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Automation Studio 4
Automation Studio 4
Studio 4
Integrated automation
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Contents
Automation Studio 4
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Automation Studio 4
Automation Studio 4
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Automation Studio 4
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Results, FAST!
Automation Studio 4 is the ultimate tool for the development as soon as the specifications are
field of machine and systems engineering. Through defined, simultaneously and hand-in-hand with
its sustainable and efficient approach to soft- the development of the mechanical and electrical
ware development, it will help you keep your components. It also means having multiple pro-
quality up, your engineering costs down and your grammers working concurrently on various aspects
time-to-market short – even in the face of ever- of the overall software solution.
increasing product complexity.
Another key to achieving ambitious development
The capital goods market expects continuously goals is reusing existing software elements that
expanding functionality while keeping prices con- have already proven themselves in the field –
stant. It demands top quality, a long useful life and whether modules developed in-house or pre-pro-
low operating and service costs. The only way for grammed technology components. This saves
machines and systems to meet these require- the time and effort that would otherwise be spent
ments and offer real added value to the bottom line on programming, testing and certification.
is through increased complexity. Increasing the
time spent planning, developing and building these As a single tool for machine and system automation,
products is not an option since fierce competition is Automation Studio 4 delivers an unprecedented
driving companies to gain a technological edge. array of cutting-edge features to support every
stage and aspect of product development. It em-
A paradigm shift towards success powers software developers to master the grow-
Parallel engineering is one of the keys to acceler- ing complexity of mechatronic systems – quickly,
ated development. This means starting software efficiently and without compromising quality.
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Faster to learn
Faster to program
Faster service
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Integrated
software engineering
Automation Studio 4 is the one development and chine, development methods have been forced
runtime environment for every aspect of an auto- to evolve dramatically.
mation solution – from control and motion tech-
nology to HMI, operation and integrated safety Time-to-market goals can no longer be achieved
technology. The 4th generation of this powerful by waiting until the machine is built and the hard-
software engineering platform for industrial auto- ware is in place before rushing through software
mation has been completely redesigned to help development under extreme time pressure. While
users work more efficiently and effectively. today’s programming tools are indeed able to
accelerate the task of programming itself, the
Today’s software developers are confronted with greatest potential for efficient and sustainable
an unprecedented diversity of hardware options, product development lies in merging the fields of
both on the machine and on their desks. To keep mechanical, electrical and software engineering
up with the mounting complexity, functional den- and treating machines and systems like the in-
sity and variety of tasks involved in each ma- tegrated creatures they really are.
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The only future-proof solution is an open solution. allows programmers to work in their preferred lan-
Openness allows you to work with the tools you are guage, it also means existing code can be inte-
most comfortable using. It allows machines to com- grated with no added effort. The availability of
municate effortlessly with external systems. And PLCopen function blocks such as those for motion
by facilitating the reuse of existing software for control and safety further simplifies programming,
future solutions, it frees up valuable time to get as do connectors for integrating code generated
your product to market faster. Proprietary solutions, automatically from simulation tools.
step aside. The future is Automation Studio 4.
Project files are shared exclusively in XML format,
Automation Studio 4 allows PLC programming in all the de facto IT standard, which ensures open
IEC 61131-3 languages, in CFC and C, as well as communication with third-party systems such as
object-oriented programming in C++. This not only material management and production planning
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software. Further support is provided by direct ac- various Internet technologies through the use of
cess to databases via the SQL interface. dedicated libraries that streamline the implemen-
tation of location-independent approaches to
Many interfaces to other systems operation and production.
Automation Studio 4 utilizes OPC Unified Architec-
ture, or OPC UA for short, for its direct connection With options for the direct integration of all fieldbus
to the plant management level. This protocol pro- systems, Automation Studio 4 opens up the full
vides convenient functions that make developers’ spectrum of available field devices and provides
lives easier, and as a young market standard with optimal support for third-party system integration.
an open architecture, it promises long-term com- Integrated safety solutions – also programmed in
patibility with an extremely wide range of third- Automation Studio 4 – are also completely inde-
party systems. Automation Studio 4 also supports pendent of the fieldbus system being used.
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Software engineering
with Automation Studio
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With Automation Studio, developers can program, ware architectures and the application of modern,
test and optimize open and closed control loops sustainable development techniques, this inte-
and algorithms, movement sequences and visu- grated development platform and real-time oper-
alization interfaces – all in a single development ating system supports time-saving development
environment. This eliminates the problems that of high-quality complete solutions from start to
arise when interfacing between separate tools and finish. Eliminate barriers between systems and tap
significantly increases development efficiency. into the full potential of reusable software com-
Through the use of open communication and soft- ponents with Automation Studio 4.
01 Communication
08 Control
02 Project management
03 Programming
06 Safety
04 Diagnostics &
Remote maintenance
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Realistic
Parallel
& modular
Parallel
When manufacturing machines and systems, the A mechatronic system merges mechanics, hydrau-
disciplines of mechanical, electrical, control and lics and pneumatics with electrical equipment,
software engineering come together to produce control technology and software. In times of tight
fully integrated mechatronic systems. While the market entry windows, tighter budgets and in-
complexity of these systems continues to grow, creasing demands on complexity and efficiency,
the amount of time permitted for developing them development of machines and systems must be
is shrinking. With the array of powerful features both fast and cost-efficient. Ruling out risks that
and intelligent links to third-party systems provided could lead to missed development targets is es-
in Automation Studio 4, developers are perfectly sential. The key to shortening the overall develop-
equipped to benefit from the synergy of mecha- ment cycle is to start work in all of these different
tronic engineering. Achieve series production disciplines simultaneously. Since the software is
readiness directly at the prototype stage – faster, responsible for the behavior of the machine or
cheaper and with uncompromising quality. system, including all processes and movements,
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its development can begin at the same time and ulator integrated in Automation Studio, allows you
based on the same specifications as the mechani- to simulate operation of a controller without any
cal design. hardware. But the options for virtual testing and
commissioning don’t end there. You can also sim-
Accelerated development through simulation ulate any of the drive systems from B&R’s ACOPOS
Simulation-based engineering using computer series, including the loads to be moved by the con-
models of the features under development helps nected motors. Or you can use a 3D hardware model
align the software with the mechanical design to simulate the real-time behavior of inputs and
very early in the development process. These outputs in conjunction with the planned hardware.
models are generated based on data from the
simulated kinematic and dynamic behavior of in- Multidisciplinary concurrent engineering
dividual components or entire modules in the CAD By removing the barriers between engineering dis-
systems used by the mechanical engineers. ciplines, Automation Studio 4 helps you optimize
the development workflow and further accelerate
Automatic code generation your time-to-market. A bidirectional interface with
The ability of simulation tools like MATLAB/Sim- the database system of the leading ECAD tool,
ulink and MapleSim to analyze simulated process- EPLAN Electric P8, helps synchronize your elec-
es and convert them into source code in C or trical and hardware configurations to avoid re-
Structured Text greatly simplifies and expedites dundant or inconsistent data entry. Support for
software development. Instead of programming EPLAN’s database platform is also provided by
everything manually, you can simply import this other tools commonly used in the field of machine
code directly into Automation Studio and use it as and systems engineering, which means it is just
a self-contained application module in the control as easy to integrate MCAD designs and plans for
software. This saves valuable development re- hydraulic and pneumatic components.
sources and eliminates a potential source of mis-
takes and misunderstandings. Symbolic algo- Automation Studio 4 allows you to import entire
rithms developed by B&R optimize and accelerate hardware topologies directly from EPLAN Electric
code execution without reducing the effective- P8, including corresponding I/O mapping data and
ness of the model. process variables, and align them bidirectionally.
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Sustainable software
Automation Studio 4 supports the standardization of software modules that are used frequently. This not only makes reusability
easier, it increases overall software quality.
The ability to break software development into modularization. They develop standard parts and
separate tasks that can be completed in parallel components to perform specific functions and
by multiple developers or teams saves an incredible combine them as needed into a complete machine
amount of time. These time savings are increased or system using well-defined connections. In
even more by being able to store frequently used many design offices, projects are split up between
functions in software modules that can be reused specialists in the various engineering disciplines.
whenever needed. Through its commitment to
intelligent software modularization, Automation Mastering product complexity
Studio 4 helps you reach your development goals The modularization approach has been fully
quickly while maintaining quality throughout every embraced by mechanical engineers and has
aspect of your project. been a mainstay in the IT world for years. To
continue using obsolete methods reminiscent
In order to respond to the increasing complexity of of the earliest days of PLC programming would
today’s products without throwing schedules and make developing software for today’s complex
budgets to the wind, mechanical designers have mechatronic systems an unnecessarily gruel-
discovered the advantages of standardization and ing endeavor.
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The System Designer feature in Automation Stu- Hardware configuration is an important stepping
dio 4 helps lay out your hardware quickly and stone in the path to a finished automation appli-
accurately by letting you arrange devices and cation. In essence, it is a complete description of
connections in a realistic control cabinet view the hardware on which the software will eventu-
and making it easy to configure common compo- ally be required to perform, including everything
nents once and reuse them again and again. It from controllers and Automation PCs, analog and
contributes to a sustainable software develop- digital I/O modules, drives and motors to HMI de-
ment process that is able to manage increasing vices for operation and visualization – not to
product complexity while still keeping quality mention safety configurations made up of safety
high and engineering costs low. controllers and safe I/O modules.
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Highlights
Automation Studio 4
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Combine programming
languages as needed
Highlights
< Complete, simple and compatible through IEC 61131-3 languages, CFC and ANSI C
< Object-oriented programming with C++
< Unrestricted use of libraries representing 1,000 man-years of experience
< Protection of user know-how through encapsulation
< Increased productivity through SmartEdit functionality
Automation Studio 4 provides support for all IEC Chart, ANSI C and the object-oriented program-
61131-3 languages in addition to C and object- ming language C++. These languages can be
oriented programming in C++. Smart editors pro- used in any combination whatsoever. All lan-
vide context-based suggestions drawn from both guages access the same process variables and
included function libraries as well as sections of use the same libraries and data types. In addi-
code that have already been programmed. tion, function blocks can be exchanged without
any rewiring, while algebraic functions can be
Automation Studio shortens the learning curve entered directly as equations.
by allowing developers to work in any of the pro-
gramming languages defined in the IEC 61131-3 Fast and accurate programming is assisted by
standard – Instruction List, Ladder Diagram, Func- intuitive editors with integrated SmartEdit func-
tion Block Diagram, Sequential Function Chart and tions, outlining, change tracking and user-de-
Structured Text – as well as Continuous Function fined code snippets.
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Integrated
HMI package
Providing the means to operate machines and mon resolutions make it easy to create process dia-
itor their behavior is a core function of any auto- grams that can be viewed on various displays, while
mation solution. Automation Studio 4 includes an Unicode support allows pages to include Asian
integrated package for creating HMI applications characters as well.
that run on all types of hardware – from simple
text to Full HD displays keys and/or touch screen.
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Automation Studio 4
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Lock in your
software investment
Highlights
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As the complexity of automation tasks increases, to a degree that allows users to make any neces-
so does the value of the time and effort invested sary modifications themselves.
in software development. It is essential for cus-
tomers to secure this asset so that it continues to Open and safe
generate profit for as long as possible and deliver Source code can be encrypted to provide restricted
a reliable ROI. Software must also be safeguarded access to selected individuals. This feature is in-
against unauthorized manipulation or reproduction. tegrated in Automation Studio and can be applied
to entire projects or limited to certain parts. Au-
One of the keys to the long-term security of an thorized end customers can then access only
investment in machine software is its compati- these parts of the project, which is stored on the
bility with multiple hardware platforms. Automa- controller and protected by a password. A modular
tion Studio manages planning, programming and software design with autonomous modules that
configuration for all B&R hardware – from the Sys- run independently on the controller provides an-
tem 2000 and Industrial PC 5000 through Power other layer of know-how protection. Modules can
Panels, Automation PCs and the X20 System. be programmed, compiled, tested and uploaded to
the hardware individually without any prior inter-
That’s hardware compatibility that reaches back action with the rest of the software.
to 1995. Future platforms will enjoy equally long-
term support through Automation Studio and en- Since it is no longer necessary to consolidate
sure maximum protection for the software it is used everything and package it as a complete software
to create. solution, there is no security risk involved in allow-
ing machine users to program individual functions
Know-how protection in Automation Studio 4 or integrate components from third-party devel-
Software developed with Automation Studio is im- opers. These in turn benefit from the protection of
mune to unlawful manipulation or access. Never- their own intellectual property since they are able
theless, Automation Studio also features the ability to provide executable modules in binary form rather
to disclose specific parts of the machine software than source code.
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Series-produced machine
manufacturing with
software on demand
Fully recognizing the trend towards the flexible to the machine with no manual intervention what-
customization of series-produced machinery, Au- soever. Only when this step is complete does the
tomation Studio’s dedication to modular soft- operating system start the real-time application.
ware doesn’t stop at the engineering stage. By A machine’s configuration can easily change later
providing the ability to upload individual modules on, however, when auxiliary options are added or
to the machine at any time, Automation Studio removed in the field. In these cases, the correspond-
makes it possible to automatically load and en- ing software modules can be loaded and enabled
able a custom version of the automation software with all of the convenience of plug-and-play.
as needed by a particular machine configura-
tion. This minimizes the effort of commissioning Flexible safety included
the software for series production of machinery Dynamic field upgrades are possible for both stan-
in batch sizes of one while streamlining upgrades dard and safety-oriented control equipment. A
performed in the field. safety upgrade takes place via a certified process
that involves an additional confirmation step
Implementing customer-specific machine adap- when implementing the necessary configuration
tations as late as possible during production is so that machine options continue to satisfy SIL 3
one way that machine builders can reduce costs. and PL e requirements.
The goal of building series machines in batch sizes
of one is achieved by offering a range of optional
features that can equip a machine to manufacture
a particular end product. This modular mechanical
design must be backed up by an equally modular Highlights
software solution that can be customized to match
the final machine. < Generation of custom software
during production
Software on demand: Factory-installed < Data point mapping when
or field upgrade production begins
Modifications to a machine’s mechanical configu- < XML format for machine options
ration can occur at many stages of its life cycle. < Batch generation of software and
This is why B&R’s real-time operating system, configuration from ERP systems
Automation Runtime, constantly updates the actual < Plug-and-play capability with the
hardware configuration. At initial commissioning configuration monitor
prior to delivery, the software can be customized < Safety configuration modifications
to match the detected configuration, verified up to SIL 3
against the ordered configuration and transferred
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Request
SAP
NetWeaver
Ethernet
Powerlink
AS4 AS4
AS4
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Integrated
online diagnostics
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Highlights
B&R hardware provides diagnostic data automatically. The System Diagnostics Manager can display this data in any web browser
and even directly in the HMI application itself.
In order to ensure maximum availability, automation provided by B&R hardware throughout the com-
systems and machine software must provide trans- missioning, field testing and operation phases.
parent access. Automation Studio’s integrated Using advanced scalable vector graphics, System
diagnostic tools support developers and users in Diagnostics Manager can be viewed on displays of
all stages of a machine or system’s life cycle. any size or even integrated in the machine’s HMI
Whether accessed on-site or remotely, these in- application.
tuitive features significantly reduce the time and
money spent on service and maintenance. In order to get a quick overview of the axes being
used in the machine, users have the option of
No external service or diagnostic software is needed querying axis information in a table. Information
to analyze the behavior of a machine or system – relevant to homing, enable status, current velocity
all the tools you need are integrated right in Auto- and position or the status of onboard inputs is
mation Studio 4. primarily displayed in the form of easily identifiable
icons. For more detailed analysis, the status of
Throughout development and commissioning, the any axis can be accessed in the System Diag-
Project Monitor feature provides a helpful compar- nostics Manager.
ison between an Automation Studio project and
the software installed on the controller, while NC No need for electrical measurements
Cockpit offers a full set of commissioning and diag- Automation Studio 4 features an integrated I/O
nostic tools for motion axes. viewer that displays the current status of every I/O
module in the system. This eliminates the tedious
Tool-free system diagnostics over the web task of checking each I/O point electrically. And
During operation, it is important for analysis and because System Diagnostics Manager allows all
diagnostic data to be available even without a di- diagnostics data to be viewed from a central com-
rect connection to Automation Studio. If you have puter, it just makes things that much easier for
a TCP/IP connection and a web browser, then you the B&R support team to perform offline analysis
have easy access to all of the diagnostic data when more in-depth service is required.
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Maximum avail-
ability through
redundancy
Simply by activating the redundancy feature in POWERLINK redundancy
Automation Studio 4, you can transform a pair of Most solutions involve a combination of PLC redun-
standard X20 controllers into a high-availability dancy, POWERLINK master redundancy and POWER-
system. Achieve maximum availability of your auto- LINK cable redundancy. To guarantee an uninter-
mation system when using POWERLINK by adding rupted flow of data in any situation that might
ring and cable redundancy. occur on the system, each network line must be
connected to each PLC.
Potential applications for high-availability systems
range from process technology (e.g. in power plants, Simple application development
the chemical industry, etc.) to complete produc- Redundant systems rely solely on standard com-
tion systems and even standalone machines. In ponents. B&R Automation Studio as the engineer-
essence, a failsafe system always makes sense ing tool and Automation Runtime as the runtime
when system or machine downtime is expensive or system on the PLC both already provide support
has expensive consequences. Conventional redun- for redundancy as a standard feature. Developing
dant systems have tended to be relatively expen- applications for redundant systems is generally
sive themselves, however, so they are mostly no different than for non-redundant systems. A
restricted to process technology applications. Yet simple switch in the engineering tool defines
with machine downtime becoming increasingly whether a system is redundant or not. The rest is
costly, B&R’s sleek solution provides an economi- handled by Automation Studio and Automation
cal redundancy option that pays off quickly for Runtime. This structure and level of integration
machine builders as well. makes it easy to upgrade a system with one PLC to
a redundant system.
Controller redundancy
PLC redundancy is achieved by coupling two iden-
tical Atom™ CPUs from the standard X20 product
line. There are no special “redundant controllers”
with specific model numbers. Highlights
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With its flexibility and diverse functions, the APROL through an array of powerful system functions
process control system is the optimum platform paired with the use of proven series products. Cus-
for automation solutions in a wide range of fields. tom out-of-the-box solutions maximize flexibility
while minimizing the time and cost of engineering.
APROL is distinguished by its scalable architecture, With an intuitive HMI system as the foundation, the
its unified and completely integrated engineering integrated alarm, trend and reporting systems form
environment and its exceptional performance. the pillars of a seamless solution for the acquisi-
Maximum reliability and availability are achieved tion of operational and process data.
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Automation Studio 4
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Automation Studio 4 is the ultimate integrated auto ing, or whether producing or packaging pharma
mation software for every industry. When it comes ceutical, food and beverage or tobacco products.
to efficient and sustainable software engineering On the other hand, there are most certainly indus-
for machines and systems, Automation Studio offers try-specific differences, as indicated by different
the power and versatility to optimize every hori- applicable standards.
zontal and vertical aspect of your system and the
openness to secure its value long into the future. The Automation Studio 4 development system
integrates every aspect of automation, providing
Manufacturers face unyielding pressure to raise uniform solutions for open and closed loop con-
the level of automation in their production lines, trol, motion control and safety technology as
with individual machines becoming increasingly well as hardware and software for operating and
automated as well. When it comes to integrating monitoring entire systems from the highest su-
handling equipment, robots and the transport pervisory level down to individual sensors and
systems that connect them, it makes no differ- actuators. The features it provides and the sys-
ence whether you’re running a production hall or tems it is used to create are suited for all indus-
processing plant. The logical next step is to merge tries, support compliance with relevant standards
individual subsystems with automated control of and are certified by the respective industrial gov-
the entire system at a supervisory level to close erning bodies.
any gaps between processes.
A selection of technology packages provides pre-
Methodological differences from industry to indus- programmed open loop, closed loop and motion
try are fading. Control algorithms and production control technology as well as visualization solu-
sequences have many similarities, whether pro- tions for typical industry-specific system compo-
cessing metal or wood, whether printing on textiles, nents, making it easy for software developers to
plastic or paper or converting them into packag- create solutions optimized for particular industries.
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The high-performance POWERLINK real-time com- centrally via the bus, greatly simplifying engineer-
munication solution is based on the IEEE 802.3 ing. The advantages are clear: save time, simplify
Ethernet standard and designed to ensure real- systems and relieve the load on control tasks.
time data transfer in the microsecond range.
Reliability
Flexibility In safety-critical real-time applications, POWER-
POWERLINK provides optimum flexibility for both LINK proves itself as an extremely robust system
centralized and decentralized architectures. Its with a high level of immunity to electromagnetic
hot plugging capability allows modules and com- disturbances. The most demanding field condi-
ponents to be connected and disconnected as tions require a system’s mechatronic components
needed during operation. This has no impact on to operate with utmost reliability, yet they also
real-time behavior and does not require restarting require the bus to ensure data transfer even if an
the system, which saves time and money. Flexi- error occurs.
ble cabling allows you to decide which topology
best meets the needs of your system. Nothing Return on investment
stands in the way of upgrading your machine or Based on IEC standards and supported by the inter-
system or continually expanding your machinery. nationally active Ethernet POWERLINK Standard-
ization Group, POWERLINK guarantees compatibility
Performance anywhere in the world. As an open solution, POW-
Highly efficient cross-communication and network ERLINK is unpatented, software-based technology
topologies with distributed intelligent sensors that is completely independent of proprietary
and actuators help minimize jitter and ensure fast hardware. Its scalability and ability to integrate
response times. The efficiency of POWERLINK makes all types of systems make POWERLINK a perfect
it possible to implement high-speed control loops solution for any industry.
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openSAFETY – The
only fieldbus-inde-
pendent safety pro-
tocol
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I/O systems outside the control cabinet Scalable PLC platform Modular I/O system
<< X67 I/O << X20 PLC << X20 I/O
<< Compact and ergonomic << Intel® Atom™ performance << Removable terminal blocks
<< IP67 protection << Fan-free and maintenance-free << Hot-pluggable electronics
<< Excellent EMC properties << Onboard POWERLINK << Unequaled component density
<< Open for all fieldbus systems << Onboard gigabit Ethernet and USB << 16 channels with total width of only 12.5 mm
<< Seamless integration of IP20-rated I/O << Modular interface expansions << Open for all fieldbus systems
<< Extremely compact << Seamless integration of IP67-rated I/O
<< Redundancy support
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Automation Studio 4
Integrated automation
Global presence
Solid partnership