Flexible automation solutions for warehouse and distribution logistics

An integrated control platform for all intralogistics applications

Traditional PLC controls cannot keep pace with the technological advances in intelligent systems for warehouse and distribution logistics. The trend towards modern and flexible warehouse technology, along with data rich systems for use with AI (artificial intelligence), such as machine learning for machine optimization and predictive maintenance, makes PC-based control technology essential. Our control system provides you with a future-proof solution for all warehouse and distribution logistics processes:

• integration and synchronization of all control functions on a single hardware and software platform
• outstanding performance thanks to powerful industrial PCs with multi-core processors
• integrated cloud connection
• TwinCAT/BSD, a UNIX-based operating system, can be used flexibly as an alternative to Windows
• the available hypervisor for TwinCAT/BSD enables execution of software running in various operating systems in virtual CPUs on a single hardware platform
• precise scalability in terms of cost, complexity and computing power

Fast, open, and ideally suited to intralogistics: EtherCAT

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 logistics centers.

EtherCAT highlights for warehouse and distribution logistics:

• virtually unlimited network expansion
• flexible connection of other fieldbus systems enables easy integration of existing network and fieldbus technology
• reduces cabling work with the EtherCAT P single cable solution
• maximum performance with speeds of 1 GBit/s or 10 GBit/s with EtherCAT G
• bandwidth utilization that supports large data acquisition across the network without impact on the cycle times
• no accumulated switch delays, ideal for linear applications such as conveyor or sorter controls

Integrated automation with TwinCAT

The TwinCAT 3 automation software integrates all engineering and runtime processes and features a consistent development environment for executing all control tasks in warehouse and distribution logistics. You can choose the programming method that is best suited to your application or combine languages based on application and skill-set. Microsoft Visual Studio is used as the standard programming workbench as it supports different version management systems and simplifies team-based programming. PLC languages according to the IEC61131-3 with object-oriented programming also supported.

TwinCAT highlights for intralogistics:

• open interfaces for seamless integration of all system parts as well as communication with the material flow computer and warehouse management system
• TwinCAT IoT enables cloud connection via standardized protocols such as OPC UA, MQTT, and HTTPS/REST
• TwinCAT Analytics offers tools for predictive maintenance, improved diagnostics and extensive remote maintenance options

The modular and easy-to-integrate safety solution

A requirement of many intralogistics equipment including mobile robots, storage and retrieval systems, and crane systems is that they require higher safety standards to ensure human interface and interaction around the equipment, some of which may be combined with various forms of drive technology. The integrated safety solution from Beckhoff ensures consistent safety: With TwinSAFE, we have provided a universal safety concept that integrates safety functionalities into the standard control platform – from the PLC to the drive technology via I/Os and integrated functions in the drive modules.

TwinSAFE: the integrated safety solution for logistics:

• all safety functions can be programmed and configured with TwinCAT
• wide range of TwinSAFE I/O modules with IP20 and IP67 protection rating
• flexible mixing of safe signals with standard signals in the terminal segment
• no special safety PLC required: Safety logic is distributed in I/Os and drives across the EtherCAT network
• TwinSAFE SC technology combines standard signals for safety tasks to accomplish analog safety such as safe position and safe velocity of mobile robots and AGVs

Control cabinet-free automation with the MX-System

The MX-System is the first to provide completely control cabinet-free automation solutions in machine and system engineering. The combination of baseplate and function modules in this modular system 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 with inputs and outputs, control of motors and actuators, and the connection level for the field devices. The consistently systemic approach greatly reduces the effort required for planning, machine installation, and maintenance. The system footprint is reduced, and system availability and flexibility are also increased.

The advantages of the MX-System for warehouse and distribution logistics:

• decentralization shortens cable routes, particularly in sprawling logistics centers
• exact scalability to logistics applications
• elimination of wiring errors and fast commissioning with the plug-and-play principle
• minimal downtime due to hot-swap functionality
• can be expanded flexibly with EtherCAT Box modules and integrated drive technology
• integrated diagnostics in each module for added system uptime

Improved efficiency, communication, and cabling for motor-driven roller conveyor systems

The EP7402 EtherCAT Box is an ideal controller for conveyor systems in intralogistics, distribution centers, and warehousing. The EP7402 takes over complete control of the roller motor irrespective of the manufacturer of the conveyor or the motor roller. The motor control operates sensorless and thus doesn’t require a specific halls or other sensor type for motor position. Dual power supply and EtherCAT communication are provided via single cable with a hybrid EtherCAT P connection.

Highlights of the EP7402 EtherCAT Box at a glance:

• direct connection of any roller motors or other BLDC motors
• can be used without additional protective cover thanks to the IP67 housing
• Zero Pressure Accumulation (ZPA) available
• unique protection from EMF (back-fed energy created from conveyor jams)
• separate circuit for motor rollers and for network/electronics
• almost unlimited extension of conveyor controls with no accumulated switch delays

ATRO: Automation Technology for Robotics

The ATRO system is a modular industrial robot system that can be used to assemble robot structures for different intralogistics applications on an individual and flexible basis. Standardized motor modules in various sizes, together with link modules in a variety of designs, are combined on a base module for cable and media feeds. Complete integration into the TwinCAT control platform offers access to a wide range of proven automation functions. The link with XPlanar and XTS and the precise synchronization of all components into the robotics system generate completely novel machine concepts.

The advantages of the ATRO system for logistics applications:

• faster cycle times due to exact synchronization of all components of the machine
• Modular set-up reduces maintenance and downtime.
• infinite rotation of all motor and link modules
• Network, power, and media feeds through the center to the end effector provide complete freedom of movement.

TwinCAT/BSD: Alternative operating system

An alternative operating system – TwinCAT/BSD – is available for selected Beckhoff Industrial PC platforms. TwinCAT/BSD combines the TwinCAT runtime with FreeBSD, an industrially tested and reliable open source UNIX-based operating system.

TwinCAT/BSD Hypervisor: Integrated VM environments

The TwinCAT/BSD Hypervisor enables simultaneous execution of virtual machines and TwinCAT real-time applications on a single Beckhoff Industrial PC. Optimized integration of the hypervisor into the TwinCAT/BSD operating system and coordination of software and hardware generate maximum performance from virtual machines while maintaining TwinCAT real-time properties. This makes it possible to use the strengths of different operating systems on one industrial PC and to improve the security properties of the overall system.

Rethinking product transport with XPlanar

With the intelligent XPlanar transport system, free-floating planar movers glide smoothly over freely arrangeable planar tiles along six axes, without colliding with each other. Transport, fillin, and picking processes can be designed in entirely new ways with XPlanar. Since the XPlanar tiles can be arranged to suit any system design, product streams can be freely directed. Quick setup changeovers accomplished completely in software shorten machine downtime.

Intelligent product and material transport with XPlanar:

• free positioning and flexible movement of the movers across the entire system
• application-specific arrangement of tiles in any geometry
• maximum flexibility: transport of individual goods via any route to any location
• movers available in different formats and for different loads
• synchronous and asynchronous motion of movers for easy transport of varying size and payload of goods
• zero wear since movers are floating over the system base