The control system for process automation

Beckhoff calls on a comprehensive modular range of components and deep-rooted, cross-sector expertise to create open automation systems using PC-based control technology. All control functions, such as PLC, visualization, cloud connection, safety technology, and measurement technology, are integrated on a universal platform.

System-integrated solutions from Beckhoff offer an efficient alternative to traditional suppliers and are suitable for use in numerous markets, including oil and gas production, chemicals and petrochemicals, the hydrogen industry, metal processing, or the water and energy industries.

PC-based control for the process industry:

• universal platform for the automation of all processes and plants
• integration of all control functions in one system
• high interoperability thanks to open interfaces in hardware and software
• control and cable redundancy for increased plant availability
• established worldwide across all industries

EtherCAT Terminals integrate all control functions

Beckhoff uses the principle of PC-based control technology to combine a range of I/O components in a single system. For example, EtherCAT Terminals used for integrating functional safety can be freely combined with EtherCAT measurement terminals and with I/O modules featuring an integrated safety barrier for connecting intrinsically safe field devices from the hazardous area. These elements can then be integrated into a holistic control system. This means that plant operators have an efficient complete solution at their disposal for all application-related requirements.

Flexible plant design with PC-based control:

• integration of all I/O components into a single system
• combination of safety, measurement technology, and explosion protection
• openness toward third-party systems
• high interoperability to simplify retrofits
• system openness for investment protection

Ideal for the process industry: The open EtherCAT fieldbus

As a universal and open high-speed fieldbus, EtherCAT is suitable for all areas of application – from PLC and drive technology to sensors and measurement and safety technology. With EtherCAT, you only need one communication technology for your entire plant and can also benefit from the safety and optimum performance of the comprehensive EtherCAT architecture. The EtherCAT-based control is also open with regard to integrating third-party EtherCAT devices and other fieldbus systems.

With its extended distance technology, EtherCAT simplifies data acquisition across expansive areas by allowing communication over distances of up to 300 m. For example, the EK1101-0010 EtherCAT Coupler, to which standard EtherCAT terminal blocks can be connected, is used. For greater distances, fiber optic solutions with a transmission length of up to 100 km are available. EtherCAT cable redundancy is used to set up a fault-tolerant ring topology to ensure that the network or network segments of a plant are always accessible. Moreover, the EtherCAT diagnostic concept enables integrated, complete, and fast error identification.

TwinCAT: The control platform for the process industry

With its TwinCAT automation software, Beckhoff offers a central platform for controlling process machines and plants. In addition to classic process control in the PLC program, algorithms written in C++ or MATLAB^®/Simulink^® can also be executed in real time. The scope of application of PC-based control for process automation is extended with the comprehensive integration of specific process technology protocols and interfaces. By supporting common standards such as NAMUR, HART, and FDT/DTM, TwinCAT covers the application areas of process engineering applications.

TwinCAT highlights for the process industry:

• control-integrated Industry 4.0 and IoT applications
• comprehensive data evaluation with analytics functions
• standardized communication via OPC UA
• support for common standards such as NAMUR, HART, and FDT/DTM
• execution of MATLAB®/Simulink® models

Integrated controller redundancy increases plant availability

With plant availability playing such a crucial role in the process industry, measures to increase this include using redundant architectures to safeguard against failures of individual control components. For redundant control operation, TwinCAT Controller Redundancy is available.

This system-integrated software solution allows two standard industrial PCs to be operated as redundant controllers that both run the same PLC program. An additional, high-performance network connection between the two controls provides the necessary data synchronization, and the fact that standard Ethernet is used means no dedicated hardware components are required. This ensures that only one of the two industrial PCs addresses the fieldbus components at any given time and that the control programs are executed on both computers with the same database. If one control fails, the second control seamlessly takes over, preventing plant downtime and data loss.

Intrinsically safe signal acquisition in IP20 and IP67

Beckhoff’s ELX and EPX EtherCAT modules combine highly compact I/O modules with safety barriers for the direct connection of intrinsically safe field devices from zone 0/20 and 1/21. This results in extremely compact EtherCAT I/Os for the direct connection of intrinsically safe sensors and actuators. With certification according to ATEX, IECEx, and NEC/CEC, as well as other country-specific standards and directives, EtherCAT I/Os can be used in virtually all markets worldwide.

Beckhoff meets the requirements with regard to functional safety with the full integration of safety technology into the automation system. The ELX terminals extended with TwinSAFE-SC thus enable the direct connection of intrinsically safe field devices up to zone 0/20 for safety-related functions.

The EPX modules in the EPX series with protection rating IP67 are suitable for the implementation of modular and control cabinet-free plant concepts. The robust EPX modules can be mounted directly on the plant and facilitate reliable data acquisition in hazardous areas where control cabinets cannot – or should not – be installed.

EtherCAT modules with intrinsically safe interfaces for Ex applications:

• direct connection of intrinsically safe field devices
• highly compact design
• IP67 modules for control cabinet-free plant concepts
• a wide range of high-resolution, accurate signals
• extensive portfolio of certificates for worldwide use

Elegant Ex panels: The CPX series in a robust aluminum design

With the CPX panel models, the tried-and-tested multi-touch technology of Beckhoff Control Panels and Panel PCs is available in a particularly robust design and meets the requirements for use in zone 2/22 hazardous areas. The exceptional functionality and high-quality workmanship ensure that the CPX panels are long-lasting pieces of equipment, even in harsh environmental conditions. At the same time, the aesthetic appeal provided by the feel and design of the aluminum housing remains unchanged – making our panels a visual highlight in the explosion-proof plant environment. The comprehensive CPX portfolio offers a wide choice of formats, sizes, mounting options, and performance features. The fanless panel PCs also offer reliable plant control.

Multi-touch for the process industry:

• capacitive touch technology for optimized operation
• high-quality design
• robust and durable
• flexible mounting
• up to 100 m distance between Ex panel and industrial PC with CP-Link 4

Module automation with TwinCAT MTP

The modularity of process plants is standardized by the Module Type Package (MTP). MTP describes individual modules based on various aspects, including their interfaces and the executable services. The information about the module is stored in an MTP file, which is imported into a higher-level control. This enables efficient commissioning and linking of modules from different manufacturers. The integration of the MTP concept into TwinCAT simplifies the guideline-compliant automation of a plant module through automatically generated source code and libraries for PLC programming.

The advantages of TwinCAT MTP:

• automatic generation and export of the MTP
• high degree of customization for optimum adaptation to existing processes
• guideline-compliant IEC 61131 function block library
• seamless integration into TwinCAT Engineering
• can be combined with TwinCAT XCAD interface

Flexible implementation of NOA concepts

NAMUR Open Architecture (NOA) is designed to make operating data easily and securely available for plant and equipment monitoring and possible optimization without affecting existing automation systems.

Beckhoff has developed an NOA edge device for reading out the additional data for the higher-level M+O (monitoring and optimization). The edge device, which consists of a compact embedded PC, EtherCAT Terminals with HART functionality, and the relevant TwinCAT project, can be placed directly in the plant.

Depending on the application, the installation of additional sensors for condition monitoring is also useful in the field level. For example, the IP67-protected EtherCAT Box modules are used here, which can be installed directly in the field and therefore do not require any space in the control cabinet.

Connection of Ethernet-APL field devices to the modular I/O system

The rise of digitalization, especially in the areas of plant diagnostics and monitoring, is currently one of the major topics in the process industry. Processing plants are generally very widespread and have particular requirements that are met by the specially developed standard Ethernet-APL, which offers a transmission rate of 10 Mbit/s and a cable length of up to 1000 meters.

Beckhoff integrates the Ethernet-APL technology into the modular terminal portfolio. The compact ELX6233 can be mounted in the control cabinet in combination with other EtherCAT Terminals. Two Ethernet-APL field devices can be connected via each ELX6233 terminal. As with all EtherCAT Terminals in the ELX series, the ELX6233 enables the direct connection of intrinsically safe field devices from zone 0.