Twincat Plc Programming

[Brittany Bhadd]

TwinCATtransforms almost any PC-based system into a real-time control complete with multiple PLC, NC, CNC, and/or robotics runtime systems. The possibility of modular extensions means functional changes and additions can be made at any time. If required, the openness of the control system allows not only the integration of third-party components, but also customized retrofit solutions for existing machines and systems. This ensures flexibility and investment protection for the customer.

With TwinCAT 3, the latest version of the software, the Beckhoff portfolio results in optimally coordinated automation concepts that fulfill the basic principles of an open and highly scalable control system.

TwinCAT 3 follows on logically from TwinCAT 2 as the latest development in the series, which is already redefining the world of automation technology as we know it. The way the complete control intelligence is implemented on a single software platform, divided into engineering and runtime, still represents the basis of the system.

TwinCAT XAE (eXtended Automation Engineering) allows hardware to be programmed and configured in a single engineering tool. In addition to the IEC 61131-3 programming languages, C/C++, MATLAB and Simulink are also available for programming. The tool even offers integrated debugging options for the program code and diagnostic functionalities for the control hardware. Functions are available to flexibly extend the basic engineering to include additional functionalities such as a software oscilloscope.

TwinCAT XAR (eXtended Automation Runtime) is a real-time-capable runtime in which the program code can be executed to control the field level of the machine. The modular architecture makes it possible to install and load extensions on an application-specific basis in the form of functions. In addition to the actual real time, which is executed independently of the operating system, an operating system always runs on the PC-based controls, which also enables other programs to be executed. This means the control platform can also be used for tasks such as visualizing or executing customer-specific software.

TwinCAT is a modular system that can be put together on a project-specific basis to suit individual requirements. In addition to the actual engineering and control system itself, this modularity is mapped via over 100 Functions, which are assigned to different subject areas.

The TwinCAT Functions extend the basic system in areas such as motion and safety individually depending on the application. Measurement or, for example, a TwinCAT HMI-based user interface are modules that interact seamlessly with the actual machine control via a uniform interface. When it comes to supporting additional communication protocols such as OPC UA, users can simply install the corresponding module at a later stage as required. Even the latest Functions, such as those from the fields of machine learning or vision, can be retrofitted to existing systems in the same way.

TwinCAT 3 HMI enables the development of platform-independent user interfaces based on current web technologies (HTML5, JavaScript/TypeScript). These act responsively and automatically adapt to the resolution, size, and orientation. The engineering of the TwinCAT HMI integrates into the familiar TwinCAT development environment and offers a graphical What-You-See-Is-What-You-Get (WYSIWYG) editor.

TwinCAT 3 Controller: Control technology tasks can also be handled with ease using products in the TwinCAT 3 modular system. In addition, a product for voice input and output is available in the form of the TF4500.

TwinCAT 3 Motion Control includes scalable software packages for motion control. It includes modules ranging from a simple PTP (point-to-point) application to robotics and sophisticated CNC applications. An abstraction layer to the hardware enables exceptionally flexible control of a wide range of drive devices.

TwinCAT 3 Connectivity: One of the great advantages of TwinCAT 3 is the wide range of options for interaction and communication with other systems. Numerous Functions are available for addressing different communication scenarios and implementing protocol functions.

TwinCAT 3 Vision offers an open and scalable image processing solution that is fully integrated into the universal TwinCAT 3 automation platform. As the configuration of the cameras and the programming of the image analysis take place in the familiar TwinCAT environment, the engineering is simplified.

In addition to the basic principle of simplification, which applies to TwinCAT 3 from the engineering process and runtime to transparent cost representation, the automation software also offers a whole host of other outstanding features:

Efficient project planning: The modular architecture of TwinCAT facilitates the reuse and maintenance of software components. Reusable structured program code can be generated on the basis of object-oriented programming. Communication between modules is also easy to implement via a standardized data exchange, so that the modules can be flexibly combined with each other in the IEC 61131-3 programming languages, C++, MATLAB and Simulink.

Free choice of interfaces: TwinCAT 3 provides a wide range of interfaces, which facilitates a connection to the IT world from databases to cloud systems via OPC UA and other protocols. The existing protocols can be extended with customer-specific adaptations. Beckhoff also supports all common fieldbus systems, which allows it to react flexibly to requirements in the fieldbus area.

Fair pricing: TwinCAT 3 Engineering is available free of charge with basic functionality. The TwinCAT Runtime environment used to execute the control code can also be trialed on a renewable 7-day license. For permanent operation, a license model applies depending on the performance of the hardware used. In terms of support, this is available free of charge to all customers worldwide.

Sound investment: TwinCAT 3 has been available on the market since 2010, and the software is constantly being further developed with innovative technologies such as image processing and machine learning. Projects created in the previous version can still be migrated today using a converter. This ensures that the expertise from older projects can continue to be exploited in new versions and expanded with the latest functionalities.

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Here I will give some background information to PLCs and TwinCAT 3, and describe the difference between the development environment and the runtime. We will also download and install the TwinCAT 3 development environment (XAE) so that we have everything up and set for our first program.

In this video we will look into the various data types that are available in the IEC 61131-3 standard, pointers & references and how to work with arrays. We will cover why pointers can be dangerous and why you generally want to prefer to use references instead. Then we will finish the course by looking at how we can convert between different data types.

Arrays allow us to define types of variables that can hold several data items of the same kind. In this part of the course we will look at a data unit type that allows us to hold several data items of different kind. We will also look at one of the basis of modularization and re-use in software development called functions. We will look at how we can get data in and out of functions, and we will also look at the difference between passing parameters by value and by reference. We will finish this part by writing our very first function!

Here we will cover if/else, case-switches, for/while-loops and some other basic instructions. We will utilize our knowledge to write a CSV (comma separate value) event logger by using a state machine.

As TwinCAT 3 conforms to the IEC61131-3 standard, there are certain things it has to be able to do. The Tc2_Standard library has many of the standard IEC functions such as timers and triggers, which we will look into in this chapter.

When designing and building a control system you will eventually want the control system to actuate something, be it a relay, a mixer, a boiler or maybe a pneumatic system. To get feedback of the actuation, sensors are needed. In this part we will cover how we communicate with the environment using inputs and outputs.

Once the complexity of your software gets to a certain level it might be a good idea to start to think about splitting the software into different libraries. This part will go through how this is accomplished and what you need to think of.

When installing the TwinCAT development environment and runtime you get access the core functionality, but sometimes you might want to extend this with additional functionality as for example adding an SQL database connection. In this chapter we will investigate some TwinCAT functions that can be added.

Version control in the world of automation has historically not been the highest priority, but with TwinCAT 3 this is entirely possible using standard version control software. In this part we will go through how we can do proper version control using the Git version control system.

When developing TwinCAT software over time you will most likely end up in a position where you must be able to develop and maintain software for various versions of TwinCAT. This chapter will go through how this is done.

Hi Jacob, I just landed a job that requires me to work extensively on PLCs, specifically TwinCAT3 and for a person who has no background in PLC programming, your videos are a real blessing. Cannot wait for all the upcoming parts.

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