Automation in manufacturing is acknowledged as the necessity by all manufacturers
Published on : Monday 01-08-2022
Jitendrakumar Kataria, Managing Director, Beckhoff Automation Pvt Ltd.
Beckhoff pioneered PC-based automation in the 1980s. How does it stand today globally and in India in terms of adoption?
Hans Beckhoff founded Beckhoff Industrie Elektronik.
The first projects used control systems based on Motorola Microprocessor for machines in the wood and window frame construction industry.
The term personal computer (PC) was associated with IBM PC with variants like X86 processor and DOS Operating system. Beckhoff modified the hardware and the operating system in such a way that motion control could also be implemented with it.
Back then PC based control was only an idea to be explored and has now become a world standard. Almost every machine whether a simple or complex is computerised and connected to the cloud servers.
Today PC based Control and TwinCAT achieve numerous milestones in automation technology history. Beckhoff’s modular TwinCAT 3 software generation is a classic example of modularity and seamless integration of IT integrated with OT (Operation Technology).
In India too, the technology conscious machine manufacturers have started implementing PC based Control and TwinCAT enabled Machine control systems. There are several examples in India how advanced machines are built using Beckhoff technology.
Beckhoff has long advocated and is also part of the movement for open automation technologies. What are the advantages for the user industry? How closer is the industry in achieving this?
Yes, Beckhoff has long advocated the PC-based Control technology for machine control, which is vindicated after 40 years as we see there is growing demand to have connected machines, Industry 4.0, AI/ML, etc., for better productivity.
There are numerous key advantages with Beckhoff control system to the user industry:
1. Openness with adequate Security: Open automation is the foundation of PC based Control where the hardware is the universal PC of industrial grade with Windows OS and TwinCAT software platform which is open. PC-based control uses EtherCAT fieldbus communication which is the backbone of flexibility, openness, and compatibility.
2. Connectivity: TwinCAT supports 22+ communication protocols used in factory automation, building automation and process automation. Also, the IT protocols like AMQP, MQTT, and OPC UA are also supported by Beckhoff control system.
3. Versatile programming possibilities in real time: TwinCAT is comprehensive automation software used in many different application areas. It is integrated in Microsoft Visual Studio framework for enabling programming in higher level languages. Programming in IEC61131-3 languages – i.e., conventional PLC programming – is used by majority of TwinCAT users. If required, higher level languages C or C++ as well as MATLABR and SimulinkR from MathWorksR can also be used and integrated seamlessly. This means that programs created in these languages can be executed in TwinCAT real time environment.
4. Integrated Safety: TwinCAT Safety Logic is available to users for machine safety. This implies safety applications can be developed in the required language- Safety can be executed in TwinCAT real time.
5. Integrated Measurement Technology: Quality Control, End of Line testing, inspection requires precise measurement. TwinCAT measurement technology enables machine builder or, system integrators to add seamlessly the precise data acquisition and measurement on the same control system platform. This helps to capture and analyse measured values on the same control system platform.
6. Analytics: TwinCAT Analytics enables easy graphical configurations for the dashboard.
7. Integrated Vision: TwinCAT Vision follows the Beckhoff philosophy of open control technology,
a. Hardware-neutral: TwinCAT Vision works both with line-scan and area-scan cameras with GigE Vision interface.
b. Software extensions: Allowing users to access raw camera data and incorporate their own image processing algorithms easily.
8. Industry 4.0: Machines and systems often need to exchange data with other machines or with ERP/MES systems. Various communication systems and protocols are available for this purpose. TwinCAT OPC U/A is certainly the most widely used protocol for machine connectivity in this context. Users confirm that TwinCAT is a future oriented software platform which fully leverages the convergence of IT and OT which further enables IoT based automation.
Certainly, these features are gaining importance because connected machines are becoming the standard of future. We see the customers who were working on just machine control and are now adding these features to get the winning edge in the market over their competitors.
How has the MX-system been received by the market? How significant is this in terms of convenience and adaptability?
MX-System is a revolution in the Automation world. This is a pluggable system solution for control cabinet-free automation. For the first time in machine and system engineering, the MX-System enables completely control cabinet-free automation solutions. By consistently combining, applying and further developing Beckhoff’s expertise, a holistic, modular pluggable system has been created. The combination of MX-System baseplate and MX-System function modules resulting from the modular construction kit combines all tasks and features of a control cabinet: energy supply, fuse protection and distribution, generation and monitoring of auxiliary voltages, sequence control with the inputs and outputs, control of motors and actuators as well as the connection level for the field devices. The full system integration of all machine functionalities is achieved via freely selectable IPC, coupler, I/O, motion, relay and system modules, which can be configured and combined suitable for the specific application.
The certification of all components to international standards enables the standardisation of control systems around the globe. The consistent systemic approach of the holistically coordinated modules reduces the effort required for planning, assembly, machine installation and maintenance enormously. Since considerably fewer components are required than in traditional control cabinet construction 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 recent launch of ATRO for robotics applications is another Beckhoff initiative towards smart manufacturing ecosystem. Is this now available for Indian users?
Automation Technology for Robotics is the modular industrial robot system – ATRO.
The new ATRO system from Beckhoff is a modular industrial robot system that can be used to assemble the optimal robot structures for different applications on an individual and flexible basis. Standardised motor modules with integrated drive functionality, together with link modules in various designs and lengths, enable almost limitless combinations of mechanics. The complete integration of the control into the holistic control platform TwinCAT offers direct access to a wide range of proven automation functions.
This opens up an extensive range of individual possibilities for users to implement their own kinematics, such as:
• 1-axis rotary indexing table with integrated power feed
• 2-axis tracking unit
• 3-axis delta robot
• 4-axis SCARA
• 5-axis palletizing robot
• 6-axis serial robot, and
• 7-axis system to increase the reach/articulation for hard-to-reach areas.
Currently we have few prototypes of these Robots, which will be tried and tested. Proposed availability for the same is planned in year 2024.
How do you see the pace of digital transformation of Indian industry post-Covid, especially in the SME sector?
Automation in manufacturing is acknowledged as a necessity by all manufacturers including the SME sector. The pace is picking up fast.
You have in the past emphasised more engagement with the end user for effective solution implementation. Is this objective now closer to realisation?
Beckhoff has been in active engagement with end users for long time. We have been highlighting to end users, the importance of appropriate selection of control system, because the technologies like Industry 4.0, connectivity, machine learning, artificial intelligence, machine vision, etc., need high CPU capacities and storages for large amount precise data from equipment’s and this is possible with computers. So, machines with right control system platform play a vital role. Further if the software platform of control system already has this feature onboard, implementation of future technologies becomes easier.
This is where Beckhoff PC based control system technology, brings advantage to the end users. More and more companies have understood this importance and are now demanding with their equipment suppliers to enable their machine with these latest technology features.
While enabling Made-by-India, any plans of Beckhoff to Make-in-India?
Beckhoff enables Made by India and not only Make in India.
To remain competitive, value addition is the only way forward for machine manufacturers and product manufacturers.
Value always tends to infinity whereas lower prices always tend to zero which leads to compromises in material cost and features.
To create value innovation is the only way for manufacturers and innovation requires openness in thinking and freedom to implement new ideas in engineering, machine design, automation and control, software, etc.