High-performance and scaleable control system

Software-PLC
A Beckhoff software PLC is controlling the operational cycle of the assembly line. This system is installed on an industrial PC together with the TopControl user interface. Thanks to the enormous capabilities of today’s PC systems, this approach allows even complex high-performance machines to be controlled. The available Ethernet TCP/IP interface permits easy connection to a customer LAN or remote servicing over the Internet. Moreover, the customer can continuously benefit from progress in PC technology.

Reusable software
The underlying software complies with the programming standard IEC 61131-3. It features reusable basic functions like communication with TopControl, axis and I/O control, error handling, etc. The modular software architecture assures the optimum integration of customerspecific sequences and processes. Sensors and actuators are simulated, so that programming work can be divided among several people, as can the testing of process sequences before the machine is ready for operation.

Fast real-time data bus
The real-time EtherCAT data bus and the appropriate bus terminals are used as the standard means of peripheral interfacing. The communication times on EtherCAT are extremely short. For instance, 1000 distributed inputs and outputs can be scanned in just 30 microseconds. Using bus couplers, the customer can also connect devices with other bus systems (CAN, Profibus, ...) quickly and easily.

High level of user comfort
TopControl is a graphical user interface employing a touch screen and runs under MS Windows®. It combines the ultimate in user comfort and data storage with authentic and realistic machine presentation. TopControl can communicate with the software PLC either via OPC or ADS (Beckhoff).

Each actuator can be individually controlled and checked regardless of the system’s operating state. This feature allows the system to be put into operation efficiently and reliably. Once saved, article data can be retrieved again later. This helps to minimize the time needed for changeovers.

The user language can be changed while TopControl is in operation. Extensive sets of data like article definitions can be entered with the keyboard.

Error messages
If an error occurs, an arrow points to the part of the machine causing the error. As a result, the errors can be quickly located and remedied all the faster.

Access rights
A special editor can be used to adapt the user interface to the needs of each operator. The system manager can determine the extent of access a user has to machine functions. For instance, he can block or hide certain entry windows or control keys. This feature protects production and quality specs.

Production data acquisition
Some statistical functions such as machine availability or good/bad informations are available as standard features in TopControl. Project-specific article data can be saved and made available to external expert systems. This feature allows the assembly process to be traced back to the individual parts.

Host computer
An overall system can consist of several sub-systems, each having their own control system and their own TopControl. In cases like these, TopControl of the first sub-system acts as the overriding host computer. It handles the central management of articles and jobs. The resulting assembly systems offer virtually unlimited possibilities.