TwinCAT PLC

PLC Development Tool-TwinCAT PLC

Beckhoff’s TwinCAT PLC is the main development tool of ViewMove Technologies, Inc. in PLC-related projects, and has accumulated more than 20 years of project development experience and related program libraries on this platform, it can rapidly assist equipment manufacturers in developing their dedicated electrical control software for their machinery.While our in-house product, HMI++ PC Graphic Control HMI, also offers communication interfaces for major Japanese, European, and domestic PLC brands, we have chosen TwinCAT PLC as our main development tool due to its flexible development environment, comprehensive online resources, compatibility with open industrial networks, and ease of data collection for historical records.

The world of TwinCAT: Open, PC-based control technology

When Beckhoff introduced its PC-based control technology, it established a global standard for automation. In the software domain, since 1996, the core of the control system has been the Windows-based control and automation technology, known as TwinCAT, an automation suite. In combination with TwinCAT, the Beckhoff portfolio results in optimally coordinated automation concepts that fulfill the basic principles of an open and highly scalable control system.

TwinCAT transforms 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 not only allows integration of third-party software modules but also permits customized retrofitting solutions for existing machinery and systems. This ensures flexibility and investment protection for customers.

Advantages of TwinCAT PLC Development Environment

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  • Compliance with IEC 61131-3 International Standard for Programmable Logic Controllers (PLCs)
IEC 61131-3 instruction
Easy conversion on PLC platforms that support this open standard: As the application field presents various possible scenarios with different peripheral requirements, production machinery must consider factors such as development time, cost, size, performance, and ease of integration. It is not feasible for a single PLC manufacturer to satisfy the best solution in all cases. Supporting an open standard allows programs developed in the past to be more easily transferred to suitable platforms, without being limited to a single PLC product of a single supplier. The IEC 61131-3 standard (currently maintained by http://www.plcopen.org/ ）has gained extensive support in European and American PLC systems, and even Japanese PLC systems, which have always been closed in the past, are gradually adding support to their product lines.
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  • Flexible multi-program syntax support is suitable for different application scenarios and developers with different backgrounds to quickly learn and implement their projects
Programming syntax support instruction
Textual：
  • Instruction List, IL：Similar to assembly language, used for high-speed operations, and reduces system resources.
  • Structured Text, ST：Based on Ada, Pascal, and C syntax, used to develop high-level programming languages suitable for writing complex algorithms and creating dedicated function libraries.
Graphical：
  • Ladder Diagram, LD：is based on relay ladder logic, and it is easy for individuals familiar with circuit switch design and traditional PLC programming to use.
  • Function Block Diagram, FBD：Similar to circuit design, views a system based on the flow of signals between components.
  • Sequential Function Chart, SFC：It uses a graphical representation for process control, making it suitable for writing control-oriented state machine mechanisms and flow control.
Developers have the freedom to choose the syntax they are familiar with or the one that suits the specific scenario to accelerate the development of systems.Furthermore, With the release of the 3rd edition in 2013, object oriented features were added to the specification. With this, classes, method, interfaces and namespaces became part of the specification, as well as namespaces, all linking it to a new generation of software programmers, as well as to other software tools.For enterprises, regardless of the development environment used, the primary focus is always on cost and efficiency. In software development, the key requirements are that engineers can develop programs in the shortest possible time, ensuring reusability of the code and minimizing the training costs for new personnel. Undoubtedly, TwinCAT system excels in these aspects.
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  • Supports major open industrial networks
Industrial Network Support Instruction

Open industrial networks support means that the entire development environment becomes more accessible for integrating various vendor-independent modules, sensors, motors, and other essential system components, enabling rapid completion of the overall system integration. Currently, the main industrial networks that are fully supported are as follows:

  • EtherCAT
  • LightBus
  • PROFIBUS
  • PROFINET
  • CANopen
  • DeviceNet
  • SERCOS
  • EtherNet/IP

Among these interfaces, EtherCAT has become the preferred choice for motor drive manufacturers when launching versions with open industrial network support. Beckhoff has been leading the promotion of this specification, and TwinCAT system has become an essential tool for motor drive manufacturers in compatibility verification.

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  • System Scalability and Flexibility
System Scalability Instruction

When taking on a development project, apart from the requirement for rapid system integration, another important aspect is to have the main control system that supports the project with corresponding cost and architecture considerations. Beckhoff addresses this need by providing a variety of scalable systems to adapt to different situations:

All of the aforementioned systems can be freely combined with Beckhoff I/O systems, allowing flexible expansion of the required electrical interfaces and industrial networks. Unlike other vendors' offerings, where selecting a small-scale system may limit the number of I/Os, For a large system, the memory capacity or expansion interface increases may significantly increase costs, Beckhoff provides the flexibility to tailor the control system based on the specific device development requirements. This approach ensures that developers can utilize the same TwinCAT development software and create control systems that are well-suited to the project's needs.

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  • Powerful Machine Data Collection Capability
Data Collection Instruction
As machines enter advanced manufacturing processes, preventing system failures and analyzing production yield trends become crucial. Whether it's the previously advocated concept of Fault Detection Classification (FDC) for online prediction of possible machine or product abnormalities, or integrating the currently popular AI technology to assist in yield analysis, the prerequisite is that the PLC controller can collect a large amount of data in real-time and archive or transmit the information to the backend analysis system.

TwinCAT PLC, in perfect integration with Windows systems on the same PC, combined with high-speed industrial network integration, and featuring low-cost memory expansion on the PC, provides the most powerful combination in terms of cost and data collection, exchange, and uploading in the PLC system.
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  • Integration Capability with Mainstream PC Development Environment
Development Environment Instruction

TwinCAT PLC, in perfect integration with Windows systems on the same PC, combined with high-speed industrial network integration, and featuring low-cost memory expansion on the PC, provides the most powerful combination in terms of cost and data collection, exchange, and uploading in the PLC system.

  • Reduced engineering workload: TwinCAT 3 integrates all project modules into Microsoft Visual Studio®. From PLC programming to visualization and data analysis, all tasks are completed within a unified environment. This not only helps reduce training and familiarization costs but also enables team members to collaborate on TwinCAT projects through connections with code management systems like Git, which makes it easy to manage anything from individual changes through to entire versions. Additionally, incorporating continuous improvement and continuous commits into the engineering workflow allows the implementation of modern agile development methods.
  • Maximum flexibility: TwinCAT 3 achieves hardware-independent application development, from small ARM-based controllers to multi-core CPUs. When writing real-time control software, developers can flexibly choose between IEC 61131-3 programming languages, C++, and MATLAB®/Simulink®.
  • Efficient project planning: TwinCAT's modular architecture facilitates the reuse and maintenance of software modules. Object-oriented programming generates reusable structured code, and communication between modules can be easily achieved through standardized data exchange, allowing flexible composition of these modules within IEC 61131-3 programming languages, C++, or MATLAB®/Simulink®.
  • Free choice of programming interfaces: TwinCAT 3 offers a wide range of interfaces, making it convenient to connect with databases and cloud systems in the IT world through OPC UA and other protocols. Existing protocols can be expanded through customer-specific adjustments.
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  • Comprehensive Online Open Resources
Open Resources Instruction
When choosing a development system, the convenience of accessing development documentation and the availability of full-function testing are crucial factors.

Beckhoff's Online Information System（https://infosys.beckhoff.com/index_en.htm）provides complete development manuals that can be accessed directly.

TwinCAT 3 offers a 7-day full-function test execution capability, and after 7 days, the program can be reactivated for further testing. This allows developers to thoroughly test program functionality during the development process and evaluate the optimal size of the control system suitable for the project's execution.

Our Perfomance

  • In 2002, ViewMove invested in the development of semiconductor single-chip wet etching machine control systems. In 2012, it achieved more than 100 online development achievements. Over the years, it has successively completed projects including wafer transfer, semiconductor immersion etching machines, PCB electrical testing and inspection machines... etc.