Innovation thrives where creativity and machine design come together – be it the simple linear motion of a carriage mover or an intelligent transport system within an Industry 4.0 application. The eXtended Transport System (XTS) from Beckhoff opens up new solutions for compact, highly dynamic machine concepts. Even motion tasks that are nearly impossible to solve with mechanical engineering can be conveniently and flexibly realised via software.
Even for simple linear movements, XTS offers numerous advantages, thanks to its dynamic movement possibilities in combination with the replacement of mechanical functions through software. It easily deals with the tasks carried out by a conventional linear motor with a movable carriage.
An example of how the ability to implement highly dynamic movements can be increased with minimal mechanical effort is the functionality of an XY table. The carriage mover is simply equipped with a conventional linear bearing and supplemented by a second mover with a linear guide that is turned by 45°. The required motion in the X direction can now be realised with jointly and similarly moving movers. The motion of the movers relative to each other creates the required Y motion via the two linear guides. In this way it is possible to realise any movement, including the circular movements required for applying adhesives.
The transport system is ready for use immediately after installation. Since power electronics and displacement measurement are included in the XTS motor modules, and the movers are completely passive, the measuring system does not have to be calibrated and the drag chains needed for conventional XY tables are no longer required. The result is a compact, durable and highly dynamic XY system. XYZ movements can be realised in a similar way with additional movers and corresponding kinematics.
Rotary transfer machines are one of the many application possibilities of a circular XTS system. Currently available motor modules can be used to implement a full circle. Furthermore, the motor modules can deliver their impressive dynamics with forces up to 100 N. The range of XTS applications can be further extended with special guide rails for high temperatures, aggressive agents or heavy contaminants.
Other ways to increase functionality in the quest to solve challenging machine tasks include combining several transport systems, whereby the installation position of each XTS can be freely selected. Additional features include automatic reversal of movers for collision and jerk avoidance and mutual synchronisation for holding or shaking processes in packaging applications. This and other application-specific movement functions can be easily implemented with TwinCAT using ready-made motion modules, resulting in a high degree of engineering efficiency.
For applications requiring even more complex machining operations, XTS can be seamlessly integrated with robotics. Beckhoff’s TwinCAT Kinematic Transformation offers levels up to Level 4 with serial 6-axis kinematics, hexapod and 5D kinematics. Using the mxAutomation library, commands can be sent directly from the PLC to a Kuka robot equipped with the KR C4 control system. The system benefits from the highly scalable computing power of Beckhoff industrial PCs, which can process XTS movements as well as robot kinematics on one CPU. This simplifies program handling and synchronisation of sub-processes.
Offering high innovation potential, XTS makes production processes more efficient and flexible, and for Industry 4.0 it is ideal as a modern machine element. In a traditional packaging or assembly process, the product is moved by a transport system and has to be repeatedly recognised, gripped and analysed. In contrast XTS enables the product to be picked up once only and then transported through the entire process with the same mover. Accordingly, the control program always knows where the product is and in what state.
Hence the ’intelligent and self-organising product’ defined by Industry 4.0 as a vision of the future can essentially be implemented today. It is easy to carry through or track and document the current process steps, quality data and error messages. This information can be used directly in the production process. If for example an error occurs in the sterilisation of food packaging, the affected pack, which is uniquely defined via the mover, can be taken through the entire process without printing or filling. At the end, the empty pack is simply discarded as a reject, without wasting additional material or filling content.
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For more information contact Kenneth McPherson, Beckhoff Automation, +27 (0)11 795 2898, [email protected], www.beckhoff.co.za
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