Labeling and grouping unit in a packaging line for toothbrushes
Koch Pac-Systeme, Germany
The change of the requirements in the print industry towards an end-to-end digital workflow is aimed at the complete networking of all sub-processes, from the order preparation and pre-print stage to the actual printing process through to print processing and dispatch handling. On the part of the control system, this requires a high degree of communication, interface variety and the handling of large quantities of data. These requirements are optimally fulfilled by the PC- and EtherCAT-based control technology. By utilizing Beckhoff Industrial PCs with PC-based control, the PLC, motion control, safety technology, robotics, measurement technology and HMI can all run on the central TwinCAT automation platform. This ensures efficient interaction of all system components and enables maximum productivity. The open hardware and software interfaces provide high degrees of freedom in machine design and enable a large number of different peripheral devices to be integrated. Support for all common fieldbus systems and software protocols guarantees integrated communication from the field level to the cloud. Thanks to the modularity and scalability of the individual components, customized, cost-effective printing applications can be created - regardless of whether it is the end-to-end automation of a new production line or the control retrofit of an existing machine.
Enhance the unique selling points of your printing machines with PC-based control
Integrated control for the entire print process
Digital printing is a relatively new printing process but is becoming increasingly popular because of its flexibility. In contrast to conventional processes, digital non-impact printing (NIP) does not require a static printing plate and is therefore particularly suitable for cost-effective production, with plenty of room for customization of print products. The application spectrum ranges from commercial sheet-fed or web printing to label and packaging printing. A wide variety of materials and surface forms can be printed. The technical challenges facing digital printing can only be mastered with open, digitally networked control technology. Thanks to its scalability, modularity and high degree of integration, PC-based control from Beckhoff is suitable as a universal control system for the entire process chain, from digital image creation to the finished print product. By supporting standardized interfaces, such as OPC UA, the machine control can be easily integrated with any production environment, thus keeping the integration effort to a minimum.
The advantages of the Beckhoff solution at a glance:
- Maximum process efficiency: increased print speed by reducing the number of interfaces between prepress and machine control. Seamless integration into all processes is achieved via standardized communication protocols, such as OPC UA, MQTT und HTTP/REST.
- Top print quality: maximum synchronization of all processes involved in printing ensures continuous print quality at the highest level.
- Continuous availability: reliable machine diagnostics based on the latest technologies, such as predictive maintenance and machine learning, reduces downtimes.
- Unbeatable output: in combination with EtherCAT and synchronization in the nanosecond range, PC-based control with cycle times in the µs range facilitates innovative machine concepts.
Rapidly changing production cycles and small batch sizes in packaging printing made economical with PC-based control
The trend in packaging printing is towards ever-increasing quality while taking sustainability and costs into account. The finer details of the requirements for packaging printing differ depending on the industry or end product such as consumer goods, food or pharmaceuticals, for example. While continuous traceability plays a key role for pharmaceutical products, other applications are more focused on cost-effective production of rapidly changing production cycles and small batch sizes. Since the external appearance of goods has a major influence on the purchasing behavior of consumers, manufacturers try to reach their customers by individualizing product series or personalizing individual products through appropriate packaging printing. In addition, there is the rapid development of new products and formats that require faster and more efficient production while maintaining the highest quality. In order to be able to produce small quantities – down to lot size of one – economically, the printing machine must be very flexible.
The advantages of the Beckhoff solution at a glance:
- Full integration: the PC- and EtherCAT-based control platform enables direct integration of vision and measurement technology systems. Eliminating the need for separate systems improves synchronization, thereby increasing the efficiency and quality of the printing process.
- Lot size of one thanks to software-based format change: with PC-based control technology, fast format changes – a requirement for realizing small order volumes – can essentially be implemented based on software. Changeover times on the machine are thus reduced to a minimum.
- Perfect synchronicity ensures high speed and precision: EtherCAT, the fast communication system, is the basis of the eXtreme Fast Control Technology (XFC) developed by Beckhoff, which synchronizes all processes in the µs range. Fast and precise recognition of the print area guarantees high-quality printing.
- Openness and transparency: open hardware and software interfaces and support of defined industry standards such as PackML allow continuous communication from the sensor to the cloud, to ERP systems or other IT structures, thus forming the basis for transparent data tracking.
The all-in-one CNC solution from Beckhoff optimizes 3D printing
Additive manufacturing processes are suitable in particular for flexible production processes with small numbers of items. With an extensive portfolio of software and hardware components, Beckhoff supports machine manufacturers in the implementation of innovative machine concepts that optimally meet the high market requirements in terms of product quality, speed and flexibility. The basis for the realization of high-precision and efficient 3D printing applications is Beckhoff's many years of experience in the CNC sector, which has been incorporated into the development of a complete CNC solution. It offers users an automation toolkit consisting of scalable and modular components. The all-in-one TwinCAT CNC maps all CNC functions on a software platform. TwinCAT CNC and NC I cover the complete range of conventional CNC path control, including high-end systems for complex motion and kinematics requirements. A maximum of 128 interpolating axes can be controlled with up to 20 channels with extensive coordinate and kinematic transformations. State-of-the-art control algorithms enable precise and highly synchronous processing. TwinCAT TcCOM provides an open interface through which customers can safely integrate their own process knowledge in the form of special, customized functionalities into the standard controller.
In combination with the motion control solutions of the TwinCAT automation software, Beckhoff Drive Technology offers a high-performance solution for all areas of application, including ultra-compact servo terminals and motors with integrated servo drive from the Beckhoff AMP8000 series to the AX5000 and AX8000 EtherCAT servo drives for the medium and upper performance class, with corresponding servomotors.
Thanks to high-performance EtherCAT I/O terminals, users have access to more than 100 signal types in variable channel density, from high-precision measurement technology to safety technology and compact drive technology. In addition, all common fieldbus systems are supported, so that users benefit from optimum flexibility and openness with regard to I/O structures. The integration of local or cloud-based applications for data analysis and automatic generation of dashboards via the TwinCAT Analytics software tool enables monitoring of machine states. For example, the print head can be monitored at any time and from any location, reducing machine downtime and enabling predictive maintenance.
The advantages of the Beckhoff solution at a glance:
- All-in-one software solution: TwinCAT CNC is integrated seamlessly into the rest of the Beckhoff software world and enables highly synchronous and precise processing through fast control algorithms.
- Open and modular I/O system: the fieldbus-neutral Bus Terminals and the EtherCAT Terminals support all common fieldbus systems and facilitate a virtually unlimited choice of I/O structures thanks to variable channel density.
- Highly scalable drive technology: Beckhoff covers the drive technology required for precise movement with a wide range of scalable high-performance gear units, motors and servo drives with EtherCAT connection.
Beckhoff technology highlights for the print industry
Open, flexible, scalable: PC-based control increases the productivity and flexibility of your printing machine
PC-based control is the universal control solution for all applications in the print industry, from digital printing to 3D printing. The flexibility and scalability as well as the high integration capability of the PC- and EtherCAT-based automation platform from Beckhoff form the basis for the universal control of the entire process chain: from creating digital images to inspecting the final print product. By supporting standardized interfaces, such as OPC UA, the machine control easily integrates with any production environment, thus keeping the integration effort to a minimum. Particularly with regard to short processing times and small circulations, through to personalized print products down to lot size of one, PC-based control provides the optimal solution. Since all control functions are mapped in software, production changes do not require the machine to be painstakingly converted. The basis for PC-based control are the Beckhoff Industrial and Embedded PCs, which offer an optimal price-to-performance ratio due to their scalability. The extensive product range of Industrial PCs covers the whole range of services: from controlling the smallest 3D printers, to wrapping and unwrapping stations and the complete printing machine.
The advantages of PC-based control are obvious:
- integration of the machines in the complete printing process by means of standardized interfaces
- utilization of tried and tested operating systems
- All system data from the printing process is freely available.
- not an island solution – instead easy integration of the control system in the IT landscapes
EtherCAT as communication standard in the print industry
As a globally recognized, established and, most importantly, extremely powerful system bus, EtherCAT impresses with many benefits for the print industry. Launched by Beckhoff in 2003 and made available as an open automation technology standard, so far more than 6,000 members have joined together in the EtherCAT Technology Group (ETG) user organization.
They all rely on the EtherCAT communication standard whether as device manufacturers, which install EtherCAT in their products, e.g., drive amplifiers, or as users, who prescribe EtherCAT as the standard in their printing machine and request it from their machine suppliers. Printing machine manufacturers as well as end customers benefit from an incredibly high product variety of EtherCAT-based devices on the market: being bound to a specific drive manufacturer or to a proprietary protocol is therefore a thing of the past. Instead, there is complete freedom and control over the components used and hence the highest level of investment security.
EtherCAT combines the fieldbus communication for I/Os, the secure communication for TwinSAFE and of course the drive communication in one system. Due to the highest synchronization accuracy, combined with cycle times of less than 1 ms, EtherCAT ensures maximum machine performance and ultimate efficiency. The printing precision achieved in combination with the Beckhoff XFC technology ensures an exact print image even in high-performance applications.
EtherCAT optimizes the control architecture in the print industry:
- worldwide established high-speed fieldbus
- just one communication technology for the entire printing machine
- flexible topologies
- seamless diagnostics
- high-precision synchronization of all processes thanks to eXtreme Fast Control (XFC)
- Proven version stability provides the best possible investment protection.
Manage multiple axes with ease and accommodate them in a space-saving manner
Hardly any machine has so many different axes as a printing machine – regardless of whether classic offset printing or applications in digital printing are involved. It is not rare to require 100 rotating, setting or even lifting axes. It is therefore no wonder that distributed drive concepts without a control cabinet, like the ones realized by Beckhoff, are celebrating a triumph in the print industry. They open up huge advantages in terms of saving space and reducing costs – and do so both at the initial installation stage as well as when it comes to maintenance and repairs. The distributed servo drives launched on the market by Beckhoff combine motor and drive amplifier in a compact design in one housing. With the help of the EtherCAT P standard, the distributed servo drive system is supplied with power and communication via one cable, thus saving on installation space in the control cabinet; when a power supply module is used, the whole system can be moved directly to the machine. Highly dynamic paper web controls can thus be implemented just as well as setting, fast clocking processes on print heads or also complex wrapping applications. Of course, the distributed drives also demonstrate their strengths in all 3D printing applications, e.g., in combination with the TwinCAT CNC.
The benefits are clear:
- reduction of the space required in the control cabinet
- reduction of the costs for control cabinets
- no additional safety components required due to integrated TwinSAFE functionality
- fast and efficient installation using standardized cables and plug types
- flexible topology
- very compact, space-saving design
Optimal M2M communication: TwinCAT Connectivity
The guiding principle of the PC-based control philosophy is its openness. With a host of software functions, TwinCAT Connectivity supports nearly all common fieldbus systems, such as PROFINET, TCP/IP and EtherNet/IP, so that the various machine modules in a printing application can communicate ideally with each other. In this way, all process stages within the production, from image generation and the printing process through to quality control, can be integrated.
At the same time, TwinCAT Connectivity enables integrated communication from the sensor to the cloud, in ERP systems or other IT structures based on standardized IoT protocols and OPC UA. TwinCAT thus forms the basis for a transparent data tracking system, integrated into any network structures.
In this respect, it is just as easy to prepare databases as it is to connect your 3D printer to any number of cloud systems by means of MQTT or also to use HTTP/HTTPS communication. The various software functions of the TwinCAT Connectivity library provide an incredible degree of freedom here. This enables seamless data communication inside the machine and communication from the sensor to the cloud via standardized protocols.
The benefits of TwinCAT Connectivity:
- seamless M2M communication based on standardized protocols such as OPC UA, EtherCAT, Modbus, TCP/IP, PROFINET and many more
- enables integrated communication from the sensor to the cloud based on MQTT, AMQP, HTTP/REST and also OPC UA
- simple integration of database systems such as XML, NoSQL and SQL
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 printing industry at a glance:
- modular: from primer to finishing process
- exact scalability: from 3D printing to large format
- IP67 protection rating for use in demanding environmental conditions
- compact design
- high signal diversity: from simple I/O sensor to GigE camera
TwinCAT Vision integrates image processing seamlessly in the automation platform
Integrating image processing into the Beckhoff automation software brings together essential functions. The classic division between image processing experts and PLC programmers is removed, and the expertise for image processing thus remains with the machine manufacturer. Furthermore, PLC and image processing can be conveniently configured and programmed in one tool.
With TwinCAT Vision the image processing algorithms are worked through and fully synchronized in real-time; communication delays are therefore compensated or eliminated, which leads to a considerable process optimization. The tremendous quality advantage of system-integrated image processing over conventional vision solutions is demonstrated here: whether it is a matter of web edge control or print control, all functions are integrated in one system.
Until now it has barely been possible to synchronize the image information from a camera integrated in the printing machine or the use of elaborate, additional hardware with the drive and position information. With a system-integrated image processing solution, this is a thing of the past. If you consider the camera to be another sensor in the system, then EtherCAT can be used to synchronize both the trigger and image capture time with the position information of a medium being printed. Hence the speeds or any slippages can be quickly and conveniently monitored using corresponding marks on the printing web.
Benefits of the seamless integration of real-time image processing:
- New machine concepts: the seamless integration of TwinCAT Vision in the classic control environment reduces interfaces used until now and enables an overall control system to be implemented, through which completely new machine concepts with increased performance are possible.
- Increased production efficiency: high-precision real-time measurement as well as optical inspection ensure the quality of the printing process.
- Know-how protection through fusion of functions: the classic division between image processing experts and PLC programmers is removed, which allows the expertise for image processing to remain with the machine manufacturer.
Beckhoff product highlights for the print industry
The C60xx excels due to scalable performance and ultra-compact design
The ultra-compact Industrial PCs in the C60xx series can be universally used in any printing application for automation, visualization and communication tasks. The product family consists of five devices with scalable processing power from single-core Intel® Atom™ CPUs to Intel® Core i7 processors with eight cores. The control platform can thus be scaled for the relevant application requirements.
- The C6015 and the C6017 are equipped with an Intel® Atom™ CPU with up to four cores and a clock speed of 1.91 GHz. The compact dimensions of 82 x 82 x 40 mm or 82 x 82 x 66 mm and the flexible installation options make the fanless multi-core IPCs the ideal controllers for compact printing applications in situations where installation space is tight, for example in 3D printing. Both PCs continue to be ideally suitable for use as edge devices for implementing Industrie 4.0 concepts. The tasks of data collection, initial data processing and forwarding of data to higher-level IT structures can be assumed by the extremely space-saving PCs. This allows new digital processes to be designed and makes designing new data-driven services easier. The C6017 extends the functional scope of the C6015 by means of additional interfaces (up to 2 x RJ45, 2 x USB 2.0) and an optional 1-second UPS.
- The C6025 is suitable as a control platform for demanding applications. This is based on the powerful processors of the Intel® Core i-U series; due to their low energy consumption, a fanless design is possible while delivering high computing power. The C6025 thus supports the green IT aspect within the machine pool despite the high computing load.
- 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 printing application.
The advantages of the C60xx series at a glance:
- universal control for every application: from edge device to classic machine control system
- ultra-compact and scalable control systems: from the Intel® Atom CPU through to Core i-U many-core performance
- optional extension of interfaces and USP functionalities
TwinCAT, the universal software platform for engineering, runtime and modelling
With the modular and scalable TwinCAT automation software, Beckhoff integrates all engineering and runtime processes on a central software platform. The TwinCAT integration in Microsoft Visual Studio offers developers the optimum infrastructure to link TwinCAT with the existing programming tools and to thereby optimally and efficiently support the engineering process, for example with automatic code generation. Open interfaces support integration into existing visualization, control and database systems, thus also enabling existing machines to be gradually converted. IEC 61131-3, including object-oriented extensions, C/C++, MATLAB® and Simulink® makes the main programming languages available for real-time applications. An extensive library of function blocks and tools facilitates the creation of even complex applications. From the simulation and commissioning of the machine through to the classic PLC, motion and safety applications, TwinCAT also offers support when it comes to data analysis, data communication and visualization.
In addition, TwinCAT combines real-time image processing with classic machine automation, thereby optimizing printing processes, whether it is a matter of web edge control or print control. By means of the EtherCAT fieldbus and the TwinCAT automation suite, the image information from the camera systems can synchronize precisely with the position information from the drive systems, thereby creating precise print images more easily and conveniently.
The benefits of TwinCAT at a glance:
- only one software for the entire programming and configuration: from classic PLC or safety applications, image processing through to data communication to the cloud or the creation of the HMIs
- TwinCAT is integrated in the Visual Studio system landscape and thus offers the necessary openness for integration in all tool landscapes.
- high degree of freedom in the choice of programming language: from IEC 61131-3 to C/C++ through to MATLAB® and Simulink®, everything is processed in real-time
- Active support of multi-core and 64-bit systems for complex machines
AX8000 brings any multi-axis configuration required compactly into any control cabinet
Optimum single- and multi-channel drive solutions can be constructed with the modular multi-axis servo system. The axis modules are arranged on the central power supply module, depending on the requirement profile. Wrapping applications can be implemented, as can continuous, rotating movements of installed printing cylinders. Rapid installation and minimum installation costs are optimally supported by the One Cable Technology (OCT) from Beckhoff with the AX8000.
Due to support for the oversampling technology, the process data can even be sampled several times within a communication cycle if required and transmitted to the controller via EtherCAT, so that even high-precision motion applications do not pose a challenge. Of course, the AX8000 system can be seamlessly integrated in TwinCAT and TwinCAT CNC, thus enabling even the most complex axis combination to be controlled.
The advantages at a glance:
- compact and modular multi-axis system individually adaptable to the relevant printing application
- supports all infrastructure components: capacitor module and energy recovery
- simple cabling thanks to OCT
- supports high-resolution process data thanks to oversampling technology
Many-core control: server-class processing power with Intel® Xeon® D processors
With the Embedded PCs of the CX20x2 series, Beckhoff offers scalable many-core computing power for installation on the DIN rail. The performance class uses Intel® Xeon®-D processors with four, eight and 12 CPU cores and enables extremely powerful controllers in a compact design. Equipped with up to 32 GB RAM, a dedicated graphics card with a separate 2 GB RAM also ensures a further increase in performance in case of highly complex printing applications.
The CX20x2 Embedded Controllers are build on the modular concept of the CX2000 series and feature a large number of interfaces: a multi-option interface assignable at the factory for different fieldbus systems as well as an extension bus based on PCI Express (PCIe) enable additional printing peripherals to be integrated, such as scanner and camera systems.
The many-core Embedded PCs are thus suitable above all for complex printing machines with many machine modules and computationally intensive process steps. The distribution of the control processes to the respective CPU cores is optimally supported by the TwinCAT 3 automation software and allows a computing load planned with fine granularity. In this way, for example, the complex motion applications of the wrapping processes or the print head movements can be separated from the computationally intensive image processing applications of a possible quality control system to enable the machine’s performance to be increased.
Many-core performance on the DIN rail – your benefits:
- scalable performance: from 4 cores at 1.3 GHz up to 12 cores at 1.5 GHz
- multi-core support to increase the performance of your printing processes
- Dedicated graphics cards: the separation of CPU RAM and GPU RAM prevents inhibitory influences.
- extension of different PCIe interfaces, such as USB, Gbit Ethernet, RS232 for the integration of peripherals, such as cameras, laser scanners, etc.
- ex-works integration of slave and master fieldbus interfaces, for example for PROFINET or EtherNetIP, to integrate third party systems
Integration of precise data logging into the control system
Fast and safe logging of the web tension? Continuous and high-precision regulation? Damp and dusty environment? For the EP3356-0022 EtherCAT Box with analysis option for force measurement rollers and standard strain gauge load cells, none of this is a problem. Designed in protection rating IP67, the EP3356, combined with appropriate sensors, can be used in a roller to log and subsequently regulate the web tension in a printing machine. High-precision signal analysis and a supported sampling rate of up to 100 µs, combined with a sturdy design for installation directly on the machine, allow fast and durable measurement with no great effort. Maintaining the web tension is just as important in digital printing as it is in offset printing, as the slightest deviations lead to print errors and influence the print result over the long term.
With EtherCAT down to the terminal or box, the EP3356 – just like any other Beckhoff EP module – is simply integrated in the I/O system, meaning that all measurements and diagnostic values are 100 % available. The simple installation, fast commissioning, reliable technology and precise data logging are clear factors for your success.
- compact and robust data logging for the web tension
- 24-bit resolution
- 2 measuring channels in a box
- alternatively also available as EL3356 for the control cabinet