Press Release

December 02, 2015
Advanced software facilitates machine diagnostics and predictive maintenance for Industry 4.0 and IoT
Beckhoff Introduces TwinCAT Analytics: Seamless Recording and Analysis of Process and Production Data

SAVAGE, Minnesota, December 2, 2015 – To answer a wide range of requirements in the implementation of Industry 4.0 and IoT concepts, particularly for machine diagnostics, Beckhoff Automation has announced TwinCAT Analytics. This feature-filled software solution includes online and offline condition analysis, predictive maintenance, pattern recognition, machine optimization and long-term data archival.

Seamless and cycle-synchronous data acquisition is a prerequisite for effective analysis and correction of processing errors in machines. To address these needs and more, Beckhoff has developed TwinCAT Analytics in the TwinCAT 3 software portfolio, serving the growing requirements of Industry 4.0 applications. Processing errors in machines frequently create excessive costs and lost production time. The situation becomes all the more serious if there is a lack of machine data and production parameters in order to analyze processing errors and avoid such errors in the future. The new TwinCAT Analytics tool can be used to rectify this information deficit by storing all process-relevant data in a cycle-synchronous manner. Data is stored in a standardized process data format with data compression, either locally in the controller, in a cloud-based solution on a server in the company network or in a public cloud, as required.

Seamless data logging opens up potential for optimizations

TwinCAT Analytics provides a complete temporal image of the manufacturing process and the production data. This offers an ideal information baseline, not only to assist in the event of an error, but also to enable comprehensive condition analysis of the machine, among other advanced functions. The recorded process and production data can be analyzed online or offline, and machine cycles can be examined for minimum, maximum and average values of the cycle times. Total runtimes and time differences of production processes can be gleaned from cycle counters or offline trace analyses, e.g. via “post-scope configuration” in TwinCAT Scope View Professional.

Further benefits arise for predictive maintenance. Logging of data from operating hour counters, frequency analysis or RMS calculations, for example, enables implementation of high-performance condition monitoring. Moreover, the system facilitates limit value monitoring for different process data. Pattern recognition for detecting irregularities and repetitions in the recorded data further improves the reliability of the process sequence.

In addition to optimum support for error analysis, TwinCAT Analytics offers numerous opportunities to further machine optimization. The status analysis provides all the information required for optimizing the machine or system in terms of energy consumption or process sequence. In addition, detailed knowledge of all processes simplifies configuration of drives, for example, and it may be possible to reduce the connected load of machines based on thorough measurement readings. This future-oriented software tool serves an increasing demand for highly flexible production down to lot size 1. In this case, TwinCAT Analytics can provide comprehensive production documentation for each individual workpiece.

Component-based analysis Software

TwinCAT Analytics consists of four main software components:
  • The TwinCAT Analytics logger enables cyclic storage of large data quantities, storing the entire process image, including the application data (e.g. from the PLC or NC), following the essence of Big Data concepts.
  • The TwinCAT Analytics workbench serves as an engineering tool for online and offline analyses of one or more machines. It includes the PLC runtime, the new Analytics configurator, the TwinCAT Analytics PLC library, a Scope View Professional license and interfaces with TwinCAT IoT for communication via the standardized MQTT protocol.
  • As a PLC library for application in the Analytics workbench, the TwinCAT Analytics library contains numerous function blocks, enabling functionality such as cycle analysis, energy demand or RMS calculations, among others.
  • TwinCAT Analytics cloud storage can house data and make it available in private or public networks via a “message broker”.


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  • Based on comprehensive and cycle-synchronous data recording, the new TwinCAT Analytics software solution enables seamless online and offline analysis of machines and production data.

    Picture caption:

    Based on comprehensive and cycle-synchronous data recording, the new TwinCAT Analytics software solution enables seamless online and offline analysis of machines and production data.
  • TwinCAT Analytics provides a variety of application scenarios: storage and analysis of data directly on the local controller, in private networks or in a public cloud, and provides the possibility to serve multiple machines at locations around the world.

    Picture caption:

    TwinCAT Analytics provides a variety of application scenarios: storage and analysis of data directly on the local controller, in private networks or in a public cloud, and provides the possibility to serve multiple machines at locations around the world.

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