System overview
The system
With the CX series of Embedded PCs Beckhoff has combined PC technology and modular I/O level to form a top-hat rail unit in the control cabinet. The CX1020 extends the CX product family by a version with higher CPU performance. The CX1020 enables direct connection of Bus Terminals and EtherCAT terminals.
While the CX1000 features an 266 MHz AMD Geode processor, the CX1010 is equipped with a 500 MHz AMD® Geode LX 800Intel(r) CPU. It is an energy-saving device that operates with ultra-low core voltage and features low thermal power dissipation of only 8 W TDP (thermal design power). As a result, no fan is required despite the compact design of the CX1010 Embedded PC. Since Compact Flash is used as boot and memory medium, no rotating media are required in the controller. This is an important aspect for increasing the MTBF (Mean Time Between Failures) of the overall system.
The case and assembly concept of the CX1010 is similar to that of its smaller brother, the CX1000:
It also consists of several components that can be assembled by the user. The simplest configuration consists of a CPU module and a multi-functional power supply unit. The PC104 bus is used for the connection between these and all other CX components, although in the CX1020 this was extended with EtherCAT signals. The basic CPU module is equipped with one RJ-45 socket.
Like the CX1000, the CX1020 can be expanded with optional system interfaces. A DVI-I (=DVI-D + VGA) output, two USB-2.0 interfaces, up to four RS232 interfaces and audio are available. The four RS232 interfaces feature opto-decoupling and can optionally be implemented as RS422/RS.
The same reusability also applies to the multi-functional power supplied units (CX1100-000x) of the CX1020: one without I/O terminal connection, one with K-Bus connection, one with K-Bus and IP-Link connection for IP-67-protected Fieldbus Box modules, and a power supply unit with direct connection facility for Beckhoff EtherCAT Terminals.
EtherCAT as a fast I/O system
The CX1010 Embedded PC was developed for optimum interaction with EtherCAT. The Ethernet interface of the CPU module is not primarily intended for EtherCAT operation. The EtherCAT connection is established via the EK1110 (EtherCAT) extension terminal. The power supply CX1100-0004 establishes the possibility to connect E-Bus Terminal to the CPU Module.
Interestingly, EtherCAT offers several options for connecting conventional fieldbus systems to the CX1010:
either as a CX1500 module directly at the CPU or as an EtherCAT device in terminal form. The PROFIBUS master is available either as a CX1500-M310 or as a EL6731 EtherCAT terminal. Both types offer the same performance characteristics - e.g. both support PROFIBUS DP-V2. In practice, this means that the PROFIBUS master can be positioned exactly where it is required within a machine. It no longer has to be implemented as a plug-in card in the IPC or a master controller in the control cabinet.
PLC, Motion Control, interpolation and visualisation
As a top-hat rail IPC and in conjunction with the TwinCAT software from Beckhoff, the CX1010 offers the same functionality as large Industrial PCs. In terms of PLC, up to four virtual IEC 61131 CPUs can be programmed with up to four tasks each, with a minimum cycle time of 50 µs. All IEC 61131-3 languages can be used.
Moreover, all TwinCAT functionalities are available for Motion Control applications:
In theory, up to 256 axes can be controlled. In addition to simple point-to-point movements, more complex multi-axis functions such as "electronic gearbox", "cam plates" and "flying saw" can be implemented. In contrast to the CX1000, due to its higher CPU performance the CX1010 can now also execute interpolating 3D path movements and DIN66025 programs.
In addition to real-time execution of control tasks, the TwinCAT real-time kernel ensures that enough time remains for the user interface (HMI), to communicate with the real-time components via software interfaces such as ADS or OPC.
For the CX1010 the same basic principle applies: it is a programming tool for all controllers.
The complete programming of PLC, Motion Control and visualization is transferable to all PC controls from Beckhoff, which is reassuring in cases where it becomes apparent during a project that more processing power is required after all. In this case a system with higher performance can be used.
Basic CPU module
Further system interfaces or fieldbus connections can be added to the basic CPU module. The CPU module requires a CX1100 type power supply module.
All CX1500 fieldbus modules and all CX1100 power supply units from the CX1000 series can be used in combination with the CX1010.
The CX1100-0004 power supply unit offers a direct interface between the CX1010 and the EtherCAT Terminals. The combination of CX1010, EtherCAT and TwinCAT enables cycle and response times of less than 1 millisecond.
The CPU module is available in several variants. These relate to:
- System interface configuration: as an option, a DVI and two USB Interfaces can be added to the combination of the Ethernet RJ 45 port that is always present.
- Operating system: There is a choice between "Microsoft Windows CE.NET" or "Microsoft Windows XP Embedded".
- Pre-installed TwinCAT software: CX1010 can be pre-installed without a TwinCAT system, with TwinCAT CE PLC, TwinCAT CE NC PTP or TwinCAT CE NCI, or with the associated full version of the individual TwinCAT levels for PLC and Motion Control.
System interfaces
Further system interfaces for serial communication (2x RS 232 or RS422, RS485), 2 x USB 2.0 interfaces, video output (DVI +) , CF card reader/writer or audio signals can be ordered separately.
Fieldbus interfaces
All CX1500 fieldbus modules and all CX1100 power supply units from the CX1000 series can be used in combination with the CX1010.
The fieldbus interfaces are currently available as master and slave versions for the following fieldbuses:
Beckhoff Lightbus, Profibus DP, CANopen, DeviceNet or SERCOS interface (only master)
The master fieldbus connections enable a CX1020 system to use Beckhoff fieldbus components (such as Bus Coupler, Bus Terminal Controller or Drive Technology) as local control components for complex systems.
Slave fieldbus connections enable the CX1020 system to be used as a subordinate distributed control system for complex or modular systems.
Note:
Documentation describing the fieldbus connections is available separately.
The software
In combination with the TwinCAT automation software, the CX1010 Industrial PC becomes a powerful IEC 61131-3 PLC with up to four user tasks. Additionally, Motion Control tasks can also be executed. Depending on the required cycle time, several servo axes can be controlled. Even special functions such as flying saw, electronic gearbox and cam plate can be realized.
The CX1010 system is programmed in the same way as other bus controllers:
Remote programming via Ethernet
This option is used if the basic unit is equipped with “Windows CE.NET”. In this case, the system is programmed via a laptop or a desktop PC, which is connected to the CX1020 via Ethernet (network or crossover cable). The programs are developed on the laptop with a standard TwinCAT software licence and then loaded into the target device.
Visualization
The Beckhoff OPC server is available for interfacing with SCADA packets, if the two operating system variants “Windows CE.NET” or “Windows XP Embedded” are used. In other words, the CX1010 also offers straightforward visualization and simultaneous control in real-time on a single system.