The company, ScandiNova Systems, has had a need for a test system that can automate and optimize fault detection of the digitizer circuit in the control system of their klystron modulators. This thesis work is intended for this need with the aim of constructing a test system built in LabVIEW, and a pulse generator to generate stimulation for the digitizer circuit board. The test system has been tested and the results have shown that it works well for the given circumstances. The analysis of how the digitizer circuit reads an analog signal works almost perfectly, given an 5%-tolerance interval from the reference value of how the pulse should be. However, not all of the digital outputs of the digitizer can be checked for faults with the current configuration of the circuit board. If the FPGA-code on the digitizer circuit is revised with the pulses of the pulse generator the Boolean error outputs of the FPGA can be correctly checked.   If a test system is to be created for other circuits in the control system based on the work done in this thesis project, the parts specified for the present circuit shall be removed from the LabVIEW-program. For example, almost all parts of the GUI that are specified for the digitizer circuit, the stepping of the DIP-switches etc,, shall be removed. Stimuli for the circuits shall also be created according to their specifications.

This thesis deals with a creation of a control system of 3-axis milling machine. The beginning of the thesis is dedicated to the general description of the problematic of the numerically controlled machines and the technologies used in this branch. The next chapter describes mechanical and electronical adjustments of the machine. Following chapters are dedicated to the creation of PLC program and HMI using the TwinCAT software. In conclusion, this thesis deals with commissioning of the machine, measuring its geometrical accuracy and testing.

<p>Med en växande produktionsindustri i Asien så blir det allt svårare för företag i Europa och Sverige att konkurrera med den effektiva och framförallt billiga arbetskraft som erbjuds i öst. För att kunna konkurrera på ett effektivt sätt så har industrirobotindustrin växt kraftigt under de senaste åren. Detta är en rapport på hur ett koncept har påbörjats för att implementera ett Ethernet baserat kommunikationssystem kallat EtherCAT i ett robotsystem från Motoman. En testutrustning har byggts och simulerat en kommunikation med en PLC. Ett första HMI gränssnitt har skrivits som översätter informationen från PLCn för att göra informationen lättförståelig för människor. Det har förberetts ett robotprogram till en robot från Motoman. Rapporten innehåller också en faktadel för hur EtherCAT fungerar och en jämförelse med andra systembussar.</p> / <p>With a fast growing production industry in Asia it’s getting harder and harder for Swedish companies to compete with the low production cost that the east offers. To be more competitive robot solutions are used more and more. This is a report of a first concept to implement a new Ethernet based communication called EtherCAT, in one of Motoman robot controllers. Test equipment has been constructed and simulated a communication with the PLC. A first HMI interface has been written to show the information from the PLC in a way that is understandable for humans. For one of Motoman’s robots a program has been prepared.</p>

Med en växande produktionsindustri i Asien så blir det allt svårare för företag i Europa och Sverige att konkurrera med den effektiva och framförallt billiga arbetskraft som erbjuds i öst. För att kunna konkurrera på ett effektivt sätt så har industrirobotindustrin växt kraftigt under de senaste åren. Detta är en rapport på hur ett koncept har påbörjats för att implementera ett Ethernet baserat kommunikationssystem kallat EtherCAT i ett robotsystem från Motoman. En testutrustning har byggts och simulerat en kommunikation med en PLC. Ett första HMI gränssnitt har skrivits som översätter informationen från PLCn för att göra informationen lättförståelig för människor. Det har förberetts ett robotprogram till en robot från Motoman. Rapporten innehåller också en faktadel för hur EtherCAT fungerar och en jämförelse med andra systembussar. / With a fast growing production industry in Asia it’s getting harder and harder for Swedish companies to compete with the low production cost that the east offers. To be more competitive robot solutions are used more and more. This is a report of a first concept to implement a new Ethernet based communication called EtherCAT, in one of Motoman robot controllers. Test equipment has been constructed and simulated a communication with the PLC. A first HMI interface has been written to show the information from the PLC in a way that is understandable for humans. For one of Motoman’s robots a program has been prepared.

This thesis deals with rebuilding of a laboratory manipulator to 3D engraving machine. First part of the thesis describes the engraving technology and lists the most common types of engraving machines. Next, the initial state of the machine is analysed and modifications of mechanical and electrical equipment are suggested. Design, realisation of a control system and human machine interface are described. The Beckhoff TwinCAT programming environment is used. The last part of the thesis deals with practical realisation and commissioning of the machine. The results of the thesis can be used as an addition for lessons of Automation of Production Machines.

The aim of this theses describes the design of the control program for the synchronous axes model and reconstruction of this model. The first main part is description of synchronous axes model, description of engines and other components of model. Then model modifications are described. Another part is discussing the TwinCAT programming environment and describe all important elements that must be performed for proper functionality of the model. There is also a description of function blocks that are used to program motion sequences. The last part is described of demonstration program and program which would be used for teaching.

Context: Flatbed applicators are machines made for laminating, primarily signs on an industrial level. These applicators are controlled manually, which exhibits potential for digitalization in order to enhance the user experience. Problem: The first challenge is to develop a user interface for a mobile app, created to provide an easy path for communication to customers, with user-friendliness as the focal point. The second challenge is being able to communicate with a flatbed applicator, through the aforementioned app. Method: This project started out with pre-studies about the required topics. The system prototype was then designed and implemented with a focus on adequate UI design guidelines for the mobile app and a suitable protocol to enable communication between the app and the applicator. Results: The app prototype was developed through the usage of J.J. Garrett’s model along with Material Design guidelines, in order to establish a customer-centric user interface. Communicating between the mobile app and a PLC using TwinCAT, MQTT and React Native appears to be a feasible solution.

The main aim of this thesis is to create a library in TwinCAT PLC for Beckhoff motion control without NC task. This library is targeted for less performance controllers. The next part deals with creating a PLC application for motion control with digital I/O variables or with serial line. A Windows application will be created to configure the main parameters of motion control in the PLC Application.

Thesis (DTech (Electrical Engineering))--Cape Peninsula University of Technology, 2016. / Majority of the industrial systems encountered are significantly non-linear in nature, so if they are synthesised and designed by linear methods, then some of salient features characterising of their performance may not be captured. Therefore designing a control system that captures the nonlinearities is important. This research focuses on the control design strategies for the Continuous Stirred Tank Reactor (CSTR) process. To control such a process a careful design strategy is required because of the nonlinearities, loop interaction and the potentially unstable dynamics characterizing the system. In these systems, linear control methods alone may not perform satisfactorily. Three different control design strategies (Dynamic decoupling, Decentralized and Input-output feedback linearization controller) are proposed and implemented .in the Matlab/Simulink platform and the developed strategies are then deployed to the design of distributed automation control system configuration using the IEC 61499 standard based functional block programming language. Twin CAT 3.1 system real-time and Matlab/Simulink (www.mathworks.com) environment are used to test the effectiveness of the models The simulation results from the investigation done between Simulink and TwinCAT 3 software (Beckhoff Automation) platforms in the case of the model transformation and closed loop simulation of the process for the considered cases have shown the suitability and the potentials of merging the Matlab/Simulink control function blocks into the TwinCAT 3.1 function blocks in real-time. The merits derived from such integration imply that the existing software and software components can be re-used. This is in line with one of the IEC 6144 standard requirements such as portability and interoperability. Similarly, the simplification of programming applications is greatly achieved. The investigation has also shown that the integration the of Matlab/Simulink models running in the TwinCAT 3.1 PLC do not need any modification, hence confirming that the TwinCAT 3.1 development platform can be used for the design and implementation of controllers from different platforms. Also, based on the steps required for model transformation the between the Matlab/Simulink to the TwinCAT 3 functional blocks, the algorithms of the control design methodologies developed, simulation results are used to verify the suitability of the controls to find whether the effective set-point tracking control and disturbance effect minimisation for the output variables can be achieved in real-time using the transformed Simulink blocks to the TwinCAT 3 functional blocks, then downloaded to the Beckhoff CX5020 PLC for real-time execution. Good set-point tracking control is achieved for the MIMO closed loop nonlinear CSTR process for the considered cases of the developed control methodologies. Similarly, the effects of disturbances are investigated. TwinCAT functional modules achieved good set-point tracking with these disturbances minimization under all the cases considered.

Laser beam welding applications are widely used in the industry. However, laser beam welding applications have a very small position tolerance to an offset. In this project, the offset is defined as the distance between the point, which the laser tool welds, and the point which laser tool should weld the weld joint. In other words, the offset is the position error in a welding application. To perform successful welding, the laser beam must hit the exact coordinate of the weld joints to weld the parts together. For dealing with these inaccuracy issues, tool manipulation systems can be used. In this project, an external axis is used for the precise manipulation of the laser beam welding tool as a complement to robotic nominal movement. Input data to the external axis system is obtained from an image from a vision system of the work pieces which need to be welded. Tool manipulation systems are used to manipulate tools to ensure certain position accuracy during any application. The tool manipulation system in this project has two main parts; a seam tracking system (outside this project) and an external axis system. The seam tracking system gives an on-line measurement of the offset, and that there is a feedback loop with a controller, which gives the system information about how much to manipulate the external axis module to the external axis system. The seam tracking system consists of two main parts; a camera and the seam tracking image processing program. In the seam tracking system, a camera takes images of the work pieces which shall be welded. Then the seam tracking program calculates the offset by image processing. This estimated offset is the input for the external axis system. The external axis system has three main parts; the external axis program, input-output module and the external axis module. The external axis program is the system which controls the input-output module for manipulating the external axis module in this project. The external axis module manipulates the laser beam welding tool by changing the orientation of the tool in order to reduce the offset. This project is about the external axis system. There is a relationship between the offset input and the required manipulation angle of the external axis. In this project, the required manipulation angle is the external axis angle. By using this relationship, the laser beam welding tool can be manipulated to weld in the desired position. The same system can be used in applications which require high position accuracy. The evaluation of the external axis system emphasizes that the accuracy demand of the laser beam welding applications can be satisfied by an external axis system. However, the investigated external axis system behaves in a way that when the offset is larger than it supposed to be, the speed of the TCP movement slows down.