Under the term "U-mation", Weidmüller combines various automation and software solutions that can be individually adapted to the customer's specific application. The portfolio combines modular automation hardware with engineering and visualization tools, enabling the connection of all process levels - from the sensor to the cloud. This includes the U-control 2000 controller with web-based visualization, the U-create software and machine learning and industrial analytics tools.

U-control addresses the machine and plant engineering sector, for example packaging machines and handling systems. The focus is on assistance machines and systems. Typical applications are carton erectors or machine and system components for line production. Carton erectors are stand-alone machines. They are able to perform their function independently and without being connected to a higher-level system. This requires decentralized automation solutions that enable autonomous control of the machine.

The control unit in the application

For the main controller of a stand-alone machine, the U-remote fieldbus coupler is simply replaced by the controller and combined with the U-create studio engineering software. With the Codesys-based software, the configuration and control of stand-alone machines is based on proven standards. This gives U-create studio a decisive advantage in the flexible, modular programming of automation solutions. The open Linux architecture enables the installation of individual software modules as well as simple diagnostics and 3D simulation of the machines.

The controller is based on the compact design of the fieldbus coupler from the U-remote family - and can replace it one-to-one. This saves space and provides maximum flexibility for individual automation applications. U-control 2000 is compatible with a wide range of components from the U-mation portfolio and offers the option of connecting U-remote I/O modules directly, for example. In mechanical and plant engineering, the components of a line are rarely produced in one and the same production facility. To prevent long installation times on site, it is advantageous to be able to commission machine parts before they are brought together. U-mation offers solutions for decentralized automation applications that the user can access from any location. With the web-based control software U-create web, the browser becomes an engineering platform.

Machine and system components for line production

In combination with U-control 2000, the Weidmüller concept enables intuitive and location-independent commissioning of individual units or machine parts. Here too, the u-remote bus coupler is replaced by the controller on which U-create web is already installed, and U-control becomes the main controller. The browser-based operation allows machine parts to be commissioned and parameterized from any location, even before the entire machine is assembled. This simplifies and accelerates the subsequent integration of decentrally manufactured machine and system parts. The U-create visu visualization software can then be used to implement an integrated operating and visualization concept for the entire system. The design of the control system is based on the U-remote remote I/O system.

Thanks to its modular design, U-control 2000 is compatible and expandable with various automation modules from the U-mation portfolio as required. U-create visu enables the user-friendly implementation of multi-touch-capable HMI solutions. The associated web server provides the user interface as a web runtime using JavaScript and HTML 5. This allows HMI panels to be calibrated using any end device. Without adequate visualization, the many possibilities of the control system could hardly be used. With the U-view multi-touch panels and U-create Visu, Weidmüller offers a solution for the operating and communication level.

Control system with many features

The U-control 2000 is a 52 mm slim controller that can be combined with input and output modules like a U-remote coupler. The control hardware is based on a powerful dual-core ARM A9 processor with a clock frequency of 624 MHz, 512 MB RAM and 4 GB internal flash memory. In addition, data and information can be stored on a micro SD memory card with up to 32 GB. The control unit is equipped with a battery-buffered real-time clock.

With the controller and the U-create software solutions, Weidmüller offers an optimally coordinated hardware and software portfolio for a wide range of automation tasks. © Weidmüller

Various interfaces are available to the user for communication and engineering of U-control. The engineering software is started via one of the two RJ45 sockets using a browser. Once the system has been programmed, data can be exchanged with a higher-level controller or an ERP system via this Ethernet TCP/IP interface. A fieldbus system with master-slave function can be connected via the second RJ45 socket. A USB connection is also available, which can also be used for programming or to retrieve diagnostic data. This is an advantage if U-control is already installed in an application and connected to other systems. A CAN interface is used for communication with intelligent components. The 24 V DC power supply feeds both the control hardware and up to 64 different U-remote modules that are connected to the controller. Just like this one, the supply connections for inputs and outputs are separate. The system is also suitable for safety applications. The U-remote power feed modules are used here, which put the machines into a safe state independently of the control system. The necessary, non-safe signals for the application program are transmitted to the control system via the backplane bus and processed there.

The special feature of the controller is that it has two autonomously operating CPU cores. One core runs a non-real-time-capable Linux operating system with Weidmüller's own engineering tool U-create web and a web server. The second processor core runs a real-time capable PLC operating system that executes the application program. Both CPU cores are isolated from each other in terms of security and exchange data with each other via Trust Zones. This means that separate software updates can be carried out independently for both systems as required. To meet the growing security requirements, a TPM chip is integrated into the device. TPM stands for "Trust Platform Module" and protects against unauthorized software updates and modified software or software extensions.

Open platform for automation

U-create Studio offers many Linux-based options for installing application-specific software modules on the U-control 2000. U-create Studio has a Codesys V3.5 development environment and supports all programming languages defined in IEC 61131-3, such as ST, IL, LD, FBD and AS. In addition, a C/C++ environment allows object-oriented programming. The engineering tool allows simple configuration, diagnostics and 3D simulation of the system. A debugging and trace tool supports error analysis. An OPC UA server is implemented for M2M communication. EtherCAT and CANopen fieldbus masters and a Modbus TCP slave complete the system. The software is compatible with U-control and U-remote.

Ralf Willmes, Trainer Automation, International Training Center, Weidmüller in Detmold / am