Have you heard of adaptive automation? The idea is that a complete, packaged automation line can be purchased and adapted to your environment. This means machine adaptability based on customer application needs. It also enables concepts to be more compact, changeable or even hygienic with washdown-capable equipment.
Beckhoff Automation is enhancing the ability of adaptive automation with products like the eXtended Transport System (XTS). The XTS is a modular, mechatronic conveyance system from Beckhoff that combines its programmable logic controller (PLC) and its drive systems to create a motion system that is compact, modular and adaptable to many machine environments or product shapes and sizes. One of the primary factors allowing this flexibility is that XTS combines linear and rotary movement.
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Changeover flexibility of modular, mechatronic conveyance
The movers can move freely as a group or individually. Gearing and cam motion are also possible. Realized gains in machine performance with XTS by Beckhoff Automation are many. Decoupled motion offers many benefits compared to legacy indexing technologies. The XTS movers can operate with practically limitless pitch and changeovers on the fly.
This means you could add tooling at your slowest process stations—for example, filling multiple bottles at once but still capping them individually—to accelerate throughput rates. You could also save time on format changes by instantly transforming the system from making stacks of cookies to sleeves without large changeovers.
Key components and specifications of Beckhoff XTS
The system is modularized with a PC-based controller, motor modules, guide rails, movers and EtherCAT networking. The motor modules fit together like an old-fashioned slot-car toy racetrack. The track layout gives many options as far as making an ideal shape to suit the product and process.
The speed can reach up to 4 m/s and 40 kg for the payload. There are linear, back, rotary and dual output options. With track management, the machine builder can transfer movers from one separate track to another via a lift mechanism. Thus, the customer product shape or application footprint does not have to hinder design.
How HepcoMotion’s V guide enhances the system
Also, the V guide track technology from HepcoMotion decreases maintenance and wear and tear due to less mechanical stress. This is good for reliability. V guide rail systems from HepcoMotion support heavier payloads, and the magnets can generate up to 210 Newtons of peak force. Using more than one mover can increase the payload. Depending on the mover, a machine can do 800 to 1,200 units a minute.
Simulating XTS operation during development: streamlining development and troubleshooting
Simulation is possible using Git code and the prepackaged human-machine interface (HMI) software allows for a simulated environment which will let a digital system be made before integration. This means that troubleshooting can happen before installation. Also, components are programmable in the same environment, making development easier—including controllers, drives and motors. Motion libraries are done so they do not have to be developed.
Factory acceptance testing and pre-assembled shipping options
In addition, Beckhoff provides the option to ship the entire motor, mover and track system fully assembled and operational. This means factory acceptance of the XTS can occur at a Beckhoff test center or at the customer location.
Recently, Beckhoff decided to put wireless technology on the movers so that inputs and outputs can be on the movers. Thus, discrete outputs can be used to pick up items on the movers. This means that assemblies can be complemented using the XTS making automated stations viable. End-of-arm tooling can be implemented on the movers, as well. Picture a two-motion robot on the XTS mover, and the ability to pick/place, grip, detect, move, reject and orient product. This is currently limited to 24 Vdc, but this is not a limiting factor. Applications include the replacement of flight pins and star wheels, filling and capping and case packing, food packaging and an infinite number of ideas and combinations.
Plug-and-play automation capabilities
Do not forget that Beckhoff’s main communications protocol is EtherCAT, which allows plug-and-play flexibility between the hardware and software over a strong network. This is part of the adaptability to interface old and new technologies, and it increases modular design prospects.
Who does not want to reduce costs, decrease space for machines and increase throughput? Not to mention that the XTS technology can directly interface with Beckhoff XPlanar technology, so adapting automation to the customer needs is fun. Beckhoff supports engineers through each step of the process, from design to assembly and testing, delivering an out-of-the-box solution with plug-and-play capability.
