25 years of the PC Control revolution – Convergence of technologies

Beckhoff Automation was established in 1980 and the first PC-based machine controller was delivered by Beckhoff just six years later. It was a ‘simple’ controller for a double miter saw, which encompassed single-axis positioning control with a few machine sequence functions. The saw was a well-known standard machine, which became a direct sales success for the machine manufacturer due to the innovative PC Control technology. The combination of IT functions and automation technology (AT) in a controller was and is still a revolution. The benefits resulting from this revolution were recognised even at the beginning and received enthusiastically by machine manufacturers and users. For example, data could be read directly into the machine controller using standard IT media (floppy disks). In 1986, this represented significant progress in productivity. more

Beckhoff expanded the company’s PC Control concept consistently and quickly in the years that followed: Multi-axis NC functions and a complete, integrated software PLC enabled the PC-based Control of highly complex machines and plants.

There have been no fundamental changes to this successful concept since then: the abstraction of the control function from the device hardware and the consistent use of ‘mainstream’ IT technologies converging with the principles of automation technology lead, on the one hand, to continuously improving performance and functionality and, on the other, to cost reductions. The PC Control principle is very simple: a powerful Industrial PC, an equally high-performance fieldbus to which peripheral devices for sensor and actuator systems are connected and control software with real-time capability for logic and motion.

Beckhoff has developed further important products over the last 25 years that are considered as milestones, since they each represent a smaller or larger revolution and have contributed in no small way to the current state of PC-based automation:

  • 1989: Lightbus – optical fiber fieldbus for fast I/O coupling
  • 1995: Bus Terminals – fine granular I/Os
  • 1996: TwinCAT – standard real-time automation software running on Windows
  • 2003: EtherCAT – real-time Ethernet for automation
  • 2005: TwinSAFE – functional safety in non-safe environments
  • 2006: Scientific Automation – measuring technology and engineering science as a control component
  • 2008: XFC – eXtreme fast controls for efficient machines and plants
  • 2010: TwinCAT 3 – engineering tool and runtime for object-oriented and modular automation

The PC Control technology has found the widest use worldwide: in machine construction and plant engineering, in measurement and testing technology, in wind turbines and photovoltaic production, in office buildings and private houses, in stage technology and on luxury yachts, in medical technology and in particle accelerators… PC Control from Beckhoff is the basis for intelligent, powerful and reliable control technology in all fields.

And the revolution continues, driven by hardware and software advances in IT and automation technology. The Multi-core technology permits the provision of virtually unlimited computing power and new software tools are improving engineering. All automation engineers are called on to use these increases in performance, for example, to control machines, plants and buildings with greater efficiency while using less resources, and in particular to give free rein to their imaginations and to contribute to the future revolutions of the next 25 years.

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25 years of PC Contol – History, technology, future
PC technology through the ages – 25 years of PC history at Beckhoff
Software breathes life into the PC-based controller
Beckhoff real-time kernels: Real-time processing – The basis for PC Control
EtherCAT: High-performance control requires high-performance communication
Interview: Scientific Automation integrates high-tech special functions into automation
TwinCAT 3: C++ drives Automation
TwinCAT 3 Safety: eXtended Automation Engineering and Runtime
TwinCAT 3 Safety: Industrial PC implements safety functions
Connectivity: From sensors to the IT cloud
Intel: Exciting processor trends for IT and industrial automation
Microsoft: The software platform – three pillars for success

PC Control – Basic technologies

TwinCAT

TwinCAT – the control plattform: TwinCAT integrates real-time control with PLC system, Motion Control and programming environment in a single package. Programming is based on the IEC 61131-3 standard

Industrial PC

IPC – The right Industrial PC for every application: High-quality components based on open standards and the rugged construction of the device housings mean that the Industrial PCs are ideally equipped for all control requirementst.

I/O

I/O – Extensive range of fieldbus components for all common I/O and fieldbus systems: The wide choice of I/O components means that the bus system best suited to the particular application can be chosen.

Motion

Motion – the advanced and complete drive system: PC-based control technology is ideally suited for single and multiple axis positioning tasks with highly dynamic requirements.