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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

Classic fieldbus systems enable automation products from different manufacturers to be combined based on standardized technology. However, limited functionality often made it necessary to use different fieldbus systems for different automation tasks.

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This made it necessary to use different tools, required the use of more interface modules and ran up against limitations regarding diagnostics and infrastructure components.

POWERLINK As a successor to classic fieldbus technology, POWERLINK provides uncompromising performance and real-time capabilities based on the established global standard, Ethernet. A transmission speed of 100 Mbit/s and a synchronization accuracy of +/- 100 ns allow even the most demanding tasks in the areas of control engineering, robotics, CNC and motion control to be combined in a single network.

This optimally supports the advantages of an integrated control system solution. Users can focus on their actual tasks of designing the machine and creating an automation solution without having to worry about the fieldbus. POWERLINK offers the performance needed to be the ideal foundation for future innovations and modular machine concepts. The freedom provided by Ethernet standard topology also allows users to optimally adapt the wiring to the design of the machine and thus reduce wiring costs. POWERLINK is an open technology and defined worldwide as an IEC standard. Leading manufacturers of control, motion, sensor, pneumatic, vision and robotics technology already rely on POWERLINK. With openSAFETY, POWERLINK offers the only open safety standard for connecting integrated safety technology in accordance with IEC61508. This increases the performance of the machine and system and reduces downtime.

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

The first open and only bus-independent standard

openSAFETY is the first open and only truly bus-independent safety standard available for all industrial Ethernet and fieldbus solutions. This technology makes it easier to implement safety solutions in compliance with current 2006/42/EC machine guidelines as well as other applicable standards. Using the "Black Channel" principle, openSAFETY is the only safety protocol in the world that can transfer secure data via any fieldbus system.

openSAFETY

In addition to its high degree of interoperability, the way this protocol communicates ensures that messages are received and processed by all recipients at the same time. This is one of the reasons why openSAFETY is a step ahead of the rest with regard to response times. Furthermore, integration via POWERLINK also drastically reduces response times. This in turn considerably increases the availability of machines and systems.

Advantages that speak for themselves

Using openSAFETY technology has many advantages. Combining faster response times with smaller safety clearances means increased productivity, which is enormously important for machine builders. System operators profit from faster commissioning and changeover times thanks to automated parameterization and configuration services.

In addition to digital I/O, the openSAFETY protocol also covers analog and temperature interfaces as well as safe speed measurement up to SIL3 and PLe. Together with safe drive technology, it enables a large number of extremely fast safe reactions, providing an opportunity for machine developers to reduce their reliance on E-stop buttons that often result in damage.

Substantially simplified wiring

Wiring safety-oriented sensors and actuators is greatly simplified with openSAFETY because they can be connected to the network at the same decentralized I/O nodes being used in parallel by the standard I/O channels. Many of today's safety-oriented components also come equipped with their own bus interface and can be connected to the network directly. In a fully integrated system, it is also no longer necessary to wire the alarm contacts from the safety system to the standard system.

With openSAFETY, B&R provides complete transparency of all safe and standard I/O channels in one system. This allows modules or machine options not permanently built into a system – including when they must be outfitted with the necessary safety features – to be set up in a standard software project and put into operation in the field by simply selecting the proper configuration on a computer screen.

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