Create ultimate guest experiences: PC-based control for the entertainment industry

The PC-based control principle

The PC-based control technology from Beckhoff has proven itself worldwide since 1980 in the widest variety of industries and applications, from machine control and the automation of wind turbines to the entertainment industry. What was regarded 40 years ago as an outsider position has developed very quickly into a standard in the automation industry. Innovative product developments that underscored Beckhoff's PC-based control philosophy followed continuously and are regarded today as milestones in automation technology, such as the modular Bus Terminal system, the high-speed fieldbus EtherCAT or the Embedded PC. The basis for the universal usability of the Beckhoff control solution is its modularity, its scalability in terms of power and its openness towards other systems and tools.

PC-based control from Beckhoff represents a modularly constructed control solution that is fully scalable in all components and maps all automation functions in software: Safety technology, measurement technology, condition monitoring and robotics are also integrated into the control platform along with sequential control, motion control and visualization. The basic principle of PC-based control is very simple: it is based on a powerful Industrial PC, a high-performance fieldbus connection with the connected peripheral devices for sensors and actuators as well as TwinCAT, the real-time capable automation software for motion control and logic. The consistent use of mainstream technologies from the world of IT and their convergence to principles of automation technology have led to a continuous increase in performance and function as well as a considerable reduction in costs. The Beckhoff control platform is supplemented by an extensive portfolio of drive components.

With PC-based control, an extensive component construction kit is available to the system integrator for the automation of the various technical systems in the entertainment industry, such as moving objects, lighting technology, AV and media technology and building automation. Worldwide references from mobile and stationary stage and show technology, from unique applications and entertainment technology prove that PC-based control technology is ideally suited to the implementation of technically sophisticated stage and media shows.

Your advantage with PC-based control:

• High performance for the high-precision control of processes and applications:
  • Industrial PCs with powerful processors of the latest generation
  • TwinCAT, the software for engineering and real-time control
  • EtherCAT, the high-speed fieldbus
• Consistency: one controller for all technical systems of an entertainment application
• Openness: simple use of third-party software (audio players, C#, C++, graphic tools, etc.)
• Use of standard components, programming standards and networks
• Modularity: enables the extension and modification of controller functions at any time
• Scalability: components in all performance categories and designs
• Extensive connectivity: from the horizontal communication of the devices with one another to the cloud connection
• High availability: due to advanced diagnostics and predictive maintenance functions
• Beckhoff is a full system supplier with a deep understanding of technology

High-speed communication with EtherCAT

EtherCAT was launched by Beckhoff in 2003 and made available as an open automation technology standard. With cycle times well below 1 ms, outstanding synchronization accuracy, flexible topology selection, extensive diagnostics and simple configuration, EtherCAT is also ideal for use in the entertainment industry. More than 6,000 companies worldwide have joined forces in the EtherCAT Technology Group (ETG), the world's largest industrial fieldbus user organization. More than twenty of the most renowned companies in the field of entertainment are also members of the ETG.

Beckhoff supplies the largest number of EtherCAT-compatible automation modules for both I/Os and drive technology. Due to worldwide support for EtherCAT, a large number of EtherCAT-compatible sensors and actuators are also available on the market, ensuring a high level of investment security. The performance of EtherCAT also supports creative people and engineers in the field of entertainment technology in the realization of unique applications. For example, a customer application such as "Kinetic Rain", which features 1,216 precisely synchronized axes, can only be realized on the basis of EtherCAT. With EtherCAT, almost any event in a show, theatre or amusement park can be synchronized, which is usually not possible with "black box" hardware in the way they are normally used. The development of the DMX terminal, which requires 512 bytes of process data, is also based on EtherCAT; as of today, this is not possible with any other fieldbus system.

The general advantages of EtherCAT are:

• high speed
• simple diagnostics
• control of up to 65,535 devices
• EtherCAT allows the transmission of up to 64 kbit per slave
• perfect synchronization

High-performance for the entertainment technology supports SMPTE-Timecode

The eXtreme Fast Control (XFC) technology enables leading-edge, high-speed automation based on an optimized control and communication architecture. It consists of a modern Industrial PC, ultra-fast I/O terminals with advanced real-time features, the EtherCAT high-speed Ethernet system and the TwinCAT automation software. With XFC it is possible to realize I/O response times < 100 µs. Due to its speed, XFC technology is used by almost all Beckhoff customers in the entertainment industry.

The development of this fast control technology was also a prerequisite for the support of the SMPTE-Timecode standard by the Beckhoff controller. The SMPTE-Timecode is a standard defined by the SMPTE (Society of Motion Picture and Television Engineers) for absolute time data that are transmitted with media metadata. The SMPTE-Timecode is mainly used to synchronize the various tracks (sound/noise, language, special effects, texts, etc.) in a media production.

EtherCAT I/O Terminals automate any functionality in the entertainment industry

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 fast EtherCAT communication system. Launched by Beckhoff as an open system, it became a global standard in automation within a few years. With around 100 signal types, an extensive EtherCAT I/O Terminal portfolio is available to users that is extremely well suited for automating every functionality in stage and show technology in terms of both its performance and variance. The Bus Terminals allow a variety of simple building bus systems to be integrated into the controller.

In contrast to the Bus Terminals, in which the fieldbus signal is converted in the Bus Coupler to the internal, fieldbus-neutral terminal bus, the EtherCAT protocol is completely preserved up to the individual terminal with EtherCAT Terminals. The EtherCAT I/Os enable DMX to be integrated into the controller. EtherCAT Terminals are used in almost every entertainment application.

Control cabinet-free automation with the MX-System

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 resulting from the modular system combines all the tasks and features of a control cabinet: power supply, fuse protection and 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 full system integration of all machine functionalities is achieved via freely selectable IPC, coupler, I/O, drive, relay, and system modules, which can be configured and combined according to the specific application.

The consistently systemic approach of comprehensively coordinated assemblies, certified to international standards, enormously reduces the effort required for planning, assembly, machine installation, and maintenance. Since considerably fewer components are required than in traditional control cabinet design to implement the same requirements, the entire MX-System is significantly more compact than previous solutions. The system footprint is reduced, and system availability and flexibility are also increased. In each life cycle phase of a control system, the MX-System offers significant advantages over the classic control cabinet.

The advantages of the MX-System for the entertainment industry at a glance:

• Savings in installation space
• Control of many axes
• EtherCAT as a fast and accurate fieldbus system
• Reusability of existing software or TwinCAT codes, since Beckhoff control technology that is already familiar is used with TwinCAT

Highly scalable, highly modular: safe automation with TwinSAFE

So that the system integrator can ensure the safety of stage equipment, Beckhoff provides TwinSAFE, a certified safety solution that is scalable in terms of both software and hardware. The I/O components are available in Bus Terminal, EtherCAT Terminal, EtherCAT plug-in module and EtherCAT Box Module form and can be used for applications up to SIL 3 according to EN 61508:2010 and Cat 4, PL e according to EN ISO 13849-1:2016-06. The possibility to transmit the safety-relevant signals over a standard bus system gives rise to substantial advantages in terms of planning, installation, operation, maintenance, diagnostics and costs. The safety application is configured or programmed in the TwinCAT software and then transferred via the fieldbus to a TwinSAFE logic component. It forms the core of the TwinSAFE system. All safety devices in the system communicate with the logic component. Through the fieldbus-neutral safety protocol (FSoE/Safety-over-EtherCAT), TwinSAFE devices can be integrated into any fieldbus system. For this purpose, they are integrated into existing networks with K-bus or EtherCAT or can be used - as an IP67 module - directly in the machine or plant. These safety I/Os form the interfaces to the safety-relevant sensors and actuators. In the field of drive technology, too, solutions without safety functionality are hardly conceivable anymore. Beckhoff therefore started integrating safety functions into its drive systems at an early stage – in both standard and compact drive technology.

Connection of motors directly in the I/O system

Beckhoff focuses on modularity and scalable power in compact drive technology: Various connections in the format of a K-bus or EtherCAT Terminal (IP20) support the connection of AC and DC motors as well as stepper and servomotors of different performance classes. The Beckhoff EtherCAT Box Modules in IP67 for stepper and DC motors are available for use without a control cabinet. The compact drive technology is used in particular in amusement parks, for example for animated figures as well as in kinetic applications; smaller auxiliary axes are used in almost all entertainment areas.

• The servo terminals from the EL72xx series for the EtherCAT I/O system integrate a complete servo drive for motors up to 200 W in the standard HD terminal housing and are ideally suited for applications with a small mounting space.
• The EtherCAT Terminals from the EL70xx series are intended for the direct connection of stepper motors in the low and medium power range. The terminal can be adapted to the motor and the application with a few parameters.
• The EL7411 BLDC motor terminal with an incremental encoder offers high control performance in a very compact design for the medium power range of BLDC motors. Due to the fast control technology and the connection of an incremental encoder, both very high-speed profiles and dynamic positioning tasks can be realized. Numerous monitoring functions provide the highest level of operational reliability. With the EL7411 EtherCAT Terminal, the control of third-party motors is also possible without any problems.

Extremely space-saving, flexibly expandable and sturdy: the new generation of ultra-compact Industrial PCs

Launched with the C6015, the series of ultra-compact Industrial PCs has positioned itself extremely successfully on the market due to its flexible application possibilities. As a sturdy control cabinet Industrial PC with an Intel^® Atom™ CPU with up to four cores and a clock speed of 1.91 GHz, the C6015 is suitable for automation, visualization and communication tasks. The small dimensions of 82 x 82 x 40 mm and the flexible mounting options make the fanless multi-core PC the ideal controller for applications with high performance requirements and minimal mounting space in almost all areas of the entertainment industry. The interfaces for transferring electrical signals, IP, image and audio signals, which are available by default, make the C6015 suitable for cost-effective control of media walls, for example.

• The C6017 multi-core computer, which measures just 82 x 82 x 66 mm, adds a variant to the family with additional optional interfaces.
• Due to its high computing power and fanless design, the C6025 is particularly suitable for demanding control applications that also take into account the aspect of green IT. The basis for this is the Intel^® Core™ i U processor, which consumes significantly less power.
• The C6030 offers advantages such as low space requirements, universal usability and flexible mounting, even for complex applications with the highest performance requirements.
• The C6032 has a further board level for modular interface and function extensions. The use of compact PCIe modules allows it to be perfectly adapted to the respective entertainment application and requirement profile.

Integration of DMX controls

DMX is the standard protocol for controlling professional stage and event equipment. Its areas of use include the dynamic illumination of showrooms and retail spaces, as well as for exclusive plays of light and color in buildings such as hotels and event centers.

In general, there are two different application scenarios:

• Controlling DMX slave devices from the Beckhoff system, for which the EL6851-0000 DMX master terminal is available. With the EL6851-0000 any DMX slave can be controlled, such as scanners, moving heads or spotlights. In addition, it can be used to drive the RDM protocol.
• Receiving signals from a third-party DMX master, for which we offer the EL6851-0010 DMX slave terminal. In this way, any DMX master (DMX console) can be integrated as an operating unit for the Beckhoff control. The control via a DMX console can also be connected with other forms of control, such as an HMI or control panels.

These two different types of application can be combined as required. Even beyond this, there are virtually no limits to the integration of further signals into the completely freely programmable Beckhoff system, and even devices that are not DMX-compatible, such as DALI lamps or bus terminals, can be addressed via the DMX console. What’s more, it is also possible to perform merge, simulation functions, and arbitrary data processing of the DMX frame.

In addition to the EL6851-0010 DMX slave terminal, we also offer the integration of light consoles via sACN, Art-Net™, PosiStageNet, and OSC.

Integration of OCA-capable audio systems into the PC controller

The AES70 standard was published by the Audio Engineering Society, which is based in New York. It defines a scalable control protocol for professional audio devices and describes monitoring and control of such devices, but not the transfer of media data. The function blocks of the TwinCAT 3 AES70 (OCA) Communication PLC library can be used to establish data exchange between a TwinCAT PLC and an (audio) device that supports the AES70 (OCA) standard. The user can query or set properties of different objects in a device (OCA device). Function blocks such as Gain, Mute and Switch are available for this purpose. They implement any OCA structure and map any OCA device. Beckhoff offers prefabricated function blocks for devices from d&b audiotechnik.

With TF8810, OCA-capable audio systems can be integrated into Beckhoff's PC-based control platform and combined with components from the wide range of Control Panels and I/Os. TF8810 includes a license for TF6310.

Powerful, reliable and flexibly extendable: the Embedded PC series for control tasks in the entertainment industry

The compact DIN-rail-mounted PCs from the CX series with directly connectable I/O level offer a space-saving industrial controller in the control cabinet. Beckhoff's extensive range of embedded controllers includes a device tailored to the budget, performance class and complexity of the control task for each application. In addition to the CPU, the individual devices from the CX series differ by the available system interfaces and power supply variants and can be plugged together and extended as a modular control system depending on the task in the entertainment sector.

The CX family includes several basic CPU modules with different processors for adaption of the performance to suit the respective control task. As a result, different applications can be implemented on the same hardware, such as a PLC and motion control system with a DVI/USB interface or a multimedia system with an audio interface.

The most powerful devices from the CX series are the CX20x2s, which are equipped with Intel^® Xeon^® processors and a separate graphic unit. They can be used to realize even sophisticated visualizations.

Maximum flexibility for proven and new operating concepts with multi-touch

The Beckhoff Panel generation with industry-standard multi-touch display offers the right solution for any application. For single-touch users, the new panel generation also offers excellent value for money and a smart alternative to other systems.

Highlights

• display sizes from 7-inch to 24-inch (16:9, 5:4, 4:3)
• landscape and portrait mode
• multi-touch (PCT): e.g., for 5-finger or 2-hand touch operation
• high touch-point density for safe operation
• high-quality aluminum housing, milled from a solid block
• metal perimeter protection for the display front
• built-in or mounting arm models
• Control Panel with CP-Link 4 or DVI/USB-Extended technology
• Panel PCs with CPUs from Intel^® Atom™ to Core™ i7
• optional electromechanical push-button extension

Continuous power measurement in entertainment technology due to integrated power measurement

Energy efficiency is also playing an increasingly important role in the entertainment industry. To save costs, peaks must be prevented, power consumption reduced and processes optimized. Complete, transparent acquisition and processing of all energy data is necessary to make the right cost-lowering decisions.

With a broad portfolio of EtherCAT Terminals for energy management, Beckhoff provides suitable technology for the ongoing monitoring of power consumption as well as for the detailed consumption analysis.

Scalable drive technology - dynamic and high-precision

In combination with the motion control solutions of the TwinCAT automation software, Beckhoff Drive Technology represents a complete drive system for positioning tasks in almost every application in the entertainment industry. The AX5000 and AX8000 servo drive series offer maximum performance and dynamics with powerful EtherCAT system communication. Both drive systems can be equipped with safety technology up to SIL 3/PLe and are suitable for the realization of stage applications with outputs of up to 120 kW. For example, the servo drives from the Beckhoff AX5000 series are used to control the movement of the spectacular stage effects in the Broadway musical "Hamilton".

The AX5000 is designed for optimum functionality and cost-effectiveness. The integrated, fast control technology supports highly dynamic positioning tasks. EtherCAT delivers high-performance system communication that enables ideal interfacing with PC-based control technology and supports coupling with other communication systems. The two-channel servo drive with variable motor output allocation optimizes both the form factor considerations and the costs per drive channel.

The AX8000 multi-axis servo system, based on EtherCAT, enables high-precision positioning and machining operations with extremely short control cycles. Its compact size reduces the space required in the control cabinet. The multi-axis servo system can be easily expanded into multi-channel drive solutions by connecting the required number of single or two-channel axis modules to the central power supply module. The AX8000 supports OCT, the One Cable Technology for power and feedback from Beckhoff, and pairs with the AM8000 (standard) and AM8500 (increased inertia) servomotors.

The synchronous servomotors from the AM8000 series are characterized by high dynamics and energy efficiency. Due to their low rotor moment of inertia and a very high overload capacity, they are suitable for the realization of highly dynamic applications. The seven flange sizes with up to four lengths cover a wide torque range from 0.2 to 129 Nm. They are equipped with One Cable Technology to reduce material and commissioning costs.

The AM8500 series expands the Beckhoff servomotor range by a complete series with increased rotor moment of inertia and covers a wide power range with four sizes, each with three lengths, with standstill torques from 1.37 to 41 Nm. Due to the high rotor inertia, the AM8500 is suitable for areas with high external inertia. It tends to oscillate less quickly and is much simpler to adjust to the application on the servo controller.

Open, PC-based control technology

TwinCAT automation software integrates real-time control with PLC, NC and CNC functions in a single package. All Beckhoff controllers are programmed using TwinCAT in accordance with the IEC 61131-3 programming standard. In addition to IEC 61131-3, TwinCAT 3 also offers C/C++, MATLAB^® and Simulink^® as programming languages.

TwinCAT 3 Highlights:

• only one software for programming and configuration
• visual Studio integration
• more freedom in the choice of programming language
• support for the object oriented extension of IEC 61131-3
• use of C/C++ as a programming language for real-time applications
• link to MATLAB^® and Simulink^®
• open interfaces for expandability and adaptation to existing tool landscape
• flexible runtime environment
• active support for multi-core and 64-bit operating systems
• migration of TwinCAT 2 projects
• automatic code generation and project creation with the TwinCAT Automation Interface

The quick way to individual user interfaces

TwinCAT HMI consistently relies on widely used IT standards such as HTML5, JavaScript and CSS. The integration of a full graphical editor with an extensive toolbox into the familiar TwinCAT engineering environment makes it possible to create extensive visualization pages for entertainment applications with little effort. Customer-specific functions that are not part of the visualization toolbox can be implemented via the above-mentioned IT standards or higher-level programming languages. The visualizations created are independent of the client's platform and responsive. The powerful basic architecture makes numerous application scenarios possible: from the local panel solution to multi-client, multi-server and multi-runtime concepts.

Beckhoff relies on IT standards:

• Visual Studio^® for engineering
• HTML5 for design
• TLS for secure communication
• Execution of the user interface on any HTML-capable browser, regardless of operating system, resolution and display

TF6310 forms the basis for supporting sACN, Art-Net, PosiStageNet, QSC and PJLink

TwinCAT TCP/IP TF6310 is used to implement and realize one or more TCP/IP servers and/or TCP/IP clients in the TwinCAT 3 PLC. Corresponding function blocks exist for the establishment/disconnection of communication as well as for the pure exchange of data (send and receive). The function blocks also support the use of multicast addresses here. Many of the communication interfaces in the entertainment industry are based on TCP/IP, which is why TF6310 is used in almost all entertainment projects with Beckhoff control technology. TF6310 is the basis for the support of sACN, Art-Net™, PosiStageNet, QSC, PJLink and more.