New generation of Axiocontrol Controllers for demanding automation

Simply more productive
Processing speed plays an increasingly important role in many automation applications, and not just in motion control applications. The focus here is on the speed of the entire application, which depends significantly on the components used. This is because the right devices enable higher processing speeds for individual work steps, which in turn increases the productivity of the entire machine or system.

The heart of every machine or system is the programmable logic controller (PLC) and a powerful I/O system. The important criteria for the PLC are the processing speed of the control program, the transmission rate of the bus system used, and the highest possible synchronicity and low jitter for data transfer between devices. This applies in particular if the applications require short reaction times or a rapid analysis of counting pulses, for example. Phoenix Contact had these considerations in mind when developing its new generation of Axiocontrol units.

The AXC 3050 offers users a high-performance control system that meets even the highest standards. This PLC is distinguished by three main characteristics that are required in different measures for different applications: fast data transmission, rugged design, and ease of use. The AXC 3050 was specifically designed for application areas that pose ongoing long-term challenges on the flexibility and speed of the application, as well as the installed components. This is the case in the renewable energies sector with application areas such as wind parks, infrastructure projects, and machine and system engineering.

Response times in the microsecond range
When seeking to increase the speed of an automation application, the time that is required for different process steps becomes very important, in addition to the processing speed. Fast response times, i.e., the time needed to read, process, and output a signal, and the rapid analysis of input signals are required in several applications to achieve this. The AXC 3050 excels in this regard with a processing speed of one microsecond per 1000 lines of code (data type: bits) as well as integrated technology functions. In applications that require rapid counting and event task processing, the high-performance controller fully exploits the speed of the Axioline I/O system. The combination of the Axiocontrol PLC and the I/O modules from the Axioline F product family makes it possible to achieve response times in the microsecond range and counting functions in the kHz range.

Minimizing system outages
The Axiocontrol AXC 3050 is designed for the mechanical stresses given by harsh environmental conditions. The robustness of the PLC is ensured by stringent test criteria and additional vibration and shock testing. Furthermore, the built-in uninterruptible power supply (UPS) helps increase the availability of machines and systems. This is because installing an external UPS in the control cabinet is not possible in several small-scale applications for reasons of cost and space. That is why the AXC 3050 already features a short-term buffer that keeps the high-performance control system ready for service during a power failure. This allows the most important data, such as the values of remanent variables, to be saved securely to an SD card, and a freely programmable user action to be executed in the application program. The PLC is therefore reliably shut down, which in most cases also applies to the machine or system. The AXC 3050’s power failure security enables application downtimes to be kept to a minimum.

Flexibility for networking
Like all the other Phoenix Contact controllers, the AXC 3050 is programmed using the PC Worx development software. The five programming languages specified in IEC 61131-3 can be used. Using this standard makes it easier to become familiar with Phoenix Contact’s controller paradigms, and it also makes it possible to reuse existing program code. Automatic inputting from the connected I/O modules and easy-to-use diagnostic and debugging functions also number among the standard functions of the Axiocontrol control system.  The AXC 3050 supports a wide range of IT protocols, which in combination with the built-in Ethernet ports make it easy to integrate the controller into a company network and provide quick access to production data statistics. The three separate Ethernet ports also create high flexibility for networking machines and systems. For example, an IP address range can be used for the standard configuration within the application while several machines are connected to a network over another range of IP addresses. The third port can then be used as a remote signaling connection to connect an additional user interface or to connect to the office IT system. Process data is exchanged over the Ethernet ports via standard protocols such as Profinet or Modbus TCP, meaning that local I/O stations as well third-party devices can be integrated seamlessly with the system.

Updates by means of USB stick or SD card
As well as easy programming and data exchanging, the Axiocontrol unit provides intuitive user interaction, and it has a very compact design that permits installation and operation even in very constricted control cabinets (Figure 3). If an update is required for the firmware or the control project, this can be done by means of a USB stick or the optional SD card (Figure 4). A PC is not required. The USB stick and the SD card can be used as logging memory or to expand the PLC’s memory.

Conclusion
The combination of the Axiocontrol AXC 3050 and AXC 1050 controllers and the Axioline I/O system not only make the machine or system faster, they also make it more rugged and easier to use. Special electromagnetic properties (Class B interference emission), the mechanical design, and power failure security increase the overall reliability of the application. Integrated technology functions, such as fast counters and event task processing, enable the implementation of the corresponding applications without using special I/O modules. This is why it pays to look closely at the individual components used in the automation solution when designing the machine or system. In this context, the AXC 3050 can significantly increase the application’s speed, flexibility and availability – without requiring significantly higher investment costs.