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Automation Technologies 2/2016

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Automation Technologies 2/2016

Recording and analysis

Recording and analysis of process and production data CONTROL AND DRIVE TECHNOLOGY Implementation of Industrie 4.0 and IoT concepts comes with a wide range of requirements, particularly for machine diagnostics, including online and offline condition analysis, predictive maintenance, pattern recognition, machine optimisation or long-term data archival. As a result, seamless and cycle-synchronous data acquisition becomes a pre-requisite for effective analysis and correction of processing errors in the machine. For this reason, Beckhoff has developed the TwinCAT Analytics tool to serve the growing needs of Industrie 4.0 applications. Processing errors in machines generally create excessive cost and lost production time. The situation becomes all the more serious if there is a lack of machine data and production parameters for analysing processing errors and avoiding such errors in the future. The new TwinCAT Analytics tool can be used to rectify this information deficit by storing all process-relevant data in a cycle-synchronous manner. Data is stored in a standardised process data format with data compression, either locally in the controller, in a cloud-based solution on a server in the company network, or in a public cloud, as required. Seamless data logging opens up optimisation potential TwinCAT Analytics provides a complete image of the process and the production data. This offers an ideal information baseline, not only to assist in the event of an error, but also to enable comprehensive condition analysis of the machine, among other functions. The recorded process and production data can be analysed online or offline, and machine cycles can be examined for minimum, maximum and average values of the cycle times. Total runtimes and time differences of production processes can be gleaned from cycle counters or offline trace analyses, e.g. via “post-scope configuration” in TwinCAT Scope View Professional. Further benefits arise for predictive maintenance. Logging of data from operating hour counters, frequency analysis or RMS calculations, for example, enables implementation of high-performance condition monitoring. Moreover, the system facilitates limit value monitoring for different process data. Pattern recognition for detecting regularities and repetitions in the recorded data further improves the reliability of the process sequence. i About Beckhoff Since the foundation of the company in 1980, continuous development of innovative products and solutions using PC-based control technology has been the basis for the success of Beckhoff. Many automation technology standards that are taken for granted today were conceptualised by Beckhoff and successfully introduced to the market. The product range covers Industrial PCs, I/O and Fieldbus Components, Drive Technology and Automation software. The Beckhoff PC Control philosophy and the invention of the Lightbus system, the Bus Terminals and TwinCAT automation software represent milestones in automation technology and have been accepted as high-performance alternatives to traditional control technology. With an annual turnover of € 510 million and over 2,900 employees, Beckhoff posted a healthy 17 % growth in revenue in 2014. Based on comprehensive and cycle-synchronous data recording, the new TwinCAT Analytics solution enables seamless online and offline analysis of machines and production data

In addition to support for error analysis, TwinCAT Analytics offers numerous opportunities to further machine optimisation. The status analysis provides all the information required for optimising the machine or system in terms of energy consumption or process sequence. In addition, detailed knowledge of all processes simplifies the drive configuration and it may be possible to reduce the connected load of machines based on sound measurement readings. This tool serves an increasing demand for highly flexible production down to batch size 1. In this case, TwinCAT Analytics can provide comprehensive production documentation for each individual workpiece. Component-based analysis software TwinCAT Analytics consists of four software components: n The TwinCAT Analytics logger enables cyclic storage of large data quantities, storing the entire process image, including the application data (e.g. from the PLC or NC), following the essence of ‘Big Data’ concepts. n The TwinCAT Analytics workbench serves as an engineering tool for online and offline analysis of one or more machines. It includes the PLC runtime, the new Analytics configurator, the TwinCAT Analytics PLC library, a Scope View Professional licence, and interfaces with TwinCAT IoT for communication via the standardised MQTT protocol. n As a PLC library for application in the Analytics workbench, the TwinCAT Analytics library contains numerous function blocks, enabling benefits such as cycle analysis, energy demand or RMS calculations, among others. n TwinCAT Analytics cloud storage can house data and make it available in private or public networks via a “message broker”. 01 TwinCAT IoT supports standardised protocols for cloud communication and for sending push notifications to smart devices TwinCAT IoT: The fast, standardised route into the cloud The interaction of TwinCAT IoT with TwinCAT Analytics offers further benefits. Setting up a TwinCAT Analytics workbench for central analysis of data from several machines offers maximum flexibility for communication of the corresponding process data through the use of different TwinCAT 3 IoT products. TwinCAT 3 IoT is fast and easy to configure. Together with an Embedded PC or Industrial PC as the IoT controller, the software provides a seamless connection between the Internet of Things (IoT) and the Internet of Services. The extension of conventional control tasks, through applications such as Big Data, pattern recognition or condition and power monitoring in the cloud, results in exciting production efficiency increases. The upgraded software platform offers users a wide range of functions for exchanging process data via standardised communication protocols and accessing special data and communication services of cloud service providers. Corresponding services can be hosted in public cloud systems, such as Microsoft Azure or Amazon Web Services. Photographs: Beckhoff Automation GmbH & Co. KG www.beckhoff.com 02 TwinCAT Analytics provides a variety of application scenarios: Storage and analysis of data directly on the local control, in private networks or in the public cloud. The analytics server can analyse several machines in the factory at once. The machine manufacturer or external analysts can get the data in various file formats or securely retrieve the data from TwinCAT Analytics Cloud Storage in the cloud AUTOMATION TECHNOLOGIES 2/2016

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