- December 03, 2015
- Beckhoff Automation
December 3, 2015 - Beckhoff Automation Introduces TwinCAT Analytics software that includes online and offline condition analysis, predictive maintenance, pattern recognition, machine optimization and long-term data archival.
Processing errors in machines frequently create excessive costs and lost production time. The situation becomes all the more serious if there is a lack of machine data and production parameters in order to analyze processing errors and avoid such errors in the future. The 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 standardized 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.
TwinCAT Analytics provides a complete temporal image of the manufacturing 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 advanced functions. The recorded process and production data can be analyzed 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 irregularities and repetitions in the recorded data further improves the reliability of the process sequence.
In addition to optimum support for error analysis, TwinCAT Analytics offers numerous opportunities to further machine optimization. The status analysis provides all the information required for optimizing the machine or system in terms of energy consumption or process sequence. In addition, detailed knowledge of all processes simplifies configuration of drives, for example, and it may be possible to reduce the connected load of machines based on thorough measurement readings. This future-oriented software tool serves an increasing demand for highly flexible production down to lot size 1. In this case, TwinCAT Analytics can provide comprehensive production documentation for each individual workpiece.
TwinCAT Analytics consists of four main software components:
- 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.
- The TwinCAT Analytics workbench serves as an engineering tool for online and offline analyses of one or more machines. It includes the PLC runtime, the Analytics configurator, the TwinCAT Analytics PLC library, a Scope View Professional license and interfaces with TwinCAT IoT for communication via the standardized MQTT protocol.
- As a PLC library for application in the Analytics workbench, the TwinCAT Analytics library contains numerous function blocks, enabling functionality such as cycle analysis, energy demand or RMS calculations, among others.
- TwinCAT Analytics cloud storage can house data and make it available in private or public networks via a “message broker.”
Beckhoff Automation is a provider of advanced and open automation solutions based upon proven technologies for customers to implement high performance control systems faster and at a lower overall cost than traditional PLC and motion control systems. Beckhoff’s “New Automation Technology” product range includes PC-based control, industrial PCs, automation controllers, operator interfaces, I/O, servo drives and motors. With representation in more than 60 countries, Beckhoff is well-positioned to provide global sales and service to its customers. Beckhoff sales and service are handled directly, with no intermediaries involved for exceptional customer service and consultation.