Precision Motion Control
Photo: Beckhoff Automation, Wikimedia Commons, CC BY 4.0, cropped.
High-precision multi-axis motion control built on Beckhoff PC-based control: TwinCAT 3 software and real-time EtherCAT, from a single stage to complete synchronised positioning systems.
Motion control on Beckhoff PLC
We design, program and commission motion control systems on Beckhoff industrial PCs and embedded controllers. One open, PC-based platform runs logic, motion, measurement and communication in real time, which keeps systems compact, fast and easy to extend.
- Multi-axis point-to-point and interpolated motion with TwinCAT NC PTP and NC I
- Synchronised axes, electronic gearing and camming, coordinated scans and trajectories
- Closed-loop positioning with high-resolution linear and rotary encoders
- Servo drives, stepper and DC motor terminals, and piezo actuators in one system
- Homing, soft limits, interlocks and safe motion with TwinSAFE
- Automatic scan routines with data acquisition synchronised to position
Technologies we work with
Control and software
- Beckhoff TwinCAT 3 (IEC 61131-3: Structured Text, function blocks, sequential function charts)
- Object-oriented PLC programming and C++ modules in the TwinCAT runtime
- MATLAB®/Simulink® models integrated into the controller
- Python, LabVIEW™ and custom GUIs for automation and data analysis
- Version control with Git and automated testing of PLC code
Fieldbus and communication
- EtherCAT real-time fieldbus with distributed clocks for µs-level synchronisation
- OPC UA, ADS and MQTT for connecting to higher-level systems and the cloud
- Integration with EPICS and Tango control systems used at research facilities
- Modbus TCP, Profinet and serial interfaces for third-party devices
Drives, motors and sensors
- Servo drives (Beckhoff AX5000, AX8000) and compact drive terminals
- Stepper, servo, direct-drive and linear motors; piezo stages and hexapods
- Absolute encoders with BiSS-C, EnDat 2.2 and SSI, and incremental encoders
- Laser interferometers and capacitive sensors for nanometre-level feedback
- Vacuum-compatible, non-magnetic and cryogenic-rated motors and stages
Engineering tools
- 3D CAD design and FEM analysis of mechanics and thermal loads
- Electrical design of control cabinets and racks
- Remote access, monitoring and diagnostics for long-term support
Example
Our five-axis positioning system for Hall-probe calibration at European XFEL combines three linear stages with 0.5 µm resolution and two goniometers with 0.45″ precision under automatic scan control. Read the project description.
Beckhoff, TwinCAT, EtherCAT and TwinSAFE are registered trademarks of Beckhoff Automation GmbH. Other names are trademarks of their respective owners.
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