New Automation Technology

Transcription

New Automation Technology
Beckhoff Applications Automotive
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Applications and Solutions
One Open System for all Branches
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Beckhoff components and system solutions are used in
almost every sector of automation engineering
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Automotive Industry
General Machine Construction
Window Construction Machines
Wood Processing Machines
Packaging Machines
Assembly Automation
Process Industries
Processing Machines and Presses
Semiconductor Manufacturing Industry
Transportation Plant and Logistics
Medicine and Lab Technology
Food and Beverages Industry
Building Automation
Environmental Engineering
Water Management
End Users
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Automotive Industry
BMW, Germany
Continental, Germany/worldwide
DaimlerChrysler, Brazil
Eberspächer, South Africa
Ford, Belgium
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Automotive Industry
Hayes-Lemmerz, Germany
RESA, Germany
Seichter, Germany
Sterner Automation Ltd.,
Canada
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Automotive Industry
Volvo Cars, Belgium
VW, Germany/South Africa
ZF Lemförder, South Africa
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BMW plant, Dingolfing, Germany
Project:
Automation of the gluing
process for the sunroof rubber
seal of the BMW 5 series
Realisation: 2003
Beckhoff customer since: 2003
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Control architecture:
I/O:
Lightbus, PROFIBUS
Fieldbus Box modules
Project realisation:
BMW-Werk, Symax Systemtechnik
Sondermaschinenbau, Beckhoff
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Customer advantages:
 Compact design enables direct
assembly on the robot arm.
 The Coupler Box collects the I/O
data via the 2 Mbit IP-Link
connection.
 The I/O modules enable coupling of
light barriers that monitor the
constant tension of the sealing
material.
 flexible and cost-effective
expansion options for the Fieldbus
Box system via IP-Link
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BMW plant, Regensburg, Germany
Project:
Control and visualisation of a
paint shop with two production
lines via 50 Beckhoff Control
Panels
Realisation: 2003
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HMI: 55 Control Panel
(customer specific design)
BMW-Werk, Symax Systemtechnik
Sondermaschinenbau, Beckhoff
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 Customer-specific Control Panels were produced precisely according to
BMW’s requirements.
 Via CP Link, Control Panels can be operated remotely from a PC at a
distance of up to 100 m.
 CP-Link solution enables connection with special graphics cards.
 simple handling, compact design
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Continental AG, Hanover, Germany
Project:
Tire building machines
Realisation: 1996
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Control structure:
CPU:
C6140 (Intel Pentium III)
HMI:
CP7031 (Visual Basic)
Central control function:
TwinCAT PLC
TwinCAT NC PTP
I/O:
Lightbus, PROFIBUSDP/MC
digital I/Os: about 550
analog I/Os: about 400
Distributed control function:
BC9000
Motion: PTP, up to 23 servo axes
Technical function:
master/slave functions
Continental AG, Beckhoff
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 engineering and runtime on one PC
 integrated system with control, motion, technology functionality
 complex HMI with user management and database on same PC
 customised control and visualisation software with cost effective
standard components
 flexibility and transparency
 reduction of refitting and set-up times
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Continental AG, Timisoara, Romania
Project:
Europe’s most modern tyre
factory driven by PC-based
control
Realisation: 2001
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Control structure:
CPU:
C6130, C6140
HMI:
CP70xx, CP71xx
I/O:
Lightbus, PROFIBUS
digital/analog I/Os
Totally PC-based control
TwinCAT NC-PTP, PLC
switched Ethernet with fibre optics
backbone
Motion: 250 Servo axes AX2000
PTP, CAM-Design
Technical functions:
closed loop temp-controllers
closed loop pressure
controllers
closed loop speed controllers
winding controllers
CCD control for web guiding
Beckhoff, Continental Suppliers:
BST Servotechnik, Calemard, Continental
Mould an Machine Factory, GfA Automation,
H.F. Meyer Maschinenfabrik, Hofmann
Prüftechnik Worms, ITW Acronic, K.E.
Fischer Maschinenfabrik, Krupp
Elastomeretechnik,Koester
Prüftechnik,Mitsubishi Heavy Industries,
Vanderlande Industries
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 reduction of costs by at least 50 %
in comparison with conventional
control technique
 All technology functions run on one
platform integrating PLC, MC and
PLS functionality.
 technical solutions for all aspects
of tire manufacturing (mixing,
extrusion, cutting, winding,
building, vulcanisation, handling
and inspecting)
 seamless integration of machine
PCs into enterprise network
 powerful and extensible solution
with flexible I/O configuration
 reduced needs concerning
availability, spares inventory and
training of employees
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Continental AG, Korbach, Germany
Project:
Triplex extruder plant for treads
(raw material for tyres)
Realisation: 2003
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CPU:
4 control cabinet IPCs
C6130 with 15“ Control Panel
CP7002/CP7032
HMI:
CP7031 (Visual Basic)
I/O:
Ethernet, Lightbus,
600 digital I/O interfaces
40 analog devices
PROFIBUS Fieldbus Card
(connection between drives
and Soft-PLC TwinCAT)
Motion: 2 servo axes
Continental AG, Beckhoff,
Control structure:
TwinCAT PLC
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 The recipe management,
visualisation, cutting machine
and colour marking are each
controlled via an IPC.
 Ethernet networking enables
integration into the factory-wide
LAN. The production management
and central process data archiving
systems have access to the
extruder plant data.
 Simple integration with the
visualisation interface provided
by the factory via TwinCAT OPC
server.
 The time required for retrofitting
and commissioning of the extruder
plant remained below the specified
limit.
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Continental, Charlotte, NC, USA
Project:
Replacing the hardware PLC of
the tire curing presses with a PCbased controller
Realisation: 2005
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CPU: 34 CP7130 Panel PCs
I/O:
Lightbus for press control
Ethernet (for controlling the tyre
drop and conveyor system)
Control structure:
TwinCAT PLC
TwinCAT OPC Server
Continental AG, Beckhoff,
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 Costs for control system and
installation time reduced by 50 %.
 switchover to manual mode
possible
 no rotating hard disk
 heat sink makes fan redundant
 Lightbus enables transfer speed of
2.5 MB/s.
 diagnostics and troubleshooting
integrated in TwinCAT
 1 Ethernet cable replaces “spaghetti
wiring”.
 Central control system reduces
cabling effort and downtimes.
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DaimlerChrysler, São Bernardo do Campo,
Brazil
Project:
Production line for CDI engines
Realisation: 2001
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Brazil
CPU:
BC9000
HMI:
standard monitor
I/O:
Ethernet
digital I/O: 270
complex I/O: 27 RS232
interfaces
Control structure:
TwinCAT PLC, 1 task, 50 ms
27 BC9000, 10 ms
DaimlerChrysler, Conexel,
Beckhoff
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Brazil
 direct communication between PC and distributed I/Os through
Ethernet
 compact hardware to fit easily to the nut runner
 I/O interfaces to fit different signal types (dig. I/O and RS232)
 efficient cost/performance ratio
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Ford, Genk, Belgium
Project:
Conveyor project for
real time transportation system
Realisation: 2000
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Ford, Genk, Belgium
CPU: 130 BC9000
HMI: WinCC, text display
I/O:
Ethernet TCP/IP
digital I/O: 1,600
complex I/O: 170 RS232
interfaces
Technical functions:
SQL: Logistical management
system
Control structure:
TwinCAT PLC, 1 task, 10 ms
130 BC9000
FORD/Genk, GTI Electro Thijs,
Multiprox
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Ford, Genk, Belgium
 simultaneous operation of
autonomous areas of the factory
 greater operational security
 multiple use of software solutions
Bart Claes, project engineer of GTI Electro Thijs, explained the decision for
distributed intelligence: “We opt for the most technically convincing
solution.”
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Hayes-Lemmerz, Königswinter, Germany
Project:
Production of car wheels
Realisation: 2001
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CPU: 16 C6140 (Pentium III, 850 MHz)
HMI: Visual Basic, interfacing via
TwinCAT OPC
8 CP7021, 2 CP7022, 2 CP7032
I/O: 20 Lightbus modules
digital I/Os: 5,000
analog I/Os: 1,000
Motion:
57 servo axes (42 synchronised,
15 asynchronous feed axes)
PTP, NCI
Control structure:
TwinCAT PLC, cycle time 9 ms
TwinCAT NC, cycle time 3 ms
Hayes-Lemmerz, Beckhoff
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 central data management
 integration of the complete Motion
Control within the TwinCAT system
 machine automation with one
single CPU
 simplified handling
 reduction of hardware costs
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RESA GmbH, Saarwellingen, Germany
Project:
“Plant Floor Process Control System”:
quality monitoring of all critical screw
joints and controlling the screw
controllers for the production of the
new Ford Fiesta in Cologne and the
Ford Focus in Saarlouis
Realisation: 2003
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CPU: 60/130 Bus Terminal
Controller BC9000
I/O:
Ethernet
Control structure:
Ford production management
computer with TwinCAT OPC
BC9000 with TwinCAT PLC
RESA GmbH, Ford-Werke
Cologne and Saarlouis, Beckhoff
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 Ethernet as an open and powerful
standard
 availability of a local, decentral
intelligence
 scalable Beckhoff control system:
IPC, Embedded-PC CX100x, Bus
Terminal Controller BX und BC
 flexibility of the hardware platform
 decentral intelligence in the
Ethernet network
 In case of change or extension of
plant, the autarkic systems
remains.
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Seichter GmbH, Hanover, Germany
Project:
Retrofitting of machines for
testing of tyres and wheels
Realisation: 2006
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CPU:
HMI:
Control cabinet PC C6150
Control Panel CP7021
I/O:
EtherCAT (control)
Lightbus (metrology)
Motion: Servo Drives AX2000
Safety: TwinSAFE
Control structure:
TwinCAT PLC/NC PTP
Bus Terminal Controller
BC2000
Seichter GmbH, Beckhoff
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 compact machine design
 use of only one software package
 avoidance of expensive hydraulics
 excellent precision, low cycle time
 flexibility in positioning of the
control panel (very little cabling
effort required)
 EtherCAT takes care of
communication and control
 openness and flexibility
 simplified maintenance
 incorporation of safety functions
into the TwinSAFE system
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Sterner Automation Ltd., Toronto, Canada
Project:
PC-based control system for a
machine that tests sensors used
in the seats of automobiles
Realisation: 2004
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Special functions:
TwinCAT Event Logger
integrated in Visual Basic
application for data protocol
CPU:
Industrial PC C6140
I/O:
PROFIBUS (data transfer to
Control structure:
the main controller)
SERCOS (communication
with drives)
TwinCAT PLC, NC PTP
Fieldbus Cards FC310x,
FC750x
Decentral control function :
TwinCAT PLC
Bus Terminals IP 20 and
Fieldbus Box modules IP 67
Oszilloscope terminal KL3362
Motion: Servo Drives
Sterner Automation Ltd.,
Canada, Beckhoff North
America
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 30 % less wiring, shorter installation
time
 smaller number of control
components
 reduced costs for maintenance
and training
 optimised remote diagnostics and
troubleshooting while maintaining
programming standards
 extended diagnostic options
 integration of PC Control into the
company network
 I/O components enable modular
machine design
 open programming in IEC 61131
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Eberspächer, Port Elizabeth, South Africa
Project:
PC-based control of a
horizontal press for pressing
of monoliths into catalytic
converter housings
Realisation: 2003
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CPU:
19 inch slide-in Industrial PC
C5102
HMI:
Control Panel CP6832 with 15“
display and touch screen
user interface: Visual Basic
I/O:
Lightbus
Motion: Servo Drive AX2020-B200,
Servo Motor AM297S
Control structure:
Soft-PLC/NC
TwinCAT NC PTP
Eberspächer, Port Elizabeth/
Jendamark Automation, Port
Elizabeth (Beckhoff Subsidiary)
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 scalability and adaptability of the control system
 Software PLC/NC TwinCAT enables implementation of user-defined values
for:
 variable speed and positioning
 motion profile
 data capture with network capability
 alarms to be triggered on error conditions
 values for the load cell system
 The system status is visualised via a Visual Basic application.
 increased operating safety and availability
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Volkswagen, Uitenhage, South Africa
Project:
Automation und process
control of the production line
for PQ24 Polo
Realisation: 2002
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CPU: 7 C3330 and C3350
HMI: Visual Basic – ADS-OCX
connection via Interbus
SCADA system: Wonderware
Intouch
I/O:
Lightbus/Interbus
approx. 6,000 I/O data
points analog, digital and
serial I/O terminals
Control structure:
TwinCAT PLC
TwinCAT OPC
Volkswagen South Africa,
Jendamark Automation, Port
Elizabeth (Beckhoff partner)
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 optimum process security for
production and machine control
 integrated data acquisition and
control of subsystems
 automatic correction, reporting
and logging of faults
 instructions for each working step,
output of process results and
statistics via HMI
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Volkswagen, Wolfsburg, Germany
Project:
Tryout multicurve press street at
Volkswagen
Realisation: 2001
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CPU:
C6140 PIII 850 MHz
HMI:
CP7032-1004
I/O:
2 x Lightbus (2-channel)
Ethernet, PROFIBUS, SERCOS
(2-channel)
digital I/O: 1,100
analog I/O: 50
complex I/O: 30
Motion: 15 servo axes
5 PTP axes with converter
Control structure:
Central control function
TwinCAT PTP
Müller-Weingarten, Beckhoff
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 low downtime and refitting time
 good scalability and flexibility
 excellent price/performance ratio
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Volvo Cars, Gent, Belgium
Project:
Automation and data connection
of the electric screwdrivers in the
assembly lines
Realisation: 2003
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CPU: 125 x CX1001-0121
Windows XPe, TwinCAT PLC
1 GB IBM microdrive
HMI: 125 x CP6801-0001
12” display touch screen
I/O:
PROFIBUS, Ethernet
24 digital and 2 analog I/Os
per system
Control structure:
TwinCAT PLC
Volvo Cars, Gent, Scanrotor,
de Jaeger Automation, Multiprox,
Beckhoff
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 comprehensive data acquisition:
screw curve velocity including
exerted force with the respective
torque
 detailed alarm system (reports faulty
execution)
 automatic recording of the executed
task and transfer to a central
database
 evaluation and analysis of the data
in terms of frequency and type of
problems
 Flexible production: The fitters can
work at four vehicles at the same
time.
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ZF Lemförder, Rosslyn, South Africa
Project:
Automation of the assembly lines
for the front and rear axles for the
E90 model of the BMW 3 series
Realisation: 2005
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Control structure:
CPU: IPC C3640 (central control)
40 CX1000 with Windows XPe
assembly station control
TwinCAT PLC
HMI: Visual Basic user interface
I/O:
Decentral control function:
TwinCAT PLC
PROFIBUS, communication with
power screwdriver control
system
Ethernet (communication
between control units)
24 digital and 2 analog I/Os
Special functions:
production monitoring via
SQL server
ZF Lemförder South Africa,
Jendamark Automation, South
Africa
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 Intelligent early detection system
enables axle production on demand
within 310 minutes.
 All station I/Os can be controlled
locally via the CX Embedded PC.
 System communication via
PROFIBUS and Ethernet
 Operator ID mechanism for safe
operation of the stations
 CX Ethernet interface for
straightforward integration into the
company network
 Product information system
provides access to part drawings
and installation instructions.
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Beckhoff applications and solutions for
all branches
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New Automation Technology

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