b maXX PLC di - Drive-integrated PLC for decentralized automation concepts

Highly synchronous motion control with drive-integrated PLC

Decentralized concept Technology function directly in the drive, e.g. for servo-hydraulics in injection molding machines

Baumüller has been successfully implementing the principle of the drive-integrated PLC for decades and, with the new PLC di, has made it future-proof and fit for the IoT. The drive-integrated control unit b maXX PLC di, “di” being short for “drive-integrated”, can execute complex motion control, technology and control functions directly in the drive.

This provides the machine manufacturer with a number of advantages: By integrating the Baumüller motion modules directly in the drive, the user can use numerous pre-programmed functionalities without having to make complex adjustments to the superordinated control unit. This relieves the load on the fieldbus, while faster communication between the PLC and drive optimizes precision and accuracy and thus the productivity of the machine. Highly synchronous processes at high speeds are possible. The integrated PLC also paves the way for a modular machine design. The advantage: individual machine modules can be manufactured independently of each other and commissioned in advance, considerably simplifying and speeding up the commissioning of the entire machine on site at the user's premises.

As the b maXX PLC di can also control other drives as an EtherCAT master, the higher-level PLC can even be omitted completely in some cases. This reduces costs for the machine manufacturer and machine operator. Thanks to its integration in the drive, the PLC di achieves minimum cycle times of up to 250 μs, making it even faster than its predecessor model.

Open system

When it comes to control technology, Baumüller relies on open systems. With the new runtime environment IEC 61131, developed entirely in-house, Baumüller offers a platform that supports current standards such as high-level programming languages such as C++ and IoT connectivity. The runtime system is based on Linux and thus ensures maximum openness for the integration of other systems and absolute flexibility in the implementation of customer-specific projects.

With interfaces such as OPC UA, MQTT, EtherCAT and Ethernet, the b maXX PLC di is ideally set up for future requirements regarding automation or the Internet of Things. This comprehensive openness improves development efficiency, time-to-market and flexibility for the machine manufacturer.

Real-time communication

The digital and analog inputs of the PLC di are also fully geared towards speed. Through digital inputs, the b maXX PLC di reacts in real time to important events such as touch probes. The advantage: The control unit works more efficiently and reliably, a plus point in particular for applications with high requirements in terms of dynamics and precision, where fast response times are required.

The analog high-speed inputs (without additional hardware, minimum scanning time 1 μs) make completely new IoT solutions possible. External sensors can be connected directly. Analyses, e.g. vibration analyses, take place in the PLC in the drive and reactions to external events are also processed directly in the drive-integrated PLC without having to go through additional components.

Communication between the PLC and servo-controller does not take place via the fieldbus but via an internal interface. This provides access to drive parameters such as voltage, current, power, torque, speed or position in “hard real time”. The servo drive thus takes on sensor tasks and enables smart monitoring with little extent of work. With the intelligent modules from the Baumüller SmartValue toolkit, processing then also takes place directly in the drive-integrated PLC.

b maXX PLC di

• Additional hardware in the drive
• Higher performance: minimum cycle times up to 250 μs for highly synchronized motion control
• Modular machines: central or decentralized topologies are possible
• Maximum connectivity: ready for future requirements and IoT
• Data from the drive are provided by an OPC server interface with your own and external systems

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