Real-time automation

Where IT meets OT

The u-control 2000 web controller integrates real-time automation and communication for the Internet of Things and thus the interface between Information Technology (IT) and Operational Technology (OT). u-control web is particularly suitable for small and medium-sized automation tasks.

An automation solution for parameterizing and controlling stand-alone machines: the u-create web engineering tool and the u-control 2000 web controller © Weidmüller

The controller is integrated into the u-mation portfolio. Under this term, Weidmüller combines various automation and software solutions that can be individually adapted to the customer's respective 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. The u-control 2000 web controller is part of the portfolio. The web connection of the controller makes it possible to access machines from any location, with any end device, regardless of the operating system. This independence is achieved by moving the software from the PC to the controller and by using open web technologies. With HTML5, CSS3 and JavaScript, any system can be monitored and programmed independently of operating systems.

With u-control 2000, automation projects can be implemented faster, more flexibly and more intelligently.

u-control 2000 is a 52 millimeter 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 Mbytes of RAM and 4 GB of internal flash memory. In addition, data and information can be stored on a micro SD memory card with up to 32 GB. The controller is equipped with a battery-buffered real-time clock.

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Various interfaces are available to the user for communication or 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 port is also available for programming or retrieving diagnostic data.

The special feature of the new controller is the fact 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. The two CPU cores are isolated from each other in terms of security and exchange data with each other via Trust Zones.

u-create web is a web-based and license-free engineering software for configuration, system parameterization and programming. The software is available via a web browser, requires no installation and is therefore independent of hardware and operating system. With HTML5, CSS3 and JavaScript, any system can be monitored and programmed independently of operating systems.

Weidmüller also relies on established technology such as the graphical development tool Node-RED to connect to the "Internet of Things". The Node-RED development tool guarantees the simple implementation of applications in the Internet of Things area. Individual function blocks (nodes) are simply contacted by drawing connections. A large number of supplied and freely available nodes cover most common services and technologies.

With its technical performance, u-control 2000 web is clearly aimed at machine and plant construction, for example packaging machines. A typical application is a carton erector. Fully automatic carton erectors speed up packaging processes considerably and guarantee efficient carton handling. They vary in their performance, whether for different carton formats or for closing the carton base with adhesive tape or hot melt glue. These different requirements call for different system concepts on the part of the machine and system manufacturer. This also results in different automation tasks. Weidmüller supports flexibility in the adaptation of tasks with the u-contol web controller. Used flexibly, the controller is able to perform its function independently and without connection to a higher-level system. The use of open web technologies makes it possible to access machines from anywhere, with any end device, regardless of the operating system.

The u-control 2000 control unit offers the option of connecting u-remote I/O modules directly. The 24-volt DC power supply for u-control feeds both the control hardware and up to 64 different u-remote modules, which are connected to the controller in the same way as a u-remote coupler. Just like this, the supply connections for inputs and outputs are separate.

Carton erectors can be automated with the u-control 2000 web control system and the u-create web engineering software. © Weidmüller

Thanks to its modular design, u-control 2000 is compatible with various automation modules from the u-mation portfolio and can be expanded as required. In addition to the remote I/O system u-remote or remote I/O modules in protection class IP 67, the portfolio includes modern operating devices (HMIs) - u-view. The range is rounded off by the Security Router. Machines and systems can be monitored efficiently and securely using the web-based remote maintenance solution u-link via the router's VPN connection. In future, Weidmüller will also incorporate the remote maintenance solution into the u-control control solutions in order to obtain a direct and secure connection to their data.

In future, u-control 2000 will enable customers to implement their automation projects faster, more flexibly, more intelligently and on the basis of the latest open web technologies. With u-control Web, OT and IT merge seamlessly for the first time. The system is rounded off by the web-based visualization u-create visu, which can be created using just an HTML 5 browser without additional software and is available as a human-machine interface. as

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