PC-based control for body construction
A giant leap for efficiency with intelligent automation
PC-based control for body construction
A giant leap for efficiency with intelligent automation
The pressure to optimize sheet metal working is increasing: fluctuating demand, small batch sizes, the shortage of skilled workers, and ever shorter product life cycles require production solutions that offer a high level of flexibility and economic efficiency. Whether for pressing, cutting, welding, punching, nibbling, or bending – machines that adapt to new requirements quickly and offer maximum efficiency and quality are in demand. You can achieve both with automation and control solutions from Beckhoff. Our fully PC-based platform combines openness, performance, and modularity to create a system that makes your machines and systems fit for the future.
Secure a competitive edge in metal forming with Beckhoff:
- high scalability for maximum agility for fluctuating order situations
- short time to market thanks to a well thought-out hardware and software portfolio
- automated productivity secures competitive edge despite skills shortage
- future-proof due to consistent modularity and open interfaces
Do you have any questions?
Optimized integration: Sheet metal working with PC-based control
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Our technology highlights for sheet metal working
Central control for maximum flexibility and performance
Sheet metal processors are under high competitive pressure. Efficient production solutions are needed so that this challenge can be faced and to elicit growth. PC-based control solutions from Beckhoff provide the key here. The basic concept revolves around using industrial PCs to implement all automation functions centrally on a software-based platform.
There is no need for communication between different hardware systems, and the associated costs and latency are eliminated. This means that consistently optimized control processes that are highly precise, freely scalable, powerful, and variable can be implemented with little engineering effort.
How you benefit from PC-based control:
- high level of flexibility: one system for PLC, CNC, motion, safety, measurement technology, and HMI – freely scalable for every application
- higher productivity: fast response times, precise motion control, and integrated analytics for process optimization
- cost efficiency: less hardware, reduced communication effort, and less engineering effort
- open standards: seamless integration into existing plants and IT systems
Ultra-fast and future-proof
With EtherCAT, Beckhoff sets the standard in industrial automation technology. Ultra-fast signal transmission and synchronization precision in the nanosecond range make the fieldbus the communication standard for real-time requirements.
EtherCAT is ideal for sheet metal working machines thanks to its performance, high topology flexibility, comprehensive diagnostic functions, simple configuration, and solutions such as eXtreme Fast Control (XFC). With EtherCAT P, you also benefit from genuine One Cable Automation (OCA) and save valuable resources – especially with line systems and modular machine concepts.
How you benefit from EtherCAT:
- high-speed communication: super speed can be provided with EtherCAT G and speeds of 1 Gbit/s or 10 Gbit/s
- maximum precision: XFC determines the state of the sheet metal working machine up to 10,000 times per second to ensure repeatable processes and fewer rejects
- investment security: EtherCAT is constantly being developed and, as an open standard, is also ready for networking with third-party solutions
Engineering and runtime platform in one
With TwinCAT, Beckhoff has created the leading ecosystem for automation. The platform offers runtime systems for real-time execution of PLC, HMI, NC, CNC, and robotics applications and serves as a development platform for programming, diagnostics, and configuration. In addition, there are TwinCAT libraries with algorithms for motion control, robot kinematics, IoT, and analytics. This all saves you valuable development time and brings your machines to market faster. TwinCAT CNC also accelerates engineering: for example, with path controls on demand or CNC solutions for the motion requirements of laser cutting systems. TwinCAT CoAgent is extra smart. It uses AI to support you in evaluating system data and optimizing energy efficiency and process technology.
How you benefit from TwinCAT:
- central platform: for all engineering and control tasks in sheet metal working
- comprehensive solution platform: modular and individually scalable
- functionality on demand: thanks to comprehensive software libraries
- AI support: intelligent engineering support through TwinCAT CoAgent
Tailor-made safety solutions for EtherCAT systems
With TwinSAFE, Beckhoff has overcome the traditional division between “safety” and “non-safety”. TwinSAFE integrates all the necessary safety functions into any control architecture. You receive a flexible and scalable complete safety package for your requirements – based on the internationally certified Safety over EtherCAT communication protocol.
With Safety over EtherCAT, safety functions can be activated via the machine controller and can also be integrated automatically: via TwinSAFE Logic-capable components. Our component portfolio includes I/O modules in all shapes and designs, all drive systems, and a vast range of tools for engineering. In addition, the TwinCAT Safety Editor is a tool for simple implementation of safety applications.
How you benefit from TwinSAFE:
- tailor-made safety: comprehensive software support for implementing customized safety applications
- open and flexible: due to the certified Safety over EtherCAT communication protocol
- highly automated: due to TwinSAFE Logic-capable components
Our product highlights for sheet metal working
Control cabinet-free automation with Beckhoff
Sheet metal working demands modular, highly flexible machines with a small footprint. The MX-System from Beckhoff creates space for innovation. It enables completely control cabinet-free automation solutions in machine and system engineering. The combination of baseplate and function modules combines all the tasks and properties of a control cabinet: power supply, fuse protection, power distribution, generation and monitoring of auxiliary voltages, sequence control, control of motors and actuators, and the connection level for the field devices. The coordinated assemblies, certified to international standards, greatly reduce the work required for planning, assembly, installation, and maintenance.
How you benefit from the MX-System:
- exact scalability for individual sheet metal working requirements
- modular and highly flexible design to save on installation space
- extensive diagnostics integrated into each module for high machine availability
- minimal downtime due to hot-swap functionality
- IP67 protection rating for demanding environmental conditions
- reduced work for engineering, installation, commissioning, and maintenance
Low-maintenance, energy-efficient, and precise
Hydraulic drive technology impresses with high dynamics in a small installation space, but is associated with higher maintenance and lower efficiency. Servo-hydraulic axes are available as an alternative. These combine the advantages of hydraulics with the strengths of electric drive technology: They are low-maintenance, energy-efficient, and precise. They are perfectly complemented by our servo drive technology with its current controller cycle time of just 16 μs. EtherCAT P eliminates the need for a separate encoder cable, saving space and reducing cabling work. Short cycle times with high precision are made possible by our adaptive parameter switching, which ensures a smooth transition between different feed constants. Another advantage is that all common hybrid axis concepts can be configured with minimal programming effort via the TwinCAT Hydraulic library.
How you benefit from servo drives for hybrid axes:
- low maintenance, high energy efficiency
- reduced cabling work due to EtherCAT P
- short machine cycle times with maximum accuracy
- optional state monitoring for pumps and energy consumption
Software library for hydraulic bending machines
Bending machines are key stations in the sheet metal working process. With TwinCAT Hydraulic Positioning, Beckhoff offers you its own software library for the development and implementation of hydraulic drive concepts. Manufacturer-independent architecture allows you to remain flexible in your choice of hydraulic components. The software-based solution allows precise motion control with maximum adaptability. There is no need for hardware controllers – the motion controller is integrated into the PLC and contains all functions for valve- or pump-controlled axes and servo pumps. Optimum operation is ensured by setpoint generators, automatic characteristic curve identification, segmented movements, and freely programmable switching between force, pressure, and position control.
How you benefit from TwinCAT Hydraulic Positioning:
- complete PLC library for controlling hydraulic axes
- open for all hydraulic components and axis control concepts
- no additional controllers, reduced effort due to PLCopen interfaces
- hydraulic axes can also be operated in interpolating mode in connection with TwinCAT NC I or TwinCAT CNC
Operation, control, and monitoring directly on the machine
With Beckhoff Panel PCs, you can add a custom-designed operator interface to your sheet metal working machines. To achieve this, we combine powerful industrial PCs with the multi-touch technology of an advanced control panel. In its attractive, high-quality housing, the device becomes the central operating and control element on the machine. The portfolio includes panel PCs in a wide range of sizes and formats – in either built-in or portable versions. Good to know: Beckhoff also offers CNC control panels – with a special CNC function design. In addition to further options, such as special equipment with operating elements or visual adaptations in corporate designs, entirely customized designs can also be accommodated.
How you benefit from Beckhoff Panel PCs:
- advanced multi-touch technology for industrial requirements
- integrated, power-scalable industrial PC
- extensive portfolio with various standard options
- options for individual adaptations
- entirely customized designs available on request
The latest generation of machine vision
In sheet metal working, machine vision is essential when it comes to process monitoring and quality inspection. With Beckhoff Vision, you can quickly and easily integrate high-performance real-time image processing into your control environment, regardless of whether the system is new or established. As a complete solution comprising hardware and software, Beckhoff Vision can be perfectly synchronized with all machine and system processes. The deep system integration that this enables overcomes the historical division between vision and automation technology. At the same time, our Vision components impress with their robust, attractive design, as well as high scalability and long-term availability.
How you benefit from Vision integration in EtherCAT:
- direct synchronization and linking with control processes
- simplified and synchronized trigger generation for image capture and exposure
- shortened response times, higher cycle rates, and accelerated processing
- reduced hardware, wiring, waiting time, installation space, and footprint
- simplified diagnostics
Beckhoff solutions specifically for your applications
High performance for the entire press line
Whether a hydraulic deep drawing press or servo-electric transfer press – Beckhoff’s modular and scalable control technology enables you to automate all press types. Powerful industrial PCs in combination with our EtherCAT fieldbus technology ensure high-performance and highly dynamic processes. Our solutions capture signals in real time and transmit control commands immediately. With fully automated transfer presses or complete press lines, this pays off in terms of a clear increase in productivity.
There are also other advantages: For example, specially optimized gear couplings and pre-controlled pressure regulators are available for the deep drawing process. Combined with PC-based control technology and cycle times of less than 250 µs, short synchronization paths are achieved – even at very high speeds of the upper tool. Our portfolio also covers all control requirements: with I/O systems for all common fieldbuses, TwinCAT automation software for PLC and motion control, a comprehensive range of drive technology components, and the integrated TwinSAFE safety solution.
Precision controllers for laser welding and cutting machines
CNC controllers from Beckhoff are world leaders when it comes to the highly precise cutting and welding of sheet metal – whether in oxy-fuel, plasma, laser, or water jet processing. Two factors are decisive for this competitive strength: the control speed and the scope of the CNC functions. Our technology is impressive in both disciplines. Firstly, EtherCAT ensures high-performance control with cycle times of less than one millisecond. This means that even the fastest cutting and welding processes can be precisely controlled. Secondly, TwinCAT is an integrated component of our control platform that covers the entire range of functions for your CNC requirements with the TwinCAT NC I and TwinCAT CNC software libraries.
Our controller is complemented by a well thought-out product portfolio. It includes compact C60xx series Industrial PCs, which have powerful processors to meet the complex requirements of sheet metal working. All components are designed to be compact. This reduces the space required in the control cabinet; in many cases, the MX-System can replace the cabinet altogether – for an even leaner machine design and the sheet metal working of the future.
PC-based control technology from Beckhoff is perfect for the challenges of punching and nibbling. Highly dynamic axis movements can be realized just as easily as fast control functions. Precisely programmable strokes, automatic tool changes, and the ability to change programs or machine settings even during operation ensure consistently high levels of productivity. Key to this are TwinCAT motion control and the TwinCAT NC I and CNC software libraries.
TwinCAT controls the movements of all servo axes and automatically adjusts the processing parameters to the sheet thickness. Thanks to precisely programmable strokes, even special shapes can be quickly punched into the sheet metal. The combination of powerful industrial PCs and EtherCAT communication enables stroke rates of over 2,000 strokes per minute. Go one step further with our eXtreme Fast Control Technology (XFC). This shortens the cycle times for data transfer to less than 100 µs. The advantage? Information from press force monitoring or tool fastening is recorded almost simultaneously by all sensors and sent to the central controller.
Individual folding and bending processes – efficiently optimized
The challenges of folding and bending sheet metal are as varied as your machines and systems. Whether round, pipe, swivel, or die bending machines – our PC-based and open control technology provides you with all the system modules you need for automation. The various function modules can be used in combination or individually. For bending, for example, we provide you with a choice of tailored technology solutions for the press beam or back gauges.
We also offer you ready-made algorithms for calculating the insertion depth and for the exact positioning of the back gauges. Collisions during the folding process are reliably avoided due to the automatic calculation of the bending order. TwinCAT automation software has open interfaces so that you can easily implement individual adaptations and extensions and add your own algorithms at any time. In addition, the entire range of Beckhoff EtherCAT I/O modules and our scalable industrial PCs are available to you. Additional functions such as suitable safety technology or solutions for energy acquisition and condition monitoring round off the portfolio.
Punching and nibbling
The Beckhoff CNC solution enables highly dynamic axis movements in punching and nibbling.
Bending
PC-based control from Beckhoff provides the ideal platform to automate folding and bending processes.
Applications and information
Application reportClosed profile rings – the advantage of the fourth bending roller
Closed profile rings – the advantage of the fourth bending roller
Moser-Baer AG, Switzerland
Moser-Baer AG in Switzerland is streamlining the production process for its world-famous railroad clocks with a new type of profile bending machine: With four bending rollers instead of the usual three, the Mobamatic MPB23 profile bending machine, with the mechanical platform developed and built by Moser-Baer, can bend a wide variety of profiles without straight end pieces. The automation specialist Pneutronic AG implemented the complete drive and control technology. PC-based control and the AX8000 multi-axis servo system with TwinSAFE ensure a compact design, precision, and safe operation without safety guards and laser scanners.
Multimedia
EuroBLECH 2024: Beckhoff Trade Show TV
In this Beckhoff Trade Show TV from EuroBLECH 2024, we will show where PC-based control from Beckhoff is used in sheet metal working, in particular on the machine from Baykal Machinery. We also show, how the MX-System can reduce the footprint of machines and systems.
Multimedia
Automating laser machinery with PC-based control
Laser ISSE, a Turkish company, relies on Beckhoff for its custom laser machines. Mustafa Özdemir, control system engineer at Laser ISSE, tells us which industries the machines are used in and which Beckhoff products are installed in them in this video.
Application reportScalable for the future with fully integrated, open control technology
Scalable for the future with fully integrated, open control technology
Cincinnati Incorporated, United States
Cincinnati Incorporated (CI) has been building sheet metal processing equipment for 125 years and continues to support its durable machines for decades. The company is able to do this because it develops everything in-house, from the hardware to the software. However, the further development of proprietary control technology became too costly and challenging to support. Since the switch to PC-based control, the only limits to development have been physical, according to the engineers at CI.
Multimedia
Industrial welding automated by Beckhoff
Clifford Machines & Technology develops and markets industrial welding, grating, and wire working equipment. We asked Lance Deysel, Managing Director, which Beckhoff products they use in their machinery and why they opted for them.
Application reportHigh die casting quality through optimum control of vacuum generation
High die casting quality through optimum control of vacuum generation
AJYa Vacuum Technology, China
In die casting, vacuum generation in the shot chamber and mold cavity helps to avoid air and gas inclusions in the castings, as these would impair the stability of the finished parts. For this purpose, AJYa Vacuum Technology from China developed a complex but particularly effective multi-stage solution. A suitable control platform was implemented in cooperation with the automation partner Beckhoff.