Future-proof control platform

Constant cost pressure and further developments in solar module technology pose major challenges for photovoltaic production. In mechanical engineering, there is a constant need to integrate new technology in order to increase plant efficiency. As an open and scalable control platform, PC-based control is therefore ideal for the photovoltaic industry: a large number of interfaces in software and hardware provide simple functional enhancements. At the same time, Beckhoff's broad portfolio of scalable industrial PCs, EtherCAT Terminals, and drive technology means that customized solutions are available for every automation task, whatever the price range, performance level, and design specification.

The integration of TwinCAT automation software, coupled with the high performance of advanced processors and the high-speed EtherCAT fieldbus, make PC-based control a powerful control platform capable of meeting both current and future production requirements.

EtherCAT: The global standard for machinery in photovoltaic production

EtherCAT forms the foundation for virtually all cutting-edge photovoltaic machines today. With cycle times well below 1 ms, outstanding synchronization precision, extensive diagnostics, and simple configuration, EtherCAT is ideal for mechanical engineering in the photovoltaic industry and has established itself here as a communication standard. The real-time fieldbus handles all communication and is an I/O, safety, and drive bus system in one. EtherCAT's high speed results in a higher cycle time while simultaneously increasing the accuracy of the processes.

Primary benefits of EtherCAT:

• extremely fast cycle times for precise and efficient processes
• perfect synchronization of all plant processes
• wide selection of EtherCAT-compatible sensors and actuators on the market
• reduced cabling work thanks to the EtherCAT P one cable solution
• maximum performance at speeds of 1 Gbit/s or 10 Gbit/s with EtherCAT G

Modular automation software TwinCAT

TwinCAT 3 automation software integrates all engineering and runtime processes and features a consistent development environment for implementing all control tasks in the photovoltaic industry. Programming is carried out using the most appropriate method for the application, including IEC 61131-3, high-level languages such as C/C++, MATLAB^®, and Simulink^®. Microsoft Visual Studio is used as the standard programming workbench since it not only supports version management, but also simplifies teamwork. Ready-made software blocks facilitate engineering and shorten development and commissioning times.

TwinCAT benefits include:

• virtual commissioning with TwinCAT 3 Interface for Inventor^®
• accelerated diagnosis and maintenance with TwinCAT Scope
• libraries for motion control and supplements for robot kinematics
• PLC function blocks for monitoring and controlling temperature-dependent processes
• web-based visualization via TwinCAT 3 HMI
• simplified implementation of functional safety with TwinSAFE
• cloud communication in common protocols with TwinCAT IoT

XFC boosts the performance of your machine

Processing solar cells is a dynamic process. Many processing operations on the cells take place on the fly without stopping. It is therefore crucially important that the exact position of the solar cells being processed is known before and during processing. The processing machines can thus be switched on and off accurately without damaging the solar cell. TwinCAT automation software and the high-speed EtherCAT fieldbus are the basic function blocks for this. Cycle times in the lower millisecond or sub-millisecond range give fast reaction and response times.

Nevertheless, these times cannot be eliminated completely. The XFC (eXtreme Fast Control) technology helps out here with its distributed clocks (DC) functionality: XFC provides the machine with a nanosecond-precise system time. All signals from the field and calculations within the controller are referenced to this time. On this basis, the time for controlling the machine can be calculated with high precision and sent to an EtherCAT output terminal together with the actual signal information. PLC and fieldbus-related delays, which are always bound to occur, can thus be compensated almost completely in this application.

Modular industrial PCs for the DIN rail

With the CX Embedded PC series, Beckhoff combines PC technology with the modular I/O level on the DIN rail in the control cabinet. By adding individual modules and interfaces, only the components required for the respective application are installed. The embedded PCs thus open up a wide range of applications – from solar wafers to solar module production.

High-performance control PCs with multi-core processor technology are available: the CX5100 and CX5200. The devices in this performance class are suitable, for example, for controlling machines for anti-reflection coating. The CX20x2 device series consists of high-end controllers for demanding applications, such as integrating image processing, implementing machine learning, or aggregating large amounts of data.

C60xx: Extremely space-saving and flexibly expandable

With the C60xx Industrial PC series, Beckhoff meets all requirements in photovoltaic production with regard to sturdiness, performance, and scalability of the control components used. The ultra-compact industrial PCs combine maximum computing power in what is currently our most compact format, with a wide range of options for installation in the control cabinet. Modern processors offer maximum scalability and the highest power density at an optimal price/performance ratio.

The advantages of highly scalable industrial PCs at a glance:

• flexible: the right industrial PC in terms of design and performance
• long-term availability: a fine balance between the latest PC technologies and the long-term availability of components
• powerful: various processor architectures cover all performance classes
• additional performance optimization: individually adapt the performance of individual CPU cores with TwinCAT Core Boost

EtherCAT I/Os integrate all functions

With around 1000 I/Os for more than 100 signal types, Beckhoff’s modular automation toolkit is well equipped to cater to a whole host of requirements. A wide range of housing units, variable channel densities, and flexible interfaces make it possible to automate any functionality in photovoltaic machines and their peripherals. In addition to standard functions, our I/O portfolio includes products for specialist applications, such as safety technology, measurement technology, and controlling small drive technology motors.

The I/O portfolio includes:

• EL3318 for detecting temperatures using thermocouples: The 8-channel input terminal with integrated cold junction compensation is very compact in terms of design and measures temperatures with high accuracy and high signal-to-noise ratio.
• EL3403 3-phase power measurement terminal for monitoring the energy consumption in a continuous furnace: In combination with TwinCAT 3, the EL3403 is used for cost-effective monitoring of the fire zones in the continuous furnace.
• EL6910 TwinSAFE Logic for integrating the safety technology into the controller: Due to its scalability, this Beckhoff safety solution is suitable for sophisticated machines as well as for use in smaller solar wafer and cell handling machines.

Precise drive solutions for the photovoltaic industry

The photovoltaic industry requires a high degree of precision: All steps in solar wafer and cell production, in laminating solar modules, and in the various handling processes must be carried out with high precision. Any deviation comes at the expense of quality and leads to complex post-processing or even to scrap, with a negative effect on the yield.

With our unparalleled range of technologies in the world of electric drives, we offer our customers a clear technological edge over the competition, whether it’s multi-axis servo systems with synchronous servomotors, highly dynamic linear servomotors, compact electric cylinders, tubular motors, or compact drives for the low-voltage range – we provide high-precision drive technology for every application.

Advantages of scalable drive technology at a glance:

• many drive technologies, one system: combine and precisely synchronize a wide variety of drive and handling technologies to suit your needs
• One Cable Technology: combines the power and feedback system in a single standard motor cable, saving installation space and time
• safety included: TwinSAFE safe automation technology is available for all Beckhoff drive solutions

Software for highly dynamic motion control

TwinCAT Motion offers scalable software packages for motion control for photovoltaic production processes. Extensive possibilities are available for controlling uncoordinated and coordinated movement of a large variety of electrical axes. Drive systems and technologies that are very different in terms of their behavior and properties can also be controlled: these include stepper motors or small servomotors for transporting solar wafers and/or cells as well as highly dynamic servo drives for diamond wire saws. The new generation of motion control with TwinCAT MC3 expands the features of TwinCAT NC2 to include a whole host of capabilities, including multi-core and multi-tasking, and thus opens up further potential in terms of efficiency and speed.

TwinCAT offers corresponding blocks for axis control:

• TwinCAT 3 NC PTP (basic package for motion control functions)
• TwinCAT 3 CAM Design Tool and NC Camming (cam plate design and runtime libraries)
• TwinCAT 3 NC Flying Saw (accurate synchronization with the master axis from any dynamic phase)
• TwinCAT 3 NC-I (interpolation of up to 3 main and 5 auxiliary axes per channel)