Revolution in motion

With the XTS linear transport system, Beckhoff offers a proven drive solution in which magnetically driven movers move along a travel path consisting of fully integrated motor modules.

An Industrial PC with TwinCAT automation software enables independent control of the movers with individual motion profiles. This results in many system-related advantages: The transport system is ready for operation immediately after assembly, since power electronics and path detection are contained in the XTS motor modules and the movers are completely passive. Thanks to the different geometries of the motor modules, both an open and a self-contained travel path can be created and the machine footprint can be reduced through individual path sequences. The XTS not only replaces conventional conveyor belts, it also enables a new design of the entire machine. With the flexible motion profiles, simple to highly complex sequences can be realised, thus optimising the entire production process.

Software functionalities enable flexible motion sequences

Each mover can be controlled to move freely and independently of other movers for individual product transport on the travel path. The dynamics as a characteristic of the individual mover can change at any time and "on the fly" - according to the respective requirements. If necessary, the movers can be synchronised to external process sequences or other movers. Group formation in motion with any number of movers as well as a moving buffer store are also possible. The individual movers are mapped as "normal" servo axes, with all the usual Motion Control functions such as flying saw, electronic gear and cam plate. Function extensions in TwinCAT take over typical XTS requirements, such as automatic accumulation, centrifugal force limitation, collision and jerk avoidance. All this and also other application-specific motion functions can be easily implemented without the complexity of the motion leading to high complexity in engineering.

Alternative solutions open up innovation potential

The innovation potential of the XTS is by no means limited to highly complex motion sequences. Rather, the system offers finely scalable adaptation possibilities with regard to application requirements, e.g. in terms of geometry, the number of movers and the range of functions. This starts with simple applications, such as the purely linear movement of a mover and the extension by a second mover to generate an XY movement. By closing the modular geometry of motor modules and guide rails, an endless linear system with any installation position is finally created. The application possibilities can be further increased by combining several XTS systems, using comprehensive TwinCAT function blocks and integrating robotics. If all this is used consistently together with condition monitoring and object-oriented control programming, the result is a highly intelligent machine or production module - entirely in the sense of Industry 4.0.

Contactless energy and data transmission to the XTS movers

Beckhoff achieves a further quantum leap in terms of machine flexibility with a new type of technology for the XTS: No Cable Technology (NCT) enables contactless, continuous power supply and synchronous real-time data transmission to the XTS movers. For this purpose, the XTS modular system has been expanded to include a special motor module and electronics that can be mounted on the mover. The hardware required for NCT is fully integrated into the motor module, so that the existing functions and compact design are retained. No additional connections and supply lines are required.

With NCT, processing steps and quality control are possible for the first time directly on the mover during the running process. Sufficient power and fast communication with the TwinCAT controller make the connection of sensors and actuators simple. Data communication with each mover is real-time capable and, in conjunction with EtherCAT, synchronises system-wide events with µs precision, so that a specific event can be triggered at an exact position. NCT offers the user new solution possibilities, particularly in the areas of product handling, machining and measuring parallel to transport, as well as machine adaptations for rapidly changing production batches.

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