1. PC-based Automation Solution
drives the Industry 4.0
Jul, 2015
Product Manager
Eric Lo

2. The Revolution of Industry 4.0

3. Industry 4.0 Key Elements

4. Services
(ERP, MES, CRM, SCM…)
Smart Production
BIGDATA
Smarter Machinery
Digital Factory
Connected Enterprise

5. IPC
Machine Vision
HMI PLC +
Motion Modules
Drive
Motor
I/O System
…(More Axes)
…(More Axes)
Sensors
System
Architecture
Smarter Machine Today
SCADA/MES
Communication
Bottleneck

6. Machine Vision
Drive
Motor
I/O System
…(More Axes)
Sensors
System
Architecture
Highly Integrated Solution
IPPC2160PE
SCADA/MES
Motion Controller with
Machine Vision

7. The Integrated Power
Gateway
PAC/
PLC
CloudHMI
PC
Physical World
Cyber World
Cyber-Physics
System
 Manufacturing Process,
 Automation,
 I/O System,
 Fieldbus Networking
 Machine Vision
 Robotic
 …
 Internet
 ERP/SCM/CRM/…
 Wireless/4G/3G/WiFi
 Big Data
 …

8. A Highly Integrated and High Performance
Multi-axes Motion Controller with
Real-time EtherCAT and Standard IEC 61131-3
makes your Machine Smarter for
Seamless IA/IT Integration and Open Connectivity to
the Digital Factory and Industry 4.0
Value Proposition of
PC-Based Motion Controller
IPPC Series
VIPA SLIO

9. Features
of PC-base Motion Controller
IPPC Series
NIFE Series
NET Series
 Compact Size
 Field Bus Interface Expansion
 Multi-core Intel Atom CPU
 Multi-touch Capability
 Comprehensive Panel Size
 Multi-core Intel Core i/Atom CPU
 High Performance Intel Core i7 CPU
 PCI/PCIe Expansion
 Up to 4x GbE LAN Port
Fanless Design
PLC/PAC + PLCopen Motion + HMI +
PC Software
Options for CNC and Robotic
functions
PC/Internet Enabling Libraries

10. Semiconductor &
Electronics
Target Markets & User Scenarios
Food & Beverage
Metal Handling
Robotic
OEM SIs &
Machine Builders

11. F&B Packaging Machine
HMI+PLC
DI:
Emergency Stop
AO:
VFD
DI:
Photoelectric
Sensor
DI:
Light Screens
AO:
Heater
Portion ValveDO/Relay:
Actuator
AI:
Scale Meter
AI:
Flow Sensor
Pressure Sensor
Temperature Sensor
DI:
Push Buttons
DO:
Indicator
DI:
Interlocking
Switches
HMI + PLC + Motion:
1. Point to Point
2. Change Speed on the Fly
3. Dancer Control
DO:
Tower Light
IPPC Series

12. Plate/Pipe Bending Machine
DO:
Tower Light
HMI
DI:
Photoelectric
Sensor
DI:
Light Screens
DO/Relay:
Actuator/
DO:
Indicator
DI:
Control Panel
PLC + Motion:
1. Loading & Unloading
2. Torque Control
3. Bending
DI:
Interlocking
Switches
NIFE Series
DI:
Push Buttons
&
Emergency Stop

13. Robotic Control (w/o Machine Vision)
Multi-Axes
Motion Control
NET Series

14. Integrated Motion Solution
 The total consultant service
 One stop integration
 Open standard
 High-performance motion
 High-computing power
 Comprehensive portfolio
System Architecture
Consultant
Mechatronics
Integration Design
PLC/PC/Motion
Program Design

15. Available Packages
X86 - Windows
• CODESYS SoftMotion – Label 3S 309001
• P/N: 6014500002X00
• CODESYS SoftMotion CNC – Label 3S 309060
• P/N: 6014500021X00
• (Including *PLC functionality, OPCServer and PLCHandler)
X86 - Linux
• CODESYS SoftMotion CNC – Label 3S 309025
• P/N: 6014500004X00
• CODESYS SoftMotion CNC + Target Visu – Label 3S 309026
• P/N: 6014500006X00
• (Including *PLC functionality)
CODESYS V3.5 SP5
for SoftMotion and SoftMotion CNC
for *PLC functionality
(FBI communication cards required)
Advanced Motion Application
(Advanced) Motion + PC Application

16. Solution Pack to Go,
FAE to your site, SPEC in Service
PC-based EtherCAT SoftMotion Solution Pack with PAC Controller + HMI + I/O + Drive + Motor
F&B Packaging
Machine
System Architecture
SoftMotion
Features & Functions

17. Highly Integrated Controller for
Seamless IA and IT Applications
Flow,
Pressure,
Temperature
Sensors
NEXCOM PC-Integrated Library
PC
Peripherals
M2M Clound
Mail
Services
Machine
Vision
Data Base
Comm.
Services
APC
Customized
Library
IT:
Seamless Integration
Ubiquitous
IoT Automation
SCADA, MES, APS …
CODESYS Gateway
Server
PLCMotion/CNC
CODESYS Runtime
PLCHanlder OPC Server
JMobile/
ServerIA:
Reliable Control
HMIIEC-61131-3

18. User Application
(Robot/Motion/Vision/… algorithm)
Integrated and Advanced Control
Kernel Space Driver
HW
Windows Kernel
Win32 Libraries
CODESYS
Control RTE
IEC61131-3
Application
Real-time Engine on one exclusive CPU core
PLC Program C/C++ Program
HAL
Proprietary
Library
NEXCOM
PC Integrated
Library
(Coming Soon)
CODESYS
PLCHandler
Library
IEC61131-3
Logic
Library
SoftMotion
Library
CNC
Library
Safety
Library

19. Why
&
???
Questions!

20. PLC Benchmark
Survey conducted by one of the most important German Automation
Magazines “Computer&AUTOMATION”, ITQ and two German Universities
(9/2011):
70 companies (machine- and plant manufacturers) were interviewed. One of the questions
asked was: Which develpment tool do you use to program your controller systems?
CODESYS based: 35% Market Share
equals to
SIEMENS: 35% Market Share

21. Marquee players who use
And more…

22. Integrated Program Design:
Control Programming Tool
&
Device Configuration Tool
A Professional IEC 61131-3
Development Utility & Automation
Software

23. Professional IEC 61131-3
Development System & Automation Software
Integrated Program Design:
Control Programming Tool
&
Fieldbus I/O Configuration Tool

24. Open, Standard, Re-usable, Expandable,
Advanced and Complete Motion Algorithm
 CODESYS SoftMotion
For single and multi-axis motion control
 CODESYS SoftMotion CNC
Extension package for CNC, interpolation and many kinematics

25. SoftMotion libraries at a glance
Robotic: Articulated, Delta, SCARA
Note: The Libraries includes SoftMotion RTE & SoftMotion CNC RTE

26. SoftMotion libraries at a glance
Robotic: Articulated, Delta, SCARA
More CODESYS SoftMotion libraries

27. Applications by SoftMotion
Encapsulation Labeling
Tracking Robotic

28. PLCopen voting members

29. - the leading edge of Industrial Ethernet
 Ease of Use
 Easy configuration and maintenance
 High Performance
 EtherCAT is the fastest Industrial Ethernet technology
 Flexible Topology
 Benefit not only for widely distributed applications
 Functional Safety
 Safety communication integrated
 Product Variety
 Great variety of available EtherCAT products

30. The fastest Real-time Control Technology in
nano sec with modern PC Architecture
 40 Axis (each 20 Byte Input- and Output-Data)
 50 I/O Station with a total of 560 EtherCAT Bus
Terminals
 2000 Digital + 200 Analog I/O, Bus Length 500 m
 Performance EtherCAT: Cycle Time = 276 µs
at 44 % Bus Load, Telegram Length = 122 µs
Master
Ethernet Header ECAT HDR PLC Data NC Data Data n Ethernet
HDR1
HDR2
HDR2
6355
2347
763
479
276
0 1000 2000 3000 4000 5000 6000 7000
Profinet I/O
Pow erlink
Profinet IRT
SERCOS III
EtherCAT
µs
µs
µs
µs
µs
in spite of this cycle time still 56%
bandwidth remaining, e.g. for TCP/IP

31. Transformation of Machines
Source: QUEST TREND MAGZINE, Nov, 2013

32. Smarter Machine Solution
Intelligent
High-speed
Powerful
1. Motion Control
2. Production Management
3. E-Traceability Service
4. Machine Self-diagnostic Service
…

33. Services
(ERP, MES, CRM, SCM…)
Digitize and Connect
BIGDATA
Smarter Machinery
Digital Factory
Connected Enterprise

34. Architecture of the Factory
MotorActuatorComponent
Plant
Information
Business Process Information Network
Operations Information Network
Control Network
Device Network
Field
Level 0
Control
Level 1
Operations
Level 2
Management
Level 3
Business &
Enterprise
Level 4,5
Ethernet
Serial
Robot
Controller
Robot Specific
Machine
MES/APS
IT Systems
...
ERP
Visualization
(SCADA/HMI)
OPC
Server
Drive
Sensor
PLC/PAC
Remote I/O
DCS
PC-based
Controller
PLM/SCM/
CRM …

35. Architecture of the Digital Factory
MotorActuatorComponent
Plant
Information
Business Process Information Network
Operations Information Network
Control Network
Device Network
Field
Level 0
Control
Level 1
Operations
Level 2
Management
Level 3
Business &
Enterprise
Level 4,5
Ethernet
Robot
Controller
Robot Smarter
Machine
MES/APS
IT Systems
...
ERP
Visualization
(SCADA/HMI)
OPC
Server
Drive
Sensor
PLC/PAC
Remote I/O
DCS
PC-based
Controller
PLM/SCM/
CRM …

36. Seamless Connectivity
IPPC Series
NIFE Series NISE Series

37. Fieldbus Enabling
Product Portfolio of Automation Platforms
Central Control
SCADA Station
High Performance
SCADA Station
Mid-level Control
SCADA Station
Field Controller &
Data Server
Communication
Gateway
NISE4000, NISE3660, NISE300 series
NISE3000 series
NISE2000 series
NISE60, NISE90, NISE105 series
NISE60, NISE90, NISE105, NISE301 series
PC-based
Fieldbus Platform
NIFE2000, NIFE100 Series
(5000 tags)
(3000 tags)
(1000 tags)
ATOM
Core i

38. Fieldbus
Protocols
The Matrix and Advantages
IPC
Platforms
OS
CPU
ARMATOM
Sandy
Bridge
Ivy
Bridge
Haswell

39. Fieldbus
Protocols
The Matrix and Advantages
IPC
Platforms
OS
CPU
ARMATOM
Sandy
Bridge
Ivy
Bridge
Haswell
Comprehensive
&
Flexible
Mainstream
Protocols
Performance Small Form Factor

40. Powerful Integration with Reliable Quality
SCADA/HMI Station

41. Reliable PLC System
Operation Network
Control Network
APPC
Machine
Control Room
Process/Batch
Control

42. And NEXCOM offers the comprehensive Solution of
PC-Based Automation connecting the Digital Factory
Operation Network
Control Network
NISE3720
PBOX520A IPPC
NISE3600NISE300
NIFE100
NIFE2310
NISE105
IPPC1960
MAC4000P4E
IWF2220
IFA3610
APPC
Process/Batch
Control
Control Room
Machine
PC-Base
Automation
Data Processing
Operation &
ManagementFront-End
Communication

43. Library – ProtocolLibrary – Motion Control
Comprehensive PC-Based Offerings
NISE
NIFE
IPPC
APPC
On-board/FPGA
LAN Ports
Add-on
Motion Cards
CNC Controller -
NControl
3rd-Party Software
SoftMotion
CNC
SoftPLC
Target
Visue
Nex ECM
VisualizationPC-Based Automation Industry 4.0
Consultant
Service –
FA/OEM
 Consultant Service for
 System Architecture
 Design of PLC/PC/Motion Integrated Application
 Mechatronics Integrated Design
 Evaluation Service for
 System Capacities
 Protocol Conversion
 Cross System Integration
Communication
Interfaces
Electrical
Signals
Automation Core
CORE VALUE

44. Library – ProtocolLibrary – Motion Control
Comprehensive PC-Based Offerings
NISE
NIFE
IPPC
APPC
On-board/FPGA
LAN Ports
Add-on
Motion Cards
CNC Controller -
NControl
3rd-Party Software
SoftMotion
CNC
SoftPLC
Target
Visue
Nex ECM
VisualizationPC-Based Automation Industry 4.0
Consultant
Service –
FA/OEM
 Consultant Service for
 System Architecture
 Design of PLC/PC/Motion Integrated Application
 Mechatronics Integrated Design
 Evaluation Service for
 System Capacities
 Protocol Conversion
 Cross System Integration
NET Series
Communication
Interfaces
NControl
Series
MAC Series
Electrical
Signals
Automation Core
NISE/NIFE & IPPC/APPC Series
CORE VALUE

45. Q & A

46. What is OEM?
 Basics of Machine
 Mechanical
 Axis
• Motor
• Drive
 Motion
• Velocity
• Position
• Torque
 That’s it.
 Advanced Machine
 PC Application
• Recipe
• Alarm Record
• Machine Vision
• Coordination
Transformation
• …

47. When you hear customer said …
 Key words of Axes Control
 Motion algorithm
 SoftMotion Function Blocks
 Velocity Control
 Position Control
 Torque Control
 PID Control
 Coordination
 X/Y/Z Axes
 Pulse command (Frequency)
 Velocity/Analog command
(0~10VDC/±10VDC)
 Encoder (A/B/Z)
 PLCopen Motion
 Key words of Characteristics
 Multi-Axes
 Large scale of Axes
 Distributed Axes
 Close/Open Loop
 Real-time Communication/Control
 Enhance Production Rate
 PLC with Motion Module
 Resolution: 12/16/17/21 bits
 RPM
 Motor Performance
 Legacy Drive/Motor
 Servo Drive/Motor
 Stepping Drive/Motor
 Small HMI

48. When you hear customer said …
 Key words of Target Customer
 OEM SI
 Machine Builder
 Distributor of Drive/Motor
 Distributor for Motion Solution
 Key words of User Scenario
 PLC Motion in Multi-Axes(16 axes
and above) is $$$$$$$$$$$$$$$$$
 The wiring of Drive and Motor is
~!@#$%^&*()_+{}|:”<>?
 The machine is so big that installation
and maintenance of the wire kills me.
 Is it possible to integrate the
HMI/PLC/Motion together?
PC-Based Automation makes your
control system, highly-integrated,
simple and powerful.

49. Available Packages
X86 - Windows
• CODESYS SoftMotion – Label 3S 309001
• P/N: 6014500002X00
• CODESYS SoftMotion CNC – Label 3S 309060
• P/N: 6014500021X00
• (Including *PLC functionality, OPCServer and PLCHandler)
X86 - Linux
• CODESYS SoftMotion CNC – Label 3S 309025
• P/N: 6014500004X00
• CODESYS SoftMotion CNC + Target Visu – Label 3S 309026
• P/N: 6014500006X00
• (Including *PLC functionality)
CODESYS V3.5 SP5
for SoftMotion and SoftMotion CNC
for *PLC functionality
(FBI communication cards required)
Advanced Motion Application
(Advanced) Motion + PC Application

50. Suggested Models for
Intel 82574L
• Life Cycle is up to 2018
Intel I210A
• APPC0804T/1240T/1245T/1540T/1740T/1940T
• IPPC1640P/1840P/2140P
• NISE3700/3720
• NIFE100/200/300
• NISE105/106/301

51. Supported Driver of
EXOR JMobile Runtime PC