TwinCAT RFID Library - Beckhoff Automation

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TwinCATApplication Note DK9322-1109-0011TwinCAT Supplement ‚RFID Reader rMiddlewareSerial interfacePLC TwinCAT RFID LibraryThe ‘TwinCAT PLC RFID Reader Communication’ supplement is a middleware for connecting RFID readersby different manufacturers to TwinCAT PLC via an abstract interface. Communication between the readerand TwinCAT PLC takes place via the serial interfaces EL60xx (Beckhoff EtherCAT Terminal system) andKL60x1 (Beckhoff Bus Terminal system) or also via the COM port of the PC, so that automated detection ofthe presence of tags can be used extending as far as write accesses to the production controller and otherapplications.Basic principles and advantages of RFIDRFID (radio frequency identification) is a contactless identification system for objects that is used in the manufacturing orlogistics controller in order to initiate further sequences and steps via presence detection. An RFID system consists of severaltransponders (tags), a reader and software that evaluates the data from the tags. A tag contains an ID, which does not changeover the entire lifetime, and a memory in which data can be stored. In addition to presence detection, the memory can beused to read or write further data. The size and writability of the memory (Write-once-Read-Only/Read-Write) of the tags aremanufacturer-specific.For application notes see disclaimer on the last pageBeckhofF New Automation Technology

TwinCATApplication Note DK9322-1109-0011TwinCAT Supplement ‚RFID Reader Communication‘IPCRFID readerRFID tag Fig. 1Structure of an RFID connectionThe object to be detected is fitted with a tag that transmits its data as soon as the object is within range of the reader.A specific alignment of the tag and the readers, such as is required with a barcode, is not necessary, since the data isreceived contactlessly within the range cone of the reader. As opposed to barcodes, tag detection is also assured in poorlighting conditions and in the case of dirty surfaces. Since RFID has short detection times and many tags can be detectedsimultaneously (bulk reading ability), the individual goods on an entire pallet of different goods, for example in a goodsreception area, can be identified individually without having to take the container apart. Thus, all goods can be identifiedwithin a very short space of time and their data made available for further processing. RFID offers many advantages over otheridentification systems and is now used as an industrial standard in almost all industries.SecurityGoods flowWaste managementForgery-proofingTracking of hazardous goodsTracingGoods markingServicingPersonnelMembership cardTime recording Fig. 2Areas of applicationfor RFIDCredit chipsImmobiliserPayment systemsAccess systemsProcess managementProduct historyParts trackingTool identificationAreas of application of RFIDFor application notes see disclaimer on the last pageBeckhofF New Automation Technology

TwinCATApplication Note DK9322-1109-0011TwinCAT Supplement ‚RFID Reader Communication‘ BarcodeRFIDWear and tearhighvariableProcurement costslowdepends on the techniqueData densitylowhighInfluence of dirt/moistruehighno or little influenceInfluence of optical coveragefailureno or little influenceManufacture by customerpossiblenot possibleComplexity of the applicationhighvery easyBulk reading capabilitynot possiblepossibleUnauthorised copyingeasydifficult or impossibleFig. 3Differences between barcode and RFIDTwinCAT PLC RFID Reader CommunicationIn order to connect RFID readers to the controller, up to now the appropriate protocols had to be implemented for the variousreaders on the basis of the serial interfaces. With the ‘TwinCAT PLC RFID Reader Communication’ TwinCAT library, a general,abstract interface has been developed that can be used for any supported reader. The user sees only one block in the userinterface. The corresponding protocols have already been implemented internally for different readers; special adaptations to areader can be carried out simply via the configuration setting. The TwinCAT library is based on the IEC 61131-3 standard, withwhich the data from the tags can be directly accessed or changed. This way, alongside the mere presence detection, the writingof the RFID tags is also integrated into the PLC eManufacturertTimeoutRxBufferTxBufferFB fo Fig. 4TwinCAT function block for reader implementationThe system hardware, consisting of transponders and readers, can be chosen by the user according to his application andFor application notes see disclaimer on the last pageBeckhofF New Automation Technology

TwinCATApplication Note DK9322-1109-0011TwinCAT Supplement ‚RFID Reader Communication‘procured externally. The RFID reader is connected to the industrial PC either via a serial interface (KL60x1 Bus Terminal EL60xxEtherCAT Terminal) or via the COM port. If the range is not sufficient for serial transmission, the connection point of the RFIDreader can be distributed anywhere in the I/O field using the corresponding coupler. The selected system can be integrated intothe automation environment via TwinCAT and the RFID reader supplement.AdvantagesIn conjunction with the serial interfaces in terminal form, the RFID reader can be used in any fieldbus. Several readers can alsobe integrated in the simplest way in the TwinCAT-encompassing automation world; all that is required for integrating severalreaders is to create multiple instances of a function block. This way, even extensive applications that use different functionsof the RFID reader can easily be implemented. The implementation expenditure is very low, because the manufacturer-specificinterface protocol does not need to be researched in detail and implemented.The handling and the interface of the PLC library are the same for all the supported RFID reader models. The frame structure,the composition of the telegrams, the command name and other protocol specifications are performed automatically by thelibrary. This saves the user valuable development and implementation time and he can concentrate fully on his application.Access to the RFID reader with tools from the Windows environment is similarly not a problem with the ‘Virtual Serial COMDriver’ supplement for virtual interfaces.If networking takes place at process control level, then detection of the RFID tags can take place at each station in order toimplement the traceability of components within the production process.Practical application: detection of the presence of componentsRFID is used to detect the presence of individual components within a production line for wooden products. The RFID tag isattached to each component and is read by readers at different stations.For application notes see disclaimer on the last pageBeckhofF New Automation Technology

TwinCATApplication Note DK9322-1109-0011TwinCAT Supplement ‚RFID Reader Communication‘Industrial PCTagsWindows XP orWindows CEHardwaremanagementTwinCATRS232COMportTwinCAT PLCRFID Reader CommunicationOption 1KL/EL60xxRFID readerFieldbus adapterOption 2 Fig. 5Two options for connecting the reader to the PLCVarious components are created from the blanks in order to minimise cutting waste. For this reason, the boards are fitted witha tag after being cut to size and the ID is assigned to an order or an assembly within a database. Once the tags have beenwritten, the components are transported by conveyor belts and parts trolleys to the individual machining centres. Due to thefully automated manufacturing, the boards reach speeds of 60 metres per minute on the conveyor belts. Since RFID, as opposedto barcodes, allows detection without stopping and speed reduction, the selection of the branching points can be executed inreal-time. If the component passes a reader attached to the conveyor belt, the tag is read, the destination is recognised and thepoints are set accordingly.– TwinCAT PLC RFID Reader Communication www.beckhoff.com/TwinCAT-RFID-Reader– Optional TwinCAT software packages www.beckhoff.com/supplements– EtherCAT Terminal, RS232 interface www.beckhoff.com/EL6001– EtherCAT Terminal, RS422/485 interface www.beckhoff.com/EL6021– EtherCAT Terminal, 2-channel RS232 interface www.beckhoff.com/EL6002– EtherCAT Terminal, 2-channel RS422/485 interface www.beckhoff.com/EL6022– Busterminal, RS232 interface www.beckhoff.com/KL6001– Busterminal, RS422/485 interface www.beckhoff.com/KL6021– Busterminals www.beckhoff.com/Busterminal– EtherCAT Terminals www.beckhoff.com/EtherCAT-Terminals For application notes see disclaimer on the last pageBeckhofF New Automation Technology

TwinCATApplication Note DK9322-1109-0011TwinCAT Supplement ‚RFID Reader Communication‘This publication contains statements about the suitability of our products for certain areas of application. These statements are based on typical features of our products. The examples shown in this publication are for demonstration purposes only. The information provided herein should not be regarded as specific operation characteristics. It is incumbent on thecustomer to check and decide whether a product is suit-able for use in a particular application. We do not give any warranty that the source code which is made available with thispublication is complete or accurate. This publication may be changed at any time with-out prior notice. No liability is assumed for errors and/or omissions. Our products are describedin detail in our data sheets and documentations. Product-specific warnings and cautions must be observed. For the latest version of our data sheets and documentations please visitour website (www.beckhoff.com). Beckhoff Automation GmbH, November 2009The reproduction, distribution and utilisation of this document as well as the communication of its contents to others without express authorisation is prohibited. Offenders will beheld liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.BeckhofF New Automation Technology

reader can be carried out simply via the configuration setting. The TwinCAT library is based on the IEC 61131-3 standard, with which the data from the tags can be directly accessed or changed. This way, alongside the m

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