Flexible XTS-Based R&D and Proof-of-Concept Assembly Platform
Challenge
Research and development teams often face a common challenge when evaluating new assembly concepts: traditional automation equipment is typically designed for a single product and process. Every new concept requires software modifications, mechanical changes, and engineering effort before testing can begin.
The objective of this project was to develop a flexible automation platform capable of supporting multiple assembly processes, product concepts, and Proof-of-Concept (PoC) studies without requiring PLC modifications for every new application.
The system needed to provide intelligent product transport, configurable workstation behavior, machine vision integration, flexible part feeding, and rapid process reconfiguration directly from the operator interface.
Solution
The platform was developed using Beckhoff TwinCAT 3 and Beckhoff XTS intelligent transport technology.
Unlike conventional assembly machines with fixed process sequences, this system was designed as a configurable multi-process platform that could be adapted to different assembly tasks through software configuration rather than code modifications.
Products were transported between stations using Beckhoff XTS movers, providing flexible routing and independent control of individual workpieces throughout the process.
The machine incorporated multiple pneumatic process stations capable of performing different assembly operations depending on the selected process configuration.
An Asyril flexible feeding system with integrated vision technology was used for intelligent component presentation and orientation. Additional inspection and positioning tasks were performed using Cognex machine vision systems integrated directly into the TwinCAT environment.
A key feature of the project was the development of a configurable Beckhoff Web HMI that allowed users to define workstation behavior and process sequences directly from the operator interface.
Engineers could configure which stations should participate in a process, define process flow logic, and adjust workstation sequences without modifying PLC software. This significantly reduced engineering effort and enabled rapid validation of new assembly concepts.
To further increase flexibility, the machine was designed with mechanically interchangeable tooling and end-effectors, allowing hardware changes to be performed quickly when testing different product variants or manufacturing processes.
TwinSAFE was implemented to provide machine safety while maintaining the flexibility required for experimental and development activities.
System Architecture
conveyor_belt
Intelligent Transport System
Beckhoff XTS
Independent mover control
Flexible process routing
Dynamic workstation sequencing
settings
Configurable Process Stations
Multiple pneumatic workstations
User-configurable process logic
Reusable station architecture
HMI-driven operation
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Flexible Feeding
Asyril flexible feeder
Integrated vision guidance
Automatic component positioning
Part orientation control
camera
Machine Vision
Cognex vision systems
Position verification
Inspection tasks
Process support functions
web
HMI and Configuration
Beckhoff Web HMI
Process configuration interface
Workstation sequence management
Runtime process customization
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Safety
TwinSAFE
Safe machine operation
Integrated safety architecture
Key Responsibilities
TwinCAT 3 software development
Beckhoff XTS integration
Configurable workstation architecture
Web HMI development
Asyril integration
Cognex vision integration
TwinSAFE implementation
Development of reusable process logic
Commissioning and optimization
Results
The completed platform provided R&D teams with a highly flexible environment for evaluating new assembly concepts and manufacturing processes.
Key achievements included:
Rapid Proof-of-Concept validation
User-configurable workstation behavior
Process sequence changes without PLC modifications
Flexible integration of different assembly operations
Reduced engineering effort for process experimentation
The system successfully demonstrated how Beckhoff XTS technology can be combined with configurable software architecture to create highly adaptable manufacturing platforms for research, development, and early-stage production engineering.
Technologies
Beckhoff TwinCAT 3
Beckhoff XTS
EtherCAT
TwinSAFE
Beckhoff Web HMI
Asyril Flexible Feeding System
Cognex Vision Systems
Pneumatic Automation
Object-Oriented Programming
Intelligent Transport Systems
Flexible Manufacturing
Proof-of-Concept Automation
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Whether you’re developing automated test equipment, force-control applications, data acquisition systems, or regulated manufacturing solutions, I can help design and implement robust Beckhoff TwinCAT-based platforms.