| worldwide | belgium PC Control 01 | 2016
Seamless integration of CAD files into the automation platform
Fully automated production of
pre-stressed concrete elements
The use of pre-stressed concrete elements, which are delivered cut-to-size and already include the necessary cutouts for plumbing
and lighting, is common in construction projects today. The hollow-core components are superior to alternative ceiling designs
because they require less concrete while delivering the same load-bearing capacity. Echo Precast Engineering, a member of the
Progress Group, specializes in building machines for the production of such elements. Flexibly adaptable and equipped with the
latest control technology, the machines make it possible to manufacture custom-tailored elements with a high degree of effi-
ciency. The PC-based controllers not only run the equipment, they also determine the cutout positions and other details based
on architect drawings.
Echo Precast Engineering in Houthalen, Belgium, is a renowned manufacturer
of machines for the production of pre-stressed concrete building materials up to
2.4 meters wide and 120 meters long. “We serve a very special market,” says Jo
Nijs, automation engineer at Echo Precast Engineering. “The machines operate
in rough environmental conditions, yet must maintain exceptional precision.”
CX2020 Embedded PC controls concrete extruder
The latest machine developed by Echo Precast Engineering, the X-Liner®, is an
extruder that uses augers to press concrete into a mould while it glides along
a track. “To ensure consistent concrete strength and short drying times, we
must control the density of the material with a relatively complex algorithm.
Compressing the concrete through vibration, while compensating for potential
variances in the concrete‘s composition and quantity in the hopper, is part of our
core competencies. Let’s not forget that concrete is a composite product with
varying properties,” explains Jo Nijs.
“We have standardized on Beckhoff automation technology within the Progress
Group, which includes Echo Precast Engineering,” says the automation expert.
“The PC-based control platform delivers the reliability and flexibility we need for
our machines. In addition, Beckhoff is a global player, just like we are. This means
that we can support our customers wherever they may be, sourcing replacement
parts on short notice.
“Our machines are designed in such a way that all the intelligence resides in
The hollow-core slabs are cut to size and shipped to construction sites with pre-cut the controller. This makes it possible to switch out components with minimal
openings for plumbing and electrical lines. configuration effort. Since the market for prefinished floors made of pre-stressed
PC Control 01 | 2016 worldwide | belgium
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Echo Precast
Echo Precast Engineering, headquartered in Houthalen, Belgium, develops and
builds machines and systems that produce pre-stressed concrete elements.
With its technological expertise, the company has made a name for itself all
over the world. Echo Precast Engineering is a subsidiary of the Progress Group,
a supplier of technology solutions to the precast concrete industry.
The machine is operated via a CP29xx multi-touch panel. The
communication between the CX2020 Embedded PC and the Control
Panel runs over the long-distance CP-Link 4 connection technology.
concrete requires an infinite number of variations, short setup changeover times mounted in the production facility. “When we move the machine up and down
are extremely important. The X-Liner® can be fully reconfigured by a single oper- the entire distance of 120 meters, the positioning remains accurate down to
ator in less than 30 minutes,” says Jo Nijs. 1.5 millimeters,” says Jo Nijs. “That’s far more accurate than what building
standards require. But it is important for our customers, as it helps them save
Application software runs side-by-side with the PLC raw materials.”
Immediately after the X-Liner® has formed a floor element, another machine, the
plotter, moves along the track and indicates with paint the location of the hollow The strategy of combining all intelligent components in the control platform also
core slabs, as well as openings for plumbing lines and other conduits which are applies to the visualization system. The machines are equipped with a CP29xx
cut in the next step. The plotter operates completely autonomously. The markings multi-touch Control Panel that provides the operator interface. Communication
are specified in a PXML file that is generated based on the architectural drawings. between the CX2020 and the Control Panel, which is installed at a distance, runs
Stef Verhelst, engineer at Echo Precast Engineering: “The file is downloaded to over CP-Link 4 connection technology from Beckhoff.
the CX2020 controller via Wi-Fi or a USB memory stick. The Echo control software
translates the data into the coordinates for the plotter. These coordinates are sent PC-based control technology enables advanced features
to the PLC, where they are used to control the plotter’s X and Y axes.” Johny Since 2014, Echo Precast Engineering has also used the CX2020 as the controller
Vangeel, sales manager at Beckhoff Belgium, adds: “The PC-based platform for its sawing machines. They run along a track like the plotter, but must still be
makes a huge difference during this step. The application software, which was positioned manually at this time. To make a cut, the operator aligns a laser-pro-
developed under Windows 7, can run on the CX2020 parallel to the PLC environ- jected beam with a marking that was previously applied by the plotter. However,
ment. The PC environment and the TwinCAT PLC communicate with each other Echo Precast Engineering is already working on the next step. In the future, the
via TwinCAT ADS. The PLC receives an ADS address from which it can read the saws should be able to use the same PXML files so that the positioning markings
coordinates as calculated by the Echo control software.” will no longer be needed. “Since the PC-based controller can handle this easily,
this is the next logical step,” explains Jo Nijs. “An additional benefit of the PC-
Compact, economical and highly dynamic drives based control system is that our machines have TeamViewer software installed,
Because of its reach of 50 centimeters, the plotter moves along the concrete ele- which allows us to log into our customers’ machines and even carry out actions
ment to be marked at a speed of 1.5 meters per minute. Beckhoff sales engineer, in real time.”
Bert Cuypers explains: “The machine is equipped with an AX5000 EtherCAT Servo
Drive for the wheels and AM8000 servomotors featuring One Cable Technology
(OCT) to drive the axes. The plotter also features a Z-axis to accommodate the
thickness of the hollow-core slab. The servomotor for this axis is controlled via
an EL7201 servo terminal.” Since the CX2020 handles the complete motion
control application in a closed-loop control circuit, drives, encoders and other
components can be replaced without any further programming or adjustments.
Precise positioning saves materials
While the machine moves, the controller receives feedback from encoders em- Further information:
bedded in its wheels. The plotter is also equipped with a laser sensor that very www.echoprecast.com
accurately determines its absolute position in relation to a reflector permanently www.beckhoff.be
