SOURCE: AIDA ENGINEERING
4. 2020
i n d u str i a l e th e r n e t b o o k
Applications Case Study
parameters for each line. ADMS individual process steps. is able to determine the optimal According to Sotoyuki Kaneko, process control simply on the basis EtherCAT has proven to be the best of the form data entered for the sheet solution for the implementation of metal part. The motion sequences can the Aida system on account of its be fine-tuned on the user interface precise synchronization and highon site. Apart from that, the motion performance data transmission controller can be adjusted in advance capabilities even over long distances: using an offline 3D simulator. As “In 2000, our group’s Electronic EtherCAT slaves, I/O terminals Development Department began collect a multitude of data such as work on a next-generation motion the tool position, information about controller, which was intended to the servomotor for positioning the replace the internally developed handling robot as well as sensor data. controllers we had used up to that Based on the control data processed point in time. The fundamental by TwinCAT in real time, ADMS decision to use a PC-based control simulates the motion sequences and system was taken at the same time. generates corresponding path control The optical fiber-based Lightbus was data. Sotoyuki Kaneko explains: the established Beckhoff fieldbus “The system benefits from the fact at that time. I can still remember that TwinCAT can integrate the very well how excited company most diverse data into the runtime founder Hans Beckhoff was when he environment and send real-time informed us that the introduction of feedback to the PLC and motion the new fieldbus standard EtherCAT controllers." was imminent. Then EtherCAT came onto the market as an open fieldbus, supporting extremely fast speeds, PC-based IoT control precise synchronization and longBy its own account, Aida is one of the distance data transmission up to 100 pioneers in the development of IoT m via a standard Ethernet cable. That systems and, according to Sotoyuki met all the requirements for the Aida Kaneko, EtherCAT components are presses, so we chose EtherCAT.” strong innovation catalysts in this Besides that, Sotoyuki Kaneko field, too. One example of this is says that there were obvious benefits the Aicare system (Aida Information in replacing previous internallyCare), based on Microsoft Azure. developed controllers with Beckhoff Aicare monitors and visualizes The individual processes within the Aida press lines are controlled components as the standard control important press data such as product by an Industrial PC with TwinCAT software as well as various platform for Aida presses: “If we had quality, operating parameters and EtherCAT terminals. continued to develop the control maintenance information. systems ourselves, we would also have Multiple data sets have to be had to develop all the I/O terminals connected controller with the EtherCAT “master clock”, acquired synchronously and in succession to to the system. In view of the enormous number which ensures seamless synchronization of all analyze the quality of the formed parts. Aicare of I/O terminals required for the wide variety presses and transfer units. does this with the help of EtherCAT distributed of individual customer specifications, this clocks. As all data are given a timestamp and In the tandem line, a robot handles the would have been virtually impossible for us. transfer of workpieces from one process to clearly identifiable in this way, the formed part Beckhoff offers not only a wide range of IPCs, the next. The appropriate distance between quality achieved with each stroke can easily but also the widest variety of I/O terminals for the robot and the forming tool is the most be analyzed in retrospect. In this context, all necessary signal types. The huge product important factor in achieving high productivity a machine learning process (Support Vector range, extensive engineering expertise and and efficiency: the smaller the distance, the Machine) is used, which according to Kaneko global distribution network were important more products the press can process. If the was easy to implement using PC-based control. reasons why we opted for Beckhoff.” distance is too small, however, this may Operational data, including data on He adds that another crucial factor was cause disruptions that can increase the risk temperatures and energy consumption, are the flexibility of the control platform. The of system failures. securely sent to Azure cloud services and IPC concept perfectly suited Aida’s design For this purpose, Aida developed a can also be viewed on the Aicare web page. philosophy because all necessary control TwinCAT-based solution featuring an ultra-fast Authorized persons automatically receive functions could be integrated with the highly control cycle, optimum synchronization and any alarms and error messages. Regarding flexible TwinCAT automation software. minimized robot distance with a high level of these features, Sotoyuki Kaneko concludes: production reliability. In this way, the servo “Aicare benefits enormously from real-time tandem line achieves 20 strokes per minute communication with EtherCAT and from Fast control and configuration In the servo-based tandem lines each of the and approximately 50 % more efficiency than PC-based control, because these technologies the predecessor series as a result. enable simple integration with cloud services machining processes is controlled by an IPC Also integrated in the servo tandem line such as Azure and the use of advanced IoT as the EtherCAT master. These communicate technology.” in turn with each other via EL669x bridge is the Aida Digital Motion System (ADMS) terminals. A further high-performance software, which allows operators to freely and conveniently configure press motion Technology report by Beckhoff Automation. Industrial PC serves as a higher-level
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