Beckhoff’s DIN rail-mountable controller features multi-optional interface

Beckhoff (www.beckhoff.com) has equipped the fanless CX9020, which is a DIN rail-mountable controller, with 1 GHz ARM Cortex A8 processor, making it suitable for various PLC and Motion Control applications in small-sized as well as medium-sized machines, buildings or systems.

Featuring a very compact design, the new controller has also been fitted with a microSD card that offers a large storage capacity. Its Embedded PC features a CPU, a number of IT connectivity solutions and optional interfaces, a direct I/O interface and power supply for Beckhoff I/O systems. It also automatically detects the connected EtherCAT Terminals (E-bus) or Bus Terminals (K-bus) as well as switches to the corresponding mode for convenient system management.

Its CPU has access to 1 GB internal DDR3 RAM and a 256 MB microSD card for its operating system. For additional operator data, the controller also offers a free microSD card slot.

The CX9020’s basic version offers two 10/100 Mbit/s Ethernet ports, a DVI-D interface and four USB 2.0 connections. Its multi-optional interface allows integration of added interface that includes PROFINET, PROFIBUS, Ethernet/IP, DeviceNet, CANopen, audio or serial interface (RS232/RS422/RS485).

Unlike the current ARM9 architecture, the controller’s ARM Cortex A8 processor features a hardware-based floating point unit, which makes floating point operations (LREAL, REAL) faster. When combined with Beckhoff’s TwinCAT automation software platform, the CX9020 system turns into a high-performance PLC and Motion Controller that can be utilized with or without visualization. The operating system of the CX9020 is Microsoft Windows Embedded Compact 7.

Beckhoff unveils a compact servo technology solution

Beckhoff Automation (www.beckhoff.com) has introduced a compact servo technology solution with the release of the EL7201 servo terminal for the EtherCAT Terminal system. This 12 mm terminal offers a complete servo drive suitable for motors up to 200 W. Its integration into the EtherCAT I/O system effectively reduces costs and cabinet size requirements, while simplifying commissioning and cabling.

The new EL7201 servo terminal with resolver interfaces offers high servo performance in an exceptionally compact design. In addition, its integrated fast EtherCAT control technology, with PI speed control and field-oriented current, can support highly dynamic positioning tasks. Aside from the direct connection of a resolver and motor, a motor holding brake connection is also possible.

“The new EL7201 servo terminal is a true game-changer in the area of servo technology,” remarked Graham Harris, President, Beckhoff Automation.

“Small servo drives have been a popular technology for years and the EL7201 is a major evolution of this trend. Machine builders and manufacturers now have the option to control small servos with a 12 mm device.”

Permanent magnet synchronous motors, featuring a rated current of up to four A, can be connected to the new terminal as loads.

The new servo terminal provides maximum operational reliability, as it monitors various parameters, including undervoltage and overvoltage, overcurrent, motor load or terminal temperature.

Since it is fully integrated into Beckhoff’s TwinCAT automation software, the EL7201 servo terminal allows convenient parameterization. For third-party masters, parameterization occurs through the CAN over EtherCAT profile (CoE).

Beckhoff unveils latest power monitoring terminal

Beckhoff (www.beckhoff.com) has unveiled its latest power monitoring terminal developed to monitor the condition of a three-phase DC or AC mains network.

Suitable for Beckhoff EtherCAT I/O system, the EL3773 power monitoring terminal collects instantaneous values of voltage and power at a remarkably fast sampling rate of up to 10,000 samples per second. This makes the voltage and the power available to the higher-level PC controller for analysis or calculation. Transferring the input channels through oversampling leads to acquisition of actual values with a notably higher resolution, with respect to time, than the communication cycle time.

The EtherCAT Terminal system utilizes the EtherCAT distributed clocks method as its basis to achieve highly accurate acquisition of measured values. The EtherCAT devices are synchronized by the distributed clocks with very high precision. Voltage and current are measured by the EL3773 EtherCAT Terminal through the three channels in every case. Based on the EtherCAT oversampling principle, the six channels are simultaneously measured with up to 100 μs temporal resolution, before they are passed on to the controller. The channel’s maximum sampling frequency is one kHz.

With the supplied data, it is now possible to calculate, with the aid of a PC, true RMS power, values, frequency and power values, including complex user-specific algorithms through the current curves and voltage. The company said that the fast sampling rate also allows the measurement of current peaks and voltage.

Beckhoff partners with Fertig Motors to develop servo motors

Beckhoff Automation GmbH’s (www.beckhoff.com) managing director Hans Beckhoff has announced the company’s collaboration with Fertig Motors GmbH to develop servo motors for EtherCat and PC-based Control — the networking technology by Beckhoff.

The first of the products will be launched at the end of 2011, said Mr. Beckhoff. The Motion division of Beckhoff is being expanded with new product lines in the servo terminals, servo motors and servo drives category, he added. Production capacities for drive technology are being expanded, and the target is to increase the Motion division to 25% of total sales in the medium term.

“Our goal is to develop the next generation of servo motors: more dynamic, more energy-efficient and available at a low cost,” said Erwin Fertig of Fertig Motors. “Our team of highly motivated specialists is looking forward to this new challenge and is going about its work with enthusiasm. In order to ensure maximum quality standards and to guarantee high availability, all motors should be ‘Made in Germany.’”

Mr. Beckhoff added: “We have always specialized in hardware and software, and naturally, we have extensive know-how in drive technology. However, our knowledge will now be decisively deepened with the development of our own motor series, especially in the area of highly dynamic magnetic mechanics and the associated control algorithms. We are delighted with this new partnership and we are convinced that we will be able to offer our customers even more powerful system solutions as a result”.

BECKHOFF Automation introduces new EP6002 EtherCAT Box Modules

BECKHOFF Automation (www.beckhoff.com) is proud to announce the release of the all-new EP6002 EtherCAT Box Modules that allow external devices to directly integrate with a serial interface, like RFID or barcode readers, in a wide field without using a control cabinet.

With the use of selectable RS232 or RS422/RS485 interfaces, the powerful and compact IP67 EtherCAT Box Modules with two channels deliver high flexibility to allow serial devices to be directly integrated into an EtherCAT network.

EtherCAT Box Modules measure only 126 mm in height, 30 mm in width, and 26.5 mm in depth, and are ideal for applications in confined spaces.

The box modules transfer data in a totally transparent way into a higher level EtherCAT controller, while the active serial communication channels function in full duplex mode to up to 115,200 Bd. The 128 byte transmit buffer and an 864 byte receive buffer are supplied for the data’s temporary storage in the EtherCAT Box.

Serial devices are linked to the EP6002 through the rugged M12 plug connectors. The EP6002 EtherCAT Box, with the “TwinCAT Virtual Serial COM Driver”, can be used without the use of a controller as a COM interface in Windows operating systems.

Beckhoff’s dynamic servo motors for the food industry

Beckhoff (www.beckhoff.com) has expanded its AM3000 Synchronous Servo motor series with a FDA-compliant model designed with a white surface coating – a high-performance servo solution for any applications in the food industry. The motors’ coating, which is ideal for use in any food products, is resistant to aggressive cleaning agents. Aside from the surface coating, the new servo motors are not different from the standard types from the AM3000 series.

Hygiene regulations within the food industry puts high demand on drive and control components regarding the materials and surfaces, which should be capable of withstanding regular exposure, as well as resistance against aggressive cleaners. By coating a standard servo motor so that it can be suited for use around food products, the automation provider breaks new ground: the white coating (typical in the food industry) is FDA (Food and Drug Administration) compliant and guarantees that the manufactured food products are not tainted by chemicals.

The new servo motors vary from the standard types of motors only by the surface and the stainless steel shaft. The advantage for the machine operator is that more motor types do not have to be “designed into” the machine in case of mixed use of standard and coated motors. Another advantage of the new servo motor is the price: the coating adds only around 30% to the price of the standard motors. The IP 67 design also allows use in harsh industrial environments.

Free EtherNet/IP Tag Wizard with automated mapping features from Beckhoff

Beckhoff Automation is proud to announce the release of the new EtherNet/IP Tag Wizard that accelerates and simplifies programming of EtherNet/IP I/O architectures. It is made to optimize programming time; its free EtherNet/IP Tag Wizard is a very dynamic tool, which permits simple integration of cost-effective Beckhoff I/O to the Allen-Bradley Logix controllers using a RSLogix™ 5000 programming.

The EtherNet/IP Tag Wizard tool can give immediate benefits to all EtherNet/IP applications, which uses Beckhoff I/O to cut down equipment costs. The company makes comprehensive Beckhoff Bus Terminal I/O system of more than 400 different signal types available to EtherNet/IP users. The IP 67-rated IL2301-B905 Fieldbus Box and IP 20-rated BK9105 Bus Coupler from Beckhoff are ODVA-certified and follow the consumer and producer model for I/O data. It is developed with the use of advanced Industrial Ethernet technology, the IL2301-B905 and BK9105 provide EtherNet/IP operators dramatic price-to-performance ratio.

After saving the RSLogix™ 5000 programmable logic controller (“PLC”) program, the EtherNet/IP Tag Wizard opens up – just like other small applications such as Microsoft Word or Excel. When it is open, the operator can map multiple I/O nodes by choosing an IL2301-B905 EtherNet/IP Fieldbus Box or a Beckhoff BK9105 EtherNet/IP Bus Coupler. After the box or coupler is addressed and selected, I/O terminals are simply added to the system by double clicking the I/O to the correct category. When a node been mapped, it can be imported by the operator into the program using a previously saved RSLogix™ 5000 program.

The new space-saving HD Bus Terminals with 16 Channel I/O in 12 mm format from Beckhoff

Beckhoff Automation (www.beckhoff.com) announced its latest Bus Terminal I/O system to deliver progressively compact I/O solutions for machine builders and manufacturers. These expanded Bus Terminals with the latest ultra-compact HD Bus Terminals featuring 16 digital I/O channels in 12 mm electronic terminal block housing. Using DIN rail-mounted controllers or Bus Couplers, the HD Bus Terminals are compatible with almost all of major fieldbus. The HD Bus Terminals are available in both EtherCAT Terminal and Beckhoff Bus Terminal versions.

For the past few years, a consistent increase in electronic efficiency has reduced power dissipation to the point that I/O points doubled its packing density today, which results in multiple cost advantages: control cabinets’ space requirements can be reduced and the price per digital I/O channel significantly drops.

The 16-channel Bus Terminals feature new possibilities for project planning: greatly reduce the field of control technology that allows designers to build their systems and machines to be more compact and even smaller.

The HD Terminals with 16 digital I/O channels have the same external dimensions to existing Bus Terminals from Beckhoff and are compatible with them. Also, the flexible HD Terminals have different versions, e.g. as eight-channel terminals for digital outputs and inputs with two-wire connection, as combination terminals with eight digital outputs and eight digital inputs or as 16-channel terminals for digital outputs or inputs.

Wiring efforts are simplified despite higher channel density because of tool-less assembly. Using the direct plug-in technique, single wire conductors are connected without tools. As usual, the cables are released using the contact release with the help of an appropriately sized screwdriver. Also, the common color coding of the signal types is employed in the HD Terminals and is integrated to the LED display.

The latest TwinSAFE(TM) Technology for EtherCAT I/O System from Beckhoff

Beckhoff Automation (www.beckhoff.com) unveiled its latest EtherCAT Terminals with embedded Safety Programmable logic controller (“PLC”) for a flexible, compact and powerful safety solution, the TwinSAFE Terminals for the EtherCAT I/O system. With simple safety I/O terminals, it helps machine manufacturers and builders streamline safety systems. Conforming to EN ISO 13849-1 PL e and IEC 61508 and rated for SIL 3, TwinSAFE Terminals for EtherCAT I/O system are certified for use across the US.

The latest safety terminals for the EtherCAT I/O system fully utilize the high-performance EtherCAT. EL6900 safety PLC terminal can process 256 safety-relevant function blocks and is capable of integrating up to 128 four-channel safety terminals (“512 safety devices”). The integrated safety function blocks in the EL6900 Safety PLC are set up according to each unique application. Through this, safety functions can be simply programmed like latches, timers, serial/parallel muting, two-hand control, emergency stop and safety door monitoring. A connection shutdown function can also be established so the equipment’s interchangeable sections with embedded safety terminals can be detached from the machine without causing any safety system errors.

With additional EL6900 Safety PLCs, systems can be expanded as necessary. Through this, the safety-relevant control tasks for plants and machines can be implemented centrally or locally according to the application. The 24V DC digital output terminals (“EL2904: 0.5A and EL2902: 2.3A”) and 24V DC digital input terminals (“EL1904”) are available for connecting safety actuators or sensors. The TwinSAFE Terminals can be set up in any position in distributed I/O systems and in the terminal system. Also, the EL6900 Safety PLC can be used for AX5000 Servo Drives from Beckhoff as a safety controller that uses EtherCAT as a motion bus.

Safety over EtherCAT(“TM”) allows the integration of safety devices to a control system without requiring segregated safety network or a stand-alone safety PLC. Safety data is handled through a black channel passing a standard Ethernet cable. This new safety solution integrated in the terminal block housing is exceptionally compact, providing the highest flexibility through nearly limitless positioning inside the EtherCAT Terminal systems. The standard EtherCAT I/O Terminal systems can be intermixed to the same node with the safety terminals.

The Beckhoff TwinSAFE, a proven safety solution, has been successfully integrated into the original Beckhoff Bus Terminal I/O system (“K-bus”) and is in use around the world in a broad range of applications. The integrated TwinSAFE technology in the EtherCAT Terminal system (“E-bus”), the high performance of EtherCAT – with enhanced diagnostics and ultra fast communication – is now available.

Safety applications can be optionally made by using simple configuration in TwinCAT software in System Manager or programmed using a TwinCAT PLC (IEC 61131-3), in case of more complex applications. The Safety PLC’s safety-relevant parameters are available in TwinCAT software and can be utilized in the standard controller. Also, typical drive functions can be linked and selected very simply.

The EL6900 Safety PLC terminal is easy and quick to replace in case of possible required service without explicitly reloading and verifying the program. The system automatically loads and verifies the configuration to dispense trouble-prone removable media. The project’s manual saving or loading is not anymore necessary in case of service.

Another feature is the integrated tool in TwinCAT for determining and calculating the PL or SIL according to EN ISO 13849-1 and EN IEC 62601. The transfer of information to an additional tool and the safety application’s previous complicated analysis are no longer required, which can lead to significant cost savings and work reductions.