Learn BECKHOFF-TWINCAT with Real Code Examples

TwinCAT turns a PC into a deterministic real-time controller.

Supports PLC, motion, robotics, CNC, and safety in one platform.

Uses IEC 61131-3 languages like ST, LD, FBD, SFC, IL, and CFC.

Integrates directly with EtherCAT for high-speed fieldbus control.

Provides engineering, debugging, visualization, and commissioning tools.

TwinCAT XAE engineering environment

TwinCAT XAR real-time runtime

PLC programming in IEC languages

Motion Control and NC PTP modules

Built-in OPC UA, MQTT, and ADS communication

Tasks - real-time execution cycles

POUs - functions, FBs, and programs

Mappings - link variables to I/O

Routes - connect engineering PC to runtime

ADS - standardized communication interface

SYSTEM - tasks & scheduling

I/O - EtherCAT and device maps

PLC - code modules and POUs

VISU - optional HMI/SCADA

CONFIG - real-time parameters

Create a TwinCAT project

Configure EtherCAT I/O

Write PLC logic

Map variables to physical or virtual I/O

Download, run, test, and debug

Beginner: simple PLC logic

Intermediate: motion control single-axis

Advanced: coordinated multi-axis systems

Expert: robotics kinematics or CNC

Architect: PC-based complex automation platforms

TwinCAT vs Siemens TIA Portal: TwinCAT excels at EtherCAT/motion; TIA more PLC mainstream.

TwinCAT vs Codesys: TwinCAT has stronger motion & EtherCAT performance.

TwinCAT vs Rockwell Studio5000: PC-based openness vs PLC-based robustness.

TwinCAT vs Mitsubishi GX Works: TwinCAT more modular and high-performance.

TwinCAT vs Omron Sysmac: Sysmac integrated hardware; TwinCAT more flexible PC control.

1996 - Initial release of TwinCAT

2003 - TwinCAT 2 major version

2010 - TwinCAT 3 announced

2014 - TwinCAT 3 widespread adoption

2017 - New motion/kinematics modules

2019 - Major OPC UA & IoT improvements

2021 - Advanced multi-core runtime

2023 - CNC & robotics expansion

2024 - EtherCAT G performance upgrades

2025 - Latest stability & real-time enhancements

ADS - Automation Device Specification protocol

POU - Program Organization Unit

DC - EtherCAT Distributed Clocks

XAR - TwinCAT runtime environment

Task - Real-time PLC execution cycle