Robotic Applications with TwinCAT
Motion Control
Agenda
TwinCAT Kinematic Transformation
 Motivation
 Architecture
 Features
Kinematic Transformation:
Motivation
 Integration of a robot into the complete machine line
 Robot cell is not any longer a black box
Beckhoff: PC-based Automation
Beckhoff PC-based Control: Setting standards for Motion Control!
TwinCAT a modular software system – in Engineering and in Runtime
Beckhoff: PC-based Automation
5
Kinematic Transformation
 Same programming tools for all parts of the machine
 No special robot language
 One CPU can control the complete line
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Kinematic Transformation
The integration of robotic control in TwinCAT offers:
 Saving of an additional CPU for robotic control
 A known and consistent tool for configuration, parameterisation
and diagnosis in one system
 No friction losses because of coaction of different CPUs and PLC,
Motion and Robotic
 Higher performance and accuracy because of direct interfaces,
complex communication between CPUs do not apply
Supported Kinematics
Cartesian Portal
Shear kinematic
2D Parallel kinematic
Roll kinematic (H-Bot)
3D Delta
Crane kinematic
SCARA
5D Kinematics (XYZAB)
Hexapod
(restricted)
6 axes seriell kinematic
(restricted)
TwinCAT Kinematic Transformation
 NEW in TF5111 TwinCAT Kinematic Transformation L2
 NEW in TF5112 TwinCAT Kinematic Transformation L3
TwinCAT Kinematic Transformation
 TF5113 - TwinCAT Kinematic Transformation L4
 extension of TwinCAT Kinematic Transformation L1..L3
 supports kinematics with more than 4 DOF
(degrees of freedom)
 Released!
 Check for export regulations!
Sample: Delta-Robot
Integration in the XAE
 The NC-Task allows to add different kinematic-groups
 Beneath the kinematic-groups you can select different
kinematic-types (e.g. Delta, 2D-Kinematic)
Integration in the XAE
Axes
 Axes of the Machine Co-ordinate System (cartesian) are
integrated as simulation-axes
 Parameterisation and programming in the MCS
 Axes of the Axis Co-ordinate Systems (ACS) are connected
with the I/O
Integration in the XAE
Axes
 Axes of the Machine Co-ordinate System (cartesian) are
integrated as simulation-axes
 Parameterisation and programming in the MCS
 Axes of the Axis Co-ordinate Systems (ACS) are connected
with the I/O
Kinematic-Groups
• Assignment of the axes for the
MCS & ACS
• Description of the kinematic via
XML
Sample: Delta Kinematics
Configuration inside the XAE
PLC Function Blocks for Kinematics
 FB to build the kinematics group
 FB to call the transformation from PLC (option)
Calculation routine of the
Kinematics
 Forward transformation
 Transforms the motor position to cartesian co-ordinate
system
 Automatically used during startup of kinematics group
 Backward transformation
 Used if movement is programmed in cartesian mode
 Calculates the motor position
 Calculation of the dynamic model
for current pre-control
Mode of operation of the
backward transformation
TwinCAT Motion
AX5000
...
Cartesian
Set-Point
Generator
Motor 2
Motor 1
Additional torque command
Pos
Velo
Acc
X, Y, Z... X, Y, Z... X, Y, Z...
Kinematic
Transformation
(Backward)
& Dynamic Modell
Torque M1
Position
Control Unit
Pos M1
-
-
Velocity
Control Unit
Torque M2
Pos M2
-
Current
Control Unit
Actual current
Actual velocity
Actual position
U
Drive
Drive
Drive
EtherCAT
uniVAL
Interaction with uniVAL-System
Interaction with uniVAL-System
https://www.youtube.com/watch?v=fK3ZQJwQDqM
TwinCAT Kinematic Transformation
 Direct robot control with TwinCAT
Kinematic Transformation TF511x
 substitues external robot controller
 Controlling KR C4 from Kuka with
mxAutomation
 PLC library enables controlling
the robot directly from TwinCAT
PLC
Live on Beckhoff booth
Live on ETG
booth
Drives
Layer
Fieldbus
Layer
Soft Motion
Layer
Soft SPS
Layer
Abstraction Layer
+
PLC
SP
Pos Ctrl
Velo Preset
Pos Meas.
Limit
+
+
Scale & Limit
Example: Manual Mode
 Axes can operate in the Cartesian Mode (MCS) or
Direct Mode (ACS)
Programming of movements
TcPlcInterpolation Library
 Alternative to G-Code
 Programming of move commands directly from PLC
 Supported Geo Types: Line, Circle, Bezier
 More flexible than a static G-Code file
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Programming of movements
 The programming of the movements can be done by
 PTP
 Cam Plate
 G-Code (DIN 66025)
 TcPlcInterpolation Library out of the PLC
 or in combination of methods above
 The target coordinates usually are given in Cartesian (X,Y,Z)
 The interpolation mode (TcPlcInterpolation) supports different
user co-ordinate systems (UCS)
 Optionally synchronization on several conveyor (tracking)
Co-ordinate systems
Work-piece (PCS)
MCS 1
MCS 2
WCS World co-ordinate system
MCS machine co-ordinate system
UCS user co-ordinate system
UCS 1
PCS programmed co-ordinate system
(work-piece)
PCS
Conveyor
UCS 2
WCS
Tracking
Synchronization on moved co-ordinate systems
 realized on application layer with flying saw
 comfortable ‘automatic’ solution (requires TC3.1)
Tracking
Application Sample: Optimized FB’s for tracking
stPickIdlePosition
1
fPickXMinimum
Z
2
4
fPickBlendLength
3
fPickSegment3Length
fPickHeightSyncAbort
Y
Robot MCS
Y
stPickPosition
X
fPickXLimit
fPickXMaximum
Current Pre-Control
The calculation of the dynamic model allows a current pre-control
and offers a
 reduction of the lag distance
 reduction of mechanical oscillation
 smooth parameterization of the controller
Current Pre-Control
Lag distance with and without pre-control
TwinCAT Kinematic Transformation
 Four levels for different complexity of transformations:
TwinCAT Kinematic Transformation
Levels
Level 1 (TF5110)
 Static transformation includes translation & rotation
Level 2 (TF5111)
 Including Level 1
 Mainly 2D-kinematic transformations like H-Bot, 2D-parallel
kinematics
Level 3 (TF5112)
 Including Level 2
 Mainly 3D-kinematic transformations like Delta, SCARA
Level 4 (TF5113)
 Including Level 3
 More than 4 axes interpolated like 6D-cable-kinematics,
5D-cutting-head
Licensing & System Requirements
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License for one CPU
The License agreements for Beckhoff software products apply
Requires TwinCAT NC I Level (TC1260 or TF5100)
TwinCAT 2.11 R3 (basis functions)
TwinCAT 3.1 (for new applications recommended)
Target system: Windows XP ,Windows 7/8, Windows CE
Thank you for your attention
Beckhoff Automation S.r.l.
Via L. Manara, 2
20812 Limbiate (MB)
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