-voltage protection circuitry to protect against external voltages applied to the thermocouple inputs.
- TwinSAFE Terminals for integrating safety technology into the controller
Due to its scalability, our safety solution is suitable for expansive, sophisticated systems with distributed I/Os as well as for small injection molding and blow molding machinery.
Electrical servo drive technology replaces hydraulic systems
The TwinCAT technology modules for plastics machinery support hydraulic drive technology and servo-electric drives and offer a wide choice for drive technology components. The integrated, fast control technology of the AX5000 servo drive series enables fast and highly dynamic motion processes to be implemented. The flexible design with 1 and 2-channel units as well as the variable distribution of motor output allocation provide a cost-optimized solution, in particular for handling systems. The comprehensive range of servomotors is optimized for the AX5000 servo drives. One Cable Technology also reduces installation space and commissioning costs. Thanks to the integrated safety technology, the servo drives meet the stringent safety requirements for plastics machinery and simplify the configuration of production cells.
In combination with EtherCAT servo drives, PC-based control is ideal for replacing hydraulic axes with electrical drive solutions, which helps to reduce the energy consumption of machinery. When it comes to energy-efficient machinery, a distinction is made between all-electric machines, in which each axis is equipped with an electric motor and a spindle, and servo hydraulics, in which the hydraulic pump is operated with a servomotor. For both drive concepts, solutions exist that include the AX5000 and the TwinCAT technology software modules. The solutions make it possible, for example, to effectively trigger crucial tool protection procedures that quickly stop the machine movement if a plastic component is detected in the mold.
Automation for various applications in the plastics industry:
Injection molding
Open automation technology with EtherCAT: ideally suited for injection molding machines
Blow molding
Open automation technology: minimizes the energy consumption of electric blow molding machines
Extrusion
Open automation technology with fieldbus diversity: ideally suited for extrusion lines
Additive manufacturing
Open automation technology with EtherCAT: perfectly suited to the additive manufacturing of plastic parts
Handling
Open automation technology with EtherCAT: perfectly suited to the handling of plastic parts
Post-processing
PC-based control optimizes the post-processing and further processing of plastic parts