Control, operation and monitoring on one multitasking platform

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 the machine controller and the automation of wind turbines to building automation and AV and media technology. What was regarded 40 years ago as an outsider position developed very quickly into a standard in the automation industry. Innovative product developments that underlined 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 EtherCAT fieldbus 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 field of AV and media technology, such as audio and video control, building automation, digital signage control as well as operation and monitoring. Worldwide references from the areas of meeting and conference, control centers, building automation and entertainment technology prove that PC-based control technology is ideally suited for the implementation of technically demanding media productions.

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 a media 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 AV and media technology. More than 6,000 companies worldwide have joined forces in the EtherCAT Technology Group (ETG), the world's largest industrial fieldbus user organization.

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 creatives and engineers in the field of AV and media technology in the realization of unique applications. For example, a customer application such as "Kinetic Rain", a dynamic art installation in which 1,216 axes are synchronized, can only be realized on the basis of EtherCAT. With EtherCAT, almost any event in a show, museum, theater or amusement park can be synchronized, which is usually not possible with dedicated "black box" hardware, as it is normally used. The development of the DMX terminal, which requires 512 bytes of process data, is also based on EtherCAT; because as of today this is not possible with any other fieldbus system.

The general advantages of EtherCAT are:

• high speed
• simple diagnostics
• control of more than 65,000 devices
• EtherCAT allows the transmission of up to 64 kbit per slave
• perfect synchronization

High-performance for AV and media technology supports SMPTE-Timecode

The XFC (eXtreme Fast Control) technology is an extremely fast control solution 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 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 Society of Motion Picture and Television Engineers (SMPTE) 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 AV and media technology

In 1995, Beckhoff launched the Bus Terminal, which has since become one of the most important technology standards in automation technology. This was followed in 2003 by the development of the EtherCAT fast 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 media applications 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, for example: KNX/EIB, DALI, M-Bus and MP-Bus. This ensures compatibility and continuity with the existing system. Existing and future investments are protected.

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 and SMPTE-Timecode to be integrated into the controller. EtherCAT Terminals are used in almost every application of AV and media technology.

The universal basic function block for automation

The I/O signals are wired decentralized to fieldbus devices or centrally to the controller. The available vendor-specific fieldbus devices with fixed input/output configurations and design often make it necessary to use an entire group of devices with similar functions. This complex signal acquisition results in high material, installation, design and documentation expenditures as well as high costs for later changes or extensions. Inventory management and service staff are put under unnecessary strain.

The Beckhoff Bus Terminal is an open and fieldbus-neutral I/O system consisting of electronic terminal blocks. The head of an electronic terminal block is the Bus Coupler with the interface to the fieldbus. Bus Couplers are available for all leading fieldbus systems.

With the master terminals, fieldbus functionalities are also available in the form of a standard Bus Terminal. This is particularly advantageous for bus systems that are integrated as subsystems into a higher-level system. It means that only one system is required for the subsystem and for the higher-level bus interface. The master terminals are available for the following building bus systems: KNX/EIB, LON, DALI, MP-Bus, M-Bus.

Simple panel connection in the field

CP-Link 4, the one cable solution for transmitting video signal, USB 2.0 and power supply via a commercially available Cat. 6A cable, allows the Control Panel to operate up to 100 meters away from the PC. Cable and assembly costs are reduced with the one cable solution. A further benefit is the use of purely passive displays. The CP-Link-4 technology is supported by the Beckhoff multi-touch Panel series CP29xx-0010 (built-in variant) and CP39xx-0010 (mounting arm variant) and is interesting for many media applications.

TF6310 is the basis for the support of 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 AV and media technology are based on TCP/IP, which is why TF6310 is used in almost all multimedia projects with Beckhoff control technology. TF6310 is the basis for the support of sACN, Art-Net, PosiStageNet, QSC and PJLink.

Optimized graphics functionality with the DisplayPort

The DisplayPort transfers image and audio signal at the same time and is therefore suitable for connecting panels or monitors to the Embedded PC. The CX5130, CX5140 and CX20x0 Embedded PC devices are available with a DisplayPort and allow the connection of a monitor with a resolution of up to 2560 x 1600 at 60 Hz. A second monitor can be controlled via the DVI interface. This enables use in a variety of media applications.

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

The Beckhoff Panel generation with industry-standard multi-touch displays offers the right solution for any application. For single-touch users, the 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-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

EL3xx3: integrated power measurement provides for transparency in power consumption

Energy efficiency is also playing an increasingly important role in media and building automation. 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 (EL3xx3) for energy management, Beckhoff provides suitable technology for the ongoing monitoring of power consumption as well as for the detailed consumption analysis. With the high-precision power measurement terminals, Beckhoff also offers a grid analysis option, which can be used for predictive maintenance purposes.

EL922x: integrates overcurrent protection into the EtherCAT I/O system

With the EL922x EtherCAT Terminal series, Beckhoff has integrated electronic overcurrent protection directly and in a highly compact manner into the EtherCAT system for the protection of 24 V DC system components. This reduces the costs and space required in the control cabinet compared to the current fusing products, without the need to use a conventional electronic solution as an inflexible stand-alone system. Due to numerous adjustment options and process data, the EL9227 also meets the most diverse requirements and enables transparent system monitoring.

The system-integrated overcurrent protection offers numerous practical advantages. The wiring work is reduced, as the supply to the neighboring I/O terminals is automatically connected when the terminal is plugged in. In addition, the control cabinet construction benefits from a space and cost saving by eliminating an otherwise necessary additional coupling product and further digital I/O or supply components. Furthermore, EtherCAT can be used to access numerous process data such as load, load current, input/output voltage, under/overvoltage and reverse supply. This enables transparent system monitoring, minimized downtimes, simplified troubleshooting and an optimal overview of the plant history.

EL3208: 8-channel Pt100 (RTD) input terminal

The EL3208 analog input terminal allows the low-cost direct connection of eight Pt100 resistance sensors in a width of 12 mm and is thus the ideal option for recording temperatures in the Beckhoff control system in media applications and to use them for control or Condition Monitoring purposes. The EtherCAT Terminal circuitry can operate 2-wire sensors. A microprocessor handles linearization across the whole temperature range, which is freely selectable. The EtherCAT Terminals standard settings are: resolution 0.1 °C.

Further terminals for the implementation of Condition Monitoring

The Beckhoff product portfolio contains various other EtherCAT Terminals for the implementation of Condition Monitoring applications; these include various analog terminals as well as support for bus systems such as IO-Link, which can be used for a huge variety of sensors.

The fast way to the individual user interface

TwinCAT HMI consistently relies on widely used IT standards such as HTML5, JavaScript and CSS. The integration of a full graphic editor with an extensive toolbox into the familiar TwinCAT engineering environment makes it possible to create extensive visualization pages for multimedia 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 in the field of media technology: from the local panel solution to multi-client, multi-server and multi-runtime concepts for digital signage applications, user interfaces for media applications, room control units or other HMI.

Beckhoff relies on proven IT standards:

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

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++ and 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

Integration in Microsoft Visual Studio makes it possible to program automation objects in parallel with the aid of the 3^rd edition of IEC 61131-3 and the C or C++ languages. The objects generated (modules) can exchange data with each other and call each other independently of the language they were written in. The TwinCAT System Manager has been integrated into the development environment. Hence, only one software is required to configure, parameterize, program and, if necessary, to diagnose automation devices.