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Beckhoff Avtomatizacija d.o.o.
EtherCAT measurement terminals in vehicle development at Mercedes-Benz
GROB-Werke GmbH & Co. KG, Germany
PC-based control technology from Beckhoff is ideally suited to the complete automation of many different processes in automotive production: from press control in car body manufacturing to the production of batteries and motors for electric vehicles. Our fast and high-performance control technology ensures our customers are well-equipped to tackle the challenges of the mobility revolution.
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An average car consists of around 10,000 individual parts. This calls for extensive production processes and machinery within the automotive industry, which all require equally diverse and sophisticated control solutions. At the same time, ever shorter product life cycles demand a high degree of flexibility. This is where PC-based control from Beckhoff provides crucial benefits, as the modular control technology offers scalable options based on specific needs. By incorporating retrofits, it safeguards investments in proven systems while also facilitating the production of cutting-edge technologies through innovative solutions. The integration of all control functions into a single PC platform makes for highly precise and efficient production processes.
The core advantages of PC-based control:
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 ideally suited for use in production plants. This is why the world’s largest automotive manufacturers are already members of EtherCAT Technology Group (ETG).
Primary benefits of EtherCAT:
The TwinCAT 3 automation software integrates all engineering and runtime processes and features a consistent development environment for implementing all control tasks in the automotive industry. Programming is carried out using the most appropriate method for the application, including IEC 61131-3, high-level languages such as C/C++, MATLAB® and Simulink®. Microsoft Visual Studio is used as the standard programming workbench since it not only supports version management, but also simplifies teamwork. Ready-made software blocks facilitate engineering and shorten development and commissioning times.
TwinCAT benefits include:
Our drive solutions cover a wide range of applications, ranging from rotary and translatory servomotors to compact servo drives in terminal format and the high-performance servo drives in the AX series. With perfect scalability in terms of design and performance, they pave the way for optimized drive concepts.
The intelligent and flexible XTS and XPlanar transport systems open up completely new application scenarios. Their individually controllable movers revolutionize the rigidly timed product transport found in conventional conveyor systems. With free-floating movers that travel across arbitrarily arranged planar tiles, the XPlanar planar motor system facilitates outstanding product handling flexibility with up to six degrees of freedom. The XTS linear transport system uses the movers to transport products along an open or closed track of motor modules. What’s more, the XTS movers even become end effectors with the contactless energy and data transmission of the No Cable Technology.
XPlanar and XTS benefits:
For the first time, the MX-System enables completely control cabinet-free automation solutions in machine and system engineering. The combination of baseplate and function modules combines all the tasks and properties of a control cabinet: power supply, fuse protection and power distribution, generation and monitoring of auxiliary voltages, sequence control, control of motors and actuators, and the connection level for the field devices. Based on coordinated assemblies and certified to international standards, this approach enormously reduces the effort required for planning, assembly, machine installation, and maintenance.
Benefits of the MX-System for the automotive industry:
A panel PC combines all the benefits of a high-performance industrial PC with the touch technology of a modern control panel. In its attractive, high-quality housing, the device becomes the central operating and control element on the machine. The product range includes a wide variety of sizes and formats in built-in or portable versions. In addition to further options, such as special equipment with operating elements or visual adaptations in customer-specific corporate designs, our in-house production capabilities mean we can also accommodate entirely custom designs.
Panel PCs as the visual hallmark of a plant:
With around 1,000 I/Os for more than 100 signal types, Beckhoff’s modular automation toolkit is well equipped to cater to a whole host of requirements. An extensive range of housings, a variety of channel densities, and flexible interfaces ensure that the ideal product is available for every application scenario.
In addition to standard functions, our I/O portfolio includes products for specialist applications, such as safety technology, explosion protection, measurement technology, and the control of small drive technology motors. Communication and power measurement terminals for charging infrastructure are also available. A large number of EtherCAT-compatible sensors and actuators are available thanks to their high level of acceptance on the market. Support for common communication protocols, such as CANopen, IO-Link, PROFINET, and Modbus, offers our customers maximum freedom in terms of control design – even when it comes to retrofits or conversions of existing systems.
With Beckhoff Vision, real-time image processing can be easily integrated into both new and existing control environments, and can be optimally synchronized with all machine and plant processes. The system integration approach effectively bridges the historical division between vision and automation technology. At the same time, Beckhoff Vision components impress with their robust, attractive design, as well as high scalability and long-term availability.
Benefits of vision integration in EtherCAT:
Here is where you will find our applications and references for the automotive industry.
Here is where you will find our brochures, videos, and webinars relating to the automotive industry.
When it comes to meeting the high requirements for speed and efficiency in battery cell production, high-performance automation solutions are indispensable. Our control technology enables end-to-end automation of all processes in battery production: from electrode production to module and pack assembly. PC-based control offers advantages for all machine types, no matter whether they produce round, pouch, or prismatic battery cells.
Our highlights for battery production:
The production of electric motors requires highly precise and fast processes, particularly when it comes to manufacturing stators. This represents yet another area in which our customers can enjoy the outstanding performance of a PC-based control system: in hairpin production lines, for example, TwinCAT serves as the central platform to facilitate the control of all axes and motion sequences. What’s more, the optimal synchronization of all functions allows for maximum output generation.
Our highlights for electric motor production:
Our scalable control technology is suitable for automating all types of presses, including hydraulic deep drawing presses and servo-electric transfer presses. When it comes to highly dynamic processes in press systems, Beckhoff Industrial PCs shine with their powerful performance. The low cycle times facilitate certain process parameters that serve to increase the output speed further and further. The control itself does not become a limiting component.
Our highlights for the control of presses in body construction:
With PC-based control and EtherCAT, we offer high-performance control solutions for assembly units, handling systems, test equipment, and robot applications. All production steps, such as feeding, joining, welding, gluing, and assembly, can be implemented consistently with TwinCAT automation software. What’s more, production cells or production lines can be adapted to changing requirements with little engineering effort.
Our highlights for handling and assembly:
As a high-performance control platform for the entire production process, PC-based control ensures efficient production flows in the field of tire manufacturing. Through many years of cooperation with machine builders and end customers, we have built up extensive experience not only in the tire industry, but also in the field of control cabinet construction. What’s more, the modularity and scalability of our control components facilitate the creation of customized and economical solutions.
Our highlights for tire production:
As development times for everything from the smallest components through to large gear units become ever shorter, customer requirements for test benches to ensure product quality are on the rise. Modern test benches have to be capable of adapting to rapidly changing conditions, which is where a modular concept offers the ideal solution. With our flexible modular system, we offer the optimal foundation for test bench projects in the automotive industry.
Our test bench highlights:
