Condition monitoring functions can be integrated simply and cost-effectively into the EtherCAT I/O system from Beckhoff using the EL3632 EtherCAT Terminal.
TwinCAT software and libraries support the tight integration of control and condition monitoring functions for PC-based control systems using the EL3632 EtherCAT terminal
For the user who is already using PC control this means: optimum integration into the control system and considerable cost reductions. The signals are analysed on the PC using either TwinCAT automation software or user software.
The EtherCAT realtime Ethernet system provides the network for high-performance communication of all measured data back to the PC.
Benefit of PC-based controller
Condition monitoring systems for tracking the status of a machine or plant undoubtedly help to reduce downtime and maintenance costs. The EL3632 EtherCAT Terminal enables the direct connection of various accelerometers via an IEPE (integrated electronics piezo-electric) or ICP (integrated circuit piezoelectric) interface. These sensors record vibrations in a machine, bearing or motor so that, by means of analysis, wear and damage can be detected before a breakdown occurs. This helps to avoid unplanned downtime or prolonged maintenance intervals. A central, PC-based controller provides significant advantage, particularly if large amounts of data from different devices need to be referred to for analysis or if damage frequency signatures need to be evaluated in relation to other data such as speed of rotation.
Precisely timed data
Through interfacing via EtherCAT and support of the distributed clocks function, the measurement results – and any detected defects – can be precisely allocated to an axis position. In this way, the user knows what is happening at each axis position on the machine. By matching positions to acceleration values, conclusions can be drawn about possible sources of error. On the software side, the EL3632 is supported by various TwinCAT libraries, eg, with high-quality filters such as FFT (Fast Fourier Transformation), digital high-pass or low-pass filters, or envelope monitoring. TwinCAT Scope is also being expanded to include condition monitoring functions.
An integrated whole
Condition monitoring becomes an integrated part of the controller when using the EL3632. The data is recorded by the standard I/O system and made available to the PC controller. The measurement signals are evaluated on the PC using a TwinCAT library or user software; the warning and shutdown thresholds are set accordingly. Adjustable filters and supply currents for matching various sensors enable the user-specific adaptation of the condition monitoring terminal.
Traditional condition monitoring systems are expensive, constructed as separate hardware devices and need to be coupled elaborately with the automation system. Other solutions merely report the respective operating status without supplying detailed information to the controller. In EtherCAT, a capable communication system is available for the high-performance relaying of the recorded status data to the PC controller.
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