Beckhoff introduced its TwinCAT automation software in 1996 as part of its PC-based control platform. The software moved from DOS to the Windows operating system, supported PLC programming in accordance with IEC 61131-3 and combined engineering tools in one environment. The platform was built around separating hardware and software functions. Today, TwinCAT includes PLC, motion control, CNC, measurement, machine vision, robotics and AI-related tools within a deterministic real-time environment.
By separating control functions from proprietary hardware devices, Beckhoff established an early foundation for PC-based automation. The introduction of The Windows Control and Automation Technology, or TwinCAT, 30 years ago extended that approach. TwinCAT was designed to bring IT standards into automation through an integrated control platform with real-time extensions.
TwinCAT was first developed for Windows and later expanded to support other operating systems including TwinCAT/BSD and Linux. Beckhoff also combined engineering tools into one software concept and supported IEC 61131-3 PLC programming standards as well as IT programming languages and tools such as C, C++, MATLAB and Simulink.
From the beginning, TwinCAT supported cycle times down to 100 µs and used PC memory resources that exceeded those typically available in dedicated control hardware at the time. The software also included motion control functions ranging from standard axes to electronic gearing, cam plates and 5-axis CNC. Over time, the number of axes supported by TwinCAT increased from 10 to 50 to 100 and now to more than 1,000, while the cost per axis declined. This software-based approach gave machine builders an alternative to conventional control hardware for implementing electric machine designs.
Built on openness and flexibility
A central feature of the TwinCAT architecture is its open software structure, which brings multiple automation functions into one platform. While the initial focus was on PLCs, motion control and I/O, the platform now includes more than 100 functions for measurement, control and communication. Machine functions are processed deterministically on a central industrial PC and transferred to the I/O level through the EtherCAT fieldbus with synchronized timing. This supports coordinated process control and regulation while helping reduce installation work, cabinet space and overall system cost.
The capabilities of industrial PCs also allow integration of additional technologies within the same software environment. TwinCAT Vision and the system-integrated robot controller are available as runtime modules. Beckhoff has also expanded the platform with artificial intelligence tools. TwinCAT Machine Learning Creator is used to generate AI models for analyzing image data, time series and process data, and can also support local monitoring and anomaly detection in the control environment. The TwinCAT CoAgent tool is intended to assist users with automation programming during engineering and machine operation.
Fit for future requirements
The TwinCAT architecture continues to develop around scalability and compatibility with IT standards. Beckhoff positions PC-based control as a foundation for IT/OT integration and connectivity with cloud and edge infrastructure. The modular software framework is intended to support changing requirements in areas such as AI, communication standards and cybersecurity, while giving machine builders a platform they can continue to adapt over time.
Beckhoff
Here are some TwinCAT developments that the Motion Control Tips team has covered over the years.
- Beckhoff launches TwinCAT MC3 motion control software for PCs
- TwinCAT/BSD offers alternative operating system for Beckhoff Industrial PCs
- Beckhoff introducing XTS, EtherCAT G, and TwinCAT Vision to the U.S. at Pack Expo
- Beckhoff Azure-certified I/O modules provide direct connectivity to Microsoft Cloud
- Real-time performance: PC-based control technology update
- Galil’s EDD EtherCAT slave drives now offers TwinCAT support
- TwinCAT IoT now supports Siemens MindSphere
- New cloud engineering software from Beckhoff aids in IoT implementation
- Beckhoff Automation offers OPC UA integration in TwinCAT Scope software
- New entry-level PC-based controller from Beckhoff
- IoT with Beckhoff at IMTS: Hardware + software + networking for machine tool and metalworking
Here are some TwinCAT developments that the Design World team has covered over the years.
- Beckhoff launches TwinCAT for Linux with virtualized PLC capabilities
- TwinCAT/BSD operating system from Beckhoff
- TwinCAT/BSD Hypervisor provides efficient engineering and execution of virtual machines
- Beckhoff Automation announces TwinCAT Remote Synchronization
- PC-based control keeps automation provider on upswing
- TwinCAT Automation Software from Beckhoff turns 25
- Beckhoff Automation introduces TwinCAT Vision software
- Beckhoff integrates dynamic weighing into standard TwinCAT Automation Software
- Modular industrial robotics: New kinematic simplicity for plant engineers
Also check out this TwinCAT-related video from the archives:
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