Industrie 4.0-compliant truck and bus tire plant
Continental Reifen Deutschland GmbH, Germany
Beckhoff provides machine builders and end customers in the tire and rubber industry with a high-performance and maximally scalable system solution that can be used throughout the entire production process: from material preparation and tire construction, through curing, conveyor technology, and material handling, right up to final inspection. TwinCAT automation software and powerful industrial PCs, together with high-performance motion control and EtherCAT-based I/Os, form the basis for the precise synchronization of all processes – including system-integrated test bench automation, vertical integration and MES integration via Industry 4.0 standards such as OPC UA.
Your head start in the tire and rubber industry with Beckhoff:
- clear competitive advantages through innovative technologies
- end-to-end solution for quick and precise applications
- customized solutions thanks to a modular and scalable portfolio
- competent advice thanks to in-depth industry expertise
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Our technologies for the tire and rubber industry
PC-based control: All control functions on a single platform
With PC-based control, Beckhoff offers an open system solution that covers all areas of the tire and rubber industry: modular in structure and scalable in terms of performance, design, and price, variable hardware is available for all machine functions – from process control, HMI, motion control, robotics, safety, and measurement technology through to system-integrated vision and IoT integration. Scalable industrial PCs form the backbone of the system, combined with the modular and real-time-capable TwinCAT software platform, along with EtherCAT as a powerful real-time Ethernet communication system. In PC-based control, Beckhoff provides you with a high-performance and future-proof solution.
The advantages of PC-based control at a glance:
- open in terms of software and hardware – from the secure integration of your own expertise through to cloud connectivity
- flexible automation and precise synchronization for even the most challenging processes and movement sequences
- bespoke solutions in terms of performance, design, and price to suit your requirements
TwinCAT 3: Flexibility, modularity, and outstanding performance at its core
The TwinCAT 3 automation software integrates all engineering and runtime processes for implementing all control tasks. TwinCAT allows you to take your sophisticated processes, including test bench automation, to the next level, offering flexibility in accordance with the standards of IEC 61131-3 and programmability in C++ or MATLAB® and Simulink®. Extensive software blocks cover all the requirements of the tire and rubber industry, including hydraulic applications. TwinCAT MC3, for example, extends the motion control functions with features such as multi-core and multi-tasking capability.
The advantages of TwinCAT at a glance:
- integration of all functions – from HMI, motion control, robotics, safety, and measurement technology through to vision, cloud integration, and machine learning
- extensive libraries for motion control as well as robot kinematics
- scalable motion control platform without fixed limits on the number of axes
- ability to synchronize movement for multiple axes and axis groups across all CPU cores (multi-core) with high precision
EtherCAT: Uncompromisingly fast, flexible, and open
EtherCAT technology was launched by Beckhoff in 2003 and made available as an open automation technology standard. Thanks to its high-speed communication, highly accurate synchronization using distributed clocks, and high usable data rate, it can deal with the whole process communication and acts as I/O, safety, and drive bus system all in one. With outstanding performance, flexible topology selection, comprehensive diagnostics, and simple configuration, EtherCAT is also ideally suited for use in the tire and rubber industry.
The advantages of EtherCAT at a glance:
- extremely fast cycle times for precise and efficient processes
- wide selection of EtherCAT-compatible sensors and actuators on the market
- flexible integration of other fieldbus systems, such as PROFINET and Ethernet/IP
- reduced cabling effort thanks to the EtherCAT P one cable solution
- maximum performance with speeds of 1 Gbit/s with EtherCAT G or 10 Gbit/s with EtherCAT G or EtherCAT 10G
Control and regulation in the sub-100 µs range
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 less than 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.
The advantages of XFC technology at a glance:
extremely short control loops with 100 µs cycle times
- fast I/O response times from 85 µs
- hard synchronization of CPU, I/O, and drives through distributed clocks with 64-bit resolution
- supported by many digital and analog input and output modules
Our product highlights for the tire and rubber industry
Eliminate the control cabinet with the MX-System
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 labor required for planning, assembly, machine installation, and maintenance.
The advantages of the MX-System at a glance:
- reduced system footprint due to the elimination of control cabinets creates more floor space in production
- robust IP67 housing facilitates use in all areas of the tire and rubber industry
- increased efficiency in machine manufacturing due to reduced engineering, assembly, and testing work
- can be flexibly combined with EtherCAT Box modules and distributed servo drive system
- integrated safety functionalities for drives and I/Os via FSoE
The complete range in one system: Standard I/Os, precise measurement terminals, and compact drive technology
The extensive Beckhoff I/O portfolio covers all application areas and environmental conditions and offers a wide variety of fieldbus protocols and signal types – including compact drive technology (up to 48 V DC), power measurement, and highly precise system-integrated measurement technology with a resolution of 24 bits, up to 50 ksps per channel, and a measurement accuracy of 100 ppm, optionally also with calibration certificate. Robust IP67-protected EtherCAT Box modules from the EP/EPP series enable signal acquisition directly at the machine. This is advantageous for a retrofit in a curing application, for example, where there are often increased temperature requirements and limited space.
The advantages of Beckhoff I/Os at a glance:
- versatile: standard I/Os, measurement technology and compact drive technology in one system
- modular: a wide variety of signal configurations can be individually configured
- robust: IP67-protected EtherCAT Box modules for extended environmental and temperature ranges
- flexible: centralized and decentralized installations can be combined as required via EtherCAT and EtherCAT P
Drive systems for dynamic and precise positioning tasks
With our unparalleled range of electric drive technology, we offer you a clear technological edge over the competition: whether it’s powerful multi-axis servo systems with synchronous servomotors, highly dynamic linear servomotors, compact electric cylinders, compact drives for the low-voltage range, or drive solutions for control cabinet-free machine concepts, all components are integrated into the system and can be combined to create high-performance assembly processes. The extensive range of linear and rotary servomotors is optimally tailored to the servo drives and is suitable for multi-axis positioning tasks with high dynamics and accuracy.
The advantages of scalable drive technology at a glance:
- many technologies, one system: combine and precisely synchronize a wide variety of drive and handling technologies to suit your needs
- revolutionized assembly processes: intelligent transport systems pave the way for superior machine concepts
- One Cable Technology: saves installation space and time
- safety included: TwinSAFE is available for all Beckhoff drive solutions
- compact drive technology: motion control for the low-voltage range
Highly scalable industrial PCs cover exactly the defined performance requirements
With a broad portfolio of scalable industrial PCs, Beckhoff covers the complete range of requirements in the tire and rubber industry. The range extends from ultra-compact industrial PCs with multi-core performance and optional graphics processors to embedded PCs with connectable I/O levels and control cabinet industrial PCs. The performance of each CPU core can also be individually adapted via TwinCAT Core Boost. There are also control panels and panel PCs that can be customized in terms of their design and with individual push-button extensions. From compact to sophisticated: in terms of space requirements, performance, and price, you can adapt our industrial PCs optimally to your requirements.
The advantages of highly scalable industrial PCs at a glance:
- variable: the right industrial PC in terms of design and performance
- long-term availability: a fine balance between the latest PC technologies and the long-term availability of components
- powerful: various processor architectures cover all performance classes
- additional performance optimization: individually adapt the performance of individual CPU cores with TwinCAT Core Boost
A safe and secure route to any cloud
Modern system concepts aligned with Industry 4.0 offer numerous advantages in terms of process efficiency and quality. Our automation platform has integrated as standard suitable interfaces for standardized communication between machinery and master computers or to cloud systems. Using the ultra-compact C60xx Industrial PCs as compact and powerful IoT edge devices, machines with older third-party controllers can also be made fit for the digital factory and their data can also be collected and aggregated. TwinCAT Analytics is available for data analysis in the cloud, with Windows, TwinCAT/BSD, and Linux® as the operating systems.
Are you looking for solutions for special applications?
Example control architecture for material preparation and tire construction
Together with the TwinCAT NC PTP software, powerful industrial PCs and control panels form the control platform for the motion control system. Standard functions such as cam plates and the flying saw are available in TwinCAT especially for use in the preparation and assembly sector. Integrating condition monitoring and vision in TwinCAT means that external solutions for monitoring and image processing are no longer required.
Servo drive technology not only supports electronic motor rating plates for plug-and-play, but also safety technology. Drive parameterization and parameter storage are completely integrated in TwinCAT. The servomotors are connected cost-effectively via One Cable Technology, which combines power and feedback signals in a single standard motor cable. For adjustable axes with absolute encoders, the servomotor terminals offer a compact solution for the I/O system.
Example control architecture for curing
Robust control panels and compact embedded PCs form the basis of the PC-based control system for curing. The fast EtherCAT fieldbus and the EtherCAT Box modules with an IP67 protection rating for standard and safety signals, the EtherCAT Terminals for an extended temperature range, and high-precision, calibrated temperature detection terminals constitute the ideal fieldbus platform for heating press control.
The basic software for hydraulic and mechanical curing presses and the TwinCAT Controller Toolbox help manufacturers bring products onto the market fast. The production data can be archived using built-in mass storage, standardized cloud protocols, and direct database connection from the PLC.
Example control architecture for conveyor technology and material handling
PC-based control with distributed EtherCAT I/O Terminals and EtherCAT Box modules from the EP/EPP series is ideally suited for use in conveyor systems for transporting tires from the machine to other processing stations. The EP7402 EtherCAT Box can be used to control roller conveyor systems. EtherCAT enables large systems with distances of up to 100 m between the individual I/O islands to be put into operation. The cable redundancy offered by EtherCAT ensures high system availability.
Distributed drive concepts, such as those commonly found in conveyer systems, can easily be integrated into the central control system, thanks to the multi-fieldbus capability of the Beckhoff automation platform. Different hardware components such as scanners, RFID units, camera systems for product tracking, or even robotic systems are controlled via gateways and interfaces. The distributed TwinSAFE safety system replaces the wire-based safety chain. The TwinSafe components read the safe signals from the system. The data transfer to the PC is performed via the Safety over EtherCAT protocol.
Example control architecture for final inspection and testing technology
PC-based control with integrated measurement technology is the optimal base for test and inspection machines in tire production. High-performance industrial PCs, control panels with touch screen and mechanical push-button fields, EtherCAT I/Os with gateways to subordinate fieldbus systems, along with TwinCAT for controlling machine processes and motion control constitute the components of a lean, highly integrated control architecture.
Sequence control and measurement tasks are carried out with PC-based control on an integrated platform. The fast and highly accurate ELM series measurement modules are used for demanding measurement tasks. The integration of the measurement technology into the control system offers the advantage of synchronous signal acquisition and full data access, which means that the whole range of process data and measurement signals are available to the control system at any time. In addition, a vision portfolio containing hardware and software is available for optical inspection. The integration of C/C++ and MATLAB® and Simulink® into the TwinCAT automation software opens up a wide range of applications in test and inspection machines for final inspection.