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B&R has the perfect solution for...

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100% integration of motion, CNC and robotics

With Generic Motion Control (GMC), B&R makes possible the complete integration of CNC, motion and robotics in a homogeneous environment. GMC allows complicated tasks to be solved elegantly and efficiently, making it easy to perfectly synchronize a conveyor belt and robot, for example. The CNC or robot program generates the path for virtual axes, which can then be coupled to other (virtual) axes or actual positions (e.g. from an encoder on the conveyor belt) and ultimately transferred to real axes. Productivity increases while the workload is reduced.

User-friendly hardware, advanced design, compact construction

The CNC panel from B&R offers an innovative design for maximum integration: PLC, HMI, motion control, CNC, robotics and safety technology are all managed on a single control system – in the most compact housing on the market. A hand-held control unit gives the user even more freedom – during commissioning as well as when monitoring the active process.

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CNC or manual path generation

Painting is a complex process. Depending on the paint or coating, it may be necessary to follow different CNC paths for the same object. For this reason, it is usually preferable to enter the path manually instead of using ISO CNC programming. In addition to conventional ISO CNC or robot languages, the Generic Motion Control (GMC) concept from B&R also offers the possibility of generating a path for any type of kinematic system using points entered manually.

Condition monitoring

The ability to predict machine and system failures before they occur reduces costs and increases availability. This is why B&R offers many different possibilities for taking advantage of condition monitoring.

Condition monitoring modules from the X20 series can accurately determine cases where service work may be needed. In addition to being extremely easy to configure, they also handle vibration analysis themselves. This makes it possible to easily leverage the data from condition monitoring modules to efficiently optimize existing processes.

APROL ConMon – an out-of-the-box condition monitoring solution also offered by B&R – provides even more extensive possibilities. This system continually measures, records and analyzes all relevant data to provide the information needed for efficient condition-based maintenance. Sustainable improvements to machine and system availability are the end result. APROL ConMon is based on and can be seamlessly integrated into B&R's APROL process control system. It is also available as a standalone version.

Distributed and scalable

X20 and X67 I/O systems from B&R provide the optimal solution for distributed and scalable applications. Whether in the control cabinet (X20 system with IP20 protection) or directly on the machine (X67 system with IP67 protection), B&R I/O is the best choice when it comes to reducing wiring costs. These systems also make it possible to offer different machine configurations without having to develop new software.

Extensive portfolio for controlling CNC machining centers

B&R offers a wide range of solutions for motion control:

• Brushless motors with integrated drive (ACOPOSmotorACOPOSmotor)

• Ultra-compact and highly dynamic servo motors and drives (8LV + ACOPOSmicro)

• Stepper motors (8OMP + ACOPOSmicro)

• LinMot linear-rotary motors (ACOPOSmicro)

With B&R, machine manufacturers can use any type of motor to control the locking head. The software is completely independent of the actuator (GMC). This means that the original manufacturer has total freedom not just to select the best solution for each machine, but also to determine how best to manage time requirements, resources and costs.

Keeping energy costs under control

Energy costs must be monitored at all times to ensure that the drying process makes sense economically. Here it is important to have an overview of steam, heating, electricity and other costs in order to ensure that the process is completely optimized. Special X20 modules record all values from the system and deliver them to APROL EnMon. EnMon not only collects the data, it also provides clear analysis and suggests corrective measures to boost the efficiency of the system.

Energy monitoring

When it comes to improving production efficiency, the first step is to analyze where, when and how much energy is actually being consumed. The APROL EnMon solution is used to acquire all relevant energy data and generate comprehensive reports for its evaluation and interpretation. This easily integrated complete solution, which runs on B&R's Automation PC 910, is a simple way to implement the requirements specified in ISO 50001. APROL EnMon helps considerably reduce energy consumption, with the resulting financial savings strengthening users' competitive edge.

Generic Motion Control

Developing machine concepts in today's world goes far and beyond the simple lining up of individual processes to be executed one after the other. There are often direct links between path control with I/O processing and process-dependent intervention in the drive functions. Auxiliary axes need to be coupled to path axes, and it must be possible to display all sequences in real time. That machines must be networked to accomplish all of this as well as for remote intervention and diagnostics goes without saying.

B&R improves the efficiency of machines and systems by combining CNC, robotics and motion control into a single software platform called Generic Motion Control (GMC). One feature that makes GMC unique is that it can be used for all drive types, including hydraulic drives and servo technology. GMC integrates seamlessly into the machine application, allowing it to be customized for the specific task at hand. The flexibility of GMC also makes it easy to integrate existing CNC and robotics dialects.

Hydraulic, electrical or hybrid solution

A great deal of force is needed to manufacture WPC products. Fortunately, B&R offers a servo-hydraulic solution that can save energy when producing WPC products. The conventional combination of hydraulic pump and frequency inverter is replaced by a servo drive and servo-hydraulic pump. This type of system consumes energy only when absolutely necessary – the improvement in energy efficiency is remarkable. Of course, B&R PLCs, Industrial PCs and Panel PCs can also be used to implement purely hydraulic or purely electrical concepts for WPC machines.

Hydraulics

Controlling hydraulic systems is an integral part of B&R's automation concept. Not only is it possible to do away with special hardware for controlling these hydraulic systems, a powerful hydraulics software library opens up all kinds of possibilities in this specific area.

• Position control

• Speed control

• Force control

• High-speed, dynamic switching between control loops

Hydraulic systems are controlled in parallel with the rest of the hardware. Not only does machinery benefit from higher performance and accuracy, costs are reduced while overall integration increases.

Customized operator panels

Customized operator panels and industry solutions from B&R exhibit the same high quality as products manufactured in series. Customers who need individualized hardware solutions need look no further – we have an entire department devoted solely to fulfilling these types of special requirements.

High-performance closed loop control

B&R has many years of experience developing industrial processes for plastics and offers a wide variety of libraries containing proven technology for control loops and autotuning procedures. Sophisticated closed loop control technology from B&R is based on the absolute latest concepts to allow maximum machine performance and precision. Find out more in the Plastics section.

MATLAB/Simulink & MapleSoft

A direct connection between MATLAB/Simulink or MapleSoft and B&R control systems provides a unique advantage when it comes to improving and optimizing the drying process. Complex mathematical models can be developed using MATLAB/Simulink and MapleSoft, not just for the drying system but for its immediate environment as well. The automatically generated C code can be easily uploaded to a B&R controller, which enables faster prototype development and shorter development times.

Not too hot, not too cold

Extrusion and injection molding machines must raise and lower the temperature in multiple zones to ensure the quality of the end product. B&R offers a software package with function blocks and HMI templates for simple implementation of temperature control. Temperature control runs on the main PLC, of course, eliminating the need for external devices. The function blocks offer the option of autotuning, which can significantly shorten commissioning times.

Open and flexible architecture

B&R has been using open standards and communication protocols for a long time. B&R systems are open to standardized communication interfaces at the machine and ERP level. Previously engineered machine software can also be used with different hardware thanks to B&R's fully scalable product portfolio. The only things that need to be configured are the communication medium itself and the protocol. Dynamic I/O configurations allow the same software to be used for different hardware topologies. The result is a cost-effective and highly flexible solution.

Optimized wiring with a distributed fieldbus system

Wiring large machines can be quite a complex venture if all I/O modules are installed in a central control cabinet. B&R's distributed approach allows easy installation and thus reduces associated costs. IP20- and IP67-rated I/O modules, control modules for valve terminals, keys, remote display units, distributed frequency inverters or servo drives or motors with integrated drives can be easily, reliably and inexpensively networked using POWERLINK. And because software and parameter settings are managed centrally, the system can be programmed as if all components are located in a single control cabinet.

POWERLINK

POWERLINK

I sistemi classici a bus di campo permettono di combinare mediante una tecnologia standardizzata prodotti per l'automazione di costruttori diversi. I limiti funzionali, tuttavia, comportano spesso la necessità di utilizzare sistemi a bus di campo differenti per le varie attività di automazione.

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Ciò costringe a servirsi di strumenti diversi, richiedendo l'uso di più moduli di interfaccia e andando incontro a limitazioni relative alla diagnostica e ai componenti infrastrutturali.

POWERLINK POWERLINK rappresenta un'evoluzione della tecnologia classica a bus di campo, offrendo prestazioni superlative e capacità real-time basate sullo standard globale riconosciuto, vale a dire Ethernet. Una velocità di trasmissione di 100 Mbit/s e un’accuratezza di sincronizzazione di +/- 100 ns permettono di combinare in un'unica rete anche le attività più complesse nel campo dell'ingegneria del controllo, della robotica, dei CNC e del controllo di movimento.

Ciò assicura uno sfruttamento ottimale dei vantaggi offerti da una soluzione di controllo integrata. Gli utenti potranno concentrarsi sulla progettazione delle macchine e sulla creazione delle soluzioni di automazione, senza doversi preoccupare dei bus di campo. POWERLINK offre le prestazioni necessarie per rappresentare la base ideale per le innovazioni future e per una concezione modulare delle macchine. La libertà offerta dalla topologia standard Ethernet consente di adattare in modo ottimale il cablaggio alla configurazione di macchina, con una conseguente riduzione dei costi di cablaggio. POWERLINK è una tecnologia aperta e definita a livello mondiale secondo una norma IEC. Vari produttori di primo piano di tecnologie di controllo, movimento, sensori, pneumatica, di visione e robotica si affidano già a POWERLINK. Con openSAFETY, POWERLINK offre l'unico standard di sicurezza aperto per il collegamento della tecnologia di sicurezza integrata in conformità con la IEC 61508, con conseguente miglioramento delle prestazioni di macchine e sistemi e riduzione dei tempi di fermo.

Safety first!

With the openSAFETY protocol as its foundation, B&R offers the most comprehensive integrated safety portfolio on the market. The fastest response time on the market, combined with SafeMOTION function blocks such as Safe Torque Off (STO), Safely Limited Speed (SLS), Safely Limited Position (SLP) and Safe Direction (SDI), makes possible the development of previously unimaginable machine concepts. The same applies to robotics applications. Here, SafeROBOTICS monitors the entire kinematic chain. Transferring openSAFETY data via POWERLINK allows the implementation of safety solutions up to SIL 3 (IEC EN 6206) or PL e category 4 (EN ISO 13849-1). The safety controller and remote safe I/O replace conventional hardwiring and increase flexibility during commissioning and operation.

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Synchronous and in real time

With POWERLINK, B&R achieves real-time synchronization for remote systems as well. Controllers and remote I/O run synchronously with a precision <100 ns. With sanding machines, for example, this means that the scanning sensors can be precisely controlled together with the conveyor belt and sanding unit. This increases processing quality and reduces costs since no special hardware is required.

Synchronization and performance

Fully scalable controllers from B&R provide enough power for any complex mathematical algorithms to run directly on the controller without requiring additional PCs. Directly connecting cameras and/or laser systems to monitor the process and ensure quality are also part of the integrated automation solutions provided by B&R. This integration and the extremely short response times achieved by POWERLINK, NetTime and reACTION technology increase productivity and improve quality.

Temperature control

An extensive temperature control library with function blocks, PID controllers and HMI templates is the ideal solution for wood drying systems.

The library supports:

• Autotuning

• Management of several different temperature zones

• Storage space for large amounts of data

The complete integration into the system goes without saying.

openSAFETY

openSAFETY

Il primo standard aperto, nonché l'unico indipendente dal bus

openSAFETY è il primo standard di sicurezza aperto, nonché l'unico davvero indipendente dal bus, attualmente disponibile per tutte le soluzioni con bus di campo ed Ethernet industriale. Questa tecnologia semplifica l'implementazione delle misure di sicurezza secondo le linee guida della direttiva macchine 2006/42/CE e di altri standard attualmente in vigore. Grazie all'adozione del principio del "black channel", openSAFETY è l'unico protocollo di sicurezza al mondo in grado di trasferire i dati di sicurezza tramite qualunque sistema di bus di campo.

openSAFETY

Oltre a un alto livello di interoperabilità, le sue modalità di funzionamento garantiscono la ricezione e l'elaborazione dei messaggi da parte di tutti i destinatari allo stesso tempo. Questo è uno dei motivi per cui openSAFETY è un passo avanti rispetto a tutti gli altri protocolli dal punto di vista dei tempi di risposta. Anche l'integrazione tramite POWERLINK assicura un'ulteriore drastica riduzione dei tempi di risposta. A sua volta ciò migliora notevolmente la disponibilità di macchine e sistemi.

Vantaggi che parlano da sé

L'adozione della tecnologia openSAFETY offre numerosi vantaggi. La combinazione di tempi di risposta più rapidi e minori distanze di sicurezza si traduce in un aumento della produttività, un fattore particolarmente importante per i produttori di macchine. Grazie ai servizi di parametrizzazione e configurazione automatizzati, gli operatori dei sistemi beneficiano di una riduzione delle tempistiche di messa in servizio e transizione.

Oltre agli I/O digitali, il openSAFETY protocollo openSAFETY copre anche le interfacce analogiche e di temperatura, nonché le misurazioni della velocità di sicurezza fino a SIL3 e PLe. Unitamente alla tecnologia di azionamento di sicurezza, il protocollo rende possibile un numero molto elevato di risposte di sicurezza estremamente rapide, offrendo agli sviluppatori di macchine un'opportunità per ridurre la loro dipendenza dai pulsanti di arresto di emergenza, spesso all’origine di diversi danni.

Sostanziale semplificazione dei cablaggi

I cablaggi dei sensori e degli attuatori orientati alla sicurezza risultano notevolmente semplificati con openSAFETY in quanto possono essere collegati alla rete tramite i medesimi nodi di I/O distribuiti utilizzati anche in parallelo dai normali canali di I/O. Molti degli attuali componenti orientati alla sicurezza dispongono inoltre di serie di una propria interfaccia per bus, che consente di collegarli direttamente alla rete. In un sistema totalmente integrato non occorre inoltre più cablare i contatti di allarme fra il sistema di sicurezza e quello standard.

Con openSAFETY, B&R offre la trasparenza completa di tutti i canali di I/O standard e di sicurezza in un unico sistema. Ciò consente di configurare in un progetto software standard i moduli o le opzioni macchina che non sono integrati in modo permanente nei sistemi, anche nel caso in cui debbano essere dotati delle necessarie caratteristiche di sicurezza, nonché di metterli in servizio sul campo semplicemente selezionando la configurazione corretta sullo schermo di un computer.

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