What options are available for data acquisition from EtherCAT and TwinCAT-based controllers?

ibaPDA provides multiple interfaces for acquiring data from TwinCAT 2 and TwinCAT 3 controllers, depending on requirements for speed, synchronization, and flexibility. Via EtherCAT, the ibaBM-eCAT bus monitor enables cycle-accurate acquisition directly from the fieldbus. For Ethernet-based communication, Generic TCP, Generic UDP, and TwinCAT-Xplorer interfaces are available. This allows users to efficiently integrate and analyze both highly dynamic processes and standard monitoring or diagnostic applications.

What are the benefits of cycle-accurate EtherCAT data acquisition?

Cycle-accurate data acquisition is essential for analyzing high-speed control and motion applications in modern automation systems. With ibaBM-eCAT, ibaPDA captures EtherCAT data synchronously at bus level, enabling precise time-correlated analysis of signal changes. This is particularly beneficial for motion control systems, drive diagnostics, and highly dynamic machinery. In addition, diagnostic information such as cycle times and telegram data can be evaluated to identify communication issues and performance deviations at an early stage.

Why is symbolic signal selection beneficial for PLC diagnostics?

Symbolic signal selection significantly simplifies data acquisition because variables can be accessed directly by their project names. With Request technology and the TwinCAT-Xplorer interface, ibaPDA provides convenient access to controller data through an integrated symbol browser. Signals can be added or modified flexibly without changing the PLC program or stopping the machine. This is especially valuable during commissioning, troubleshooting, and process optimization, as it reduces engineering effort and improves diagnostic efficiency.

When are polling-based interfaces suitable for industrial process monitoring?

Polling-based interfaces are ideal for applications where full cycle accuracy is not required. Using the TwinCAT-Xplorer interface, ibaPDA can cyclically request controller data over standard Ethernet connections without additional hardware or complex project modifications. This approach is well suited for process monitoring, condition monitoring, commissioning, and quick diagnostics of individual machines. At the same time, users benefit from cost-efficient integration and high flexibility in signal selection.

What role does flexible PLC connectivity play in modern automation environments?

Flexible PLC connectivity enables unified data acquisition across different controller platforms and forms the foundation for centralized process analysis. In addition to TwinCAT systems, ibaPDA supports controllers from Siemens, ABB, Allen-Bradley, Mitsubishi, OMRON, B&R, and other vendors through its Xplorer interfaces. This allows heterogeneous automation environments to be integrated without complex additional solutions. Combined with ibaAnalyzer, the acquired data can then be used for root cause analysis, performance monitoring, and long-term optimization projects.

Acquire Data From TwinCAT 2 and 3 Controllers

Customized Monitoring

An ibaPDA system can be connected to TwinCAT controllers via EtherCAT or Ethernet communication.

Which method is best depends on, amongst other things, how quickly the data needs to be acquired, whether scan-cycle-synchronous data transmission is required and which hardware is available. In addition, the Request method and the Xplorer interface offer the option of selecting signals using the symbolic identifiers via a symbol browser without any programming effort.

At a Glance

Connection to TwinCAT controllers via various interfaces: ibaBM-eCAT, Generic-TCP, Generic-UDP, TwinCAT-Xplorer
Free selection of symbols with Request method or Xplorer interface
Scan-cycle-precise acquisition via EtherCAT with ibaBM‑eCAT bus monitor
Connection without additional hardware with software interfaces Generic-TCP, Generic-UDP and TwinCAT-Xplorer
Simple, cost-effective connection via Xplorer interface

The different ways to acquire data from TwinCat Controllers in the iba system

Direct interface via EtherCAT

If data needs to be acquired quickly and precisely with each scan cycle, the TwinCAT system should be connected via EtherCAT with the ibaBM-eCAT bus monitor.

The bus monitor can also be configured as EtherCAT slave; the programming of the output takes place directly in the program. The setup of the signals can be retrieved from the EtherCAT project file from the automation system, provided that the ENI export file of the EtherCAT configuration has been imported in ibaPDA. Hence, the signals of all configured terminals are available in ibaPDA. The signals can be comfortably selected just by a mouseclick using the symbol browser.

EtherCAT Browser and Diagnostics

If no ENI export file of the Ether- CAT configuration is available, the symbol browser cannot be used for signal selection. Using the EtherCAT browser, it is optionally possible to select the values for acquisition directly from the EtherCAT bus. The EtherCAT browser also contains diagnostic functions of the bus. For example, the individual telegrams can be analyzed and cycle and turnaround times can be displayed. A large number of diagnostic signals describing the EtherCAT bus are available for acquisition in ibaPDA.

Connection via Ethernet

When connected via Ethernet, the communication depends on the communication performance of the controller and the network load. Therefore, the acquisition via Ethernet cannot be scancycle- precise. The advantage, however, is that the standard network connection of the controller can be used; in ibaPDA, only a software interface is required.

Regardless of whether the connection is via EtherCAT or Ethernet, the values to be recorded must be programmed in the controller and be sent by the controller program. Each change of values requires a program change.

Signal selection without programming

Using special iba solutions, programming effort can be avoided: With the Xplorer interface or Request method, measured values can be changed without intervention in the programming while the controller is running. In addition, the measured values can be flexibly selected by importing the address book.

Request method

The Request method allows users to record signals from the controller by free signal selection. The measured values can be selected from the address book of the project and simply accessed via their symbolic names. A PLC-code block („Request block“) must be integrated into the TwinCAT system program once. After the request, the Twin- CAT system sends the measured values cyclically to the ibaPDA system. The Request method is available for connections via EtherCAT and Ethernet UDP.

How does the Xplorer interface work?

With the TwinCAT-Xplorer interface, it is possible to easily and cost-effectively connect to TwinCAT systems. Like the Request method, the Xplorer interface allows free access to the internal data of a controller. The standard procedures of the respective controller are used; additional hardware is not required when connecting via Ethernet. However, the measured values are cyclically requested and sent by the controller in a „polling“ procedure. Data acquisition is not scan-cycle-precise since the data is only sent by the controller when the request can be processed.

The signals can be easily selected in ibaPDA with a mouse click using the symbol browser. The selection of signals can be changed at any time without interruption to the controller running operation.

Different Xplorer interfaces

An Xplorer interface is available not only for TwinCAT controllers but also for SIMATIC S7 systems, ABB controllers, Allen-Bradley controllers (PLC5, SLC500, ControlLogix), B&R systems, CODESYS V2 and V3 based systems, Mitsubishi MELSEC controllers, OMRON controllers as well as SIGMATEK controllers. All available Xplorer interfaces are provided as a bundle for ibaPDA. A cost-effective entry-level solution is also available: ibaPDA-PLC-Xplorer offers the full ibaPDA functionality with all available Xplorer interfaces for up to 64 signals. This is ideal for applications, such as troubleshooting or commissioning.

Used Functions

The following functions of the iba system are used in this application.

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Frequently Asked Questions (FAQ)

What options are available for data acquisition from EtherCAT and TwinCAT-based controllers?: ibaPDA provides multiple interfaces for acquiring data from TwinCAT 2 and TwinCAT 3 controllers, depending on requirements for speed, synchronization, and flexibility. Via EtherCAT, the ibaBM-eCAT bus monitor enables cycle-accurate acquisition directly from the fieldbus. For Ethernet-based communication, Generic TCP, Generic UDP, and TwinCAT-Xplorer interfaces are available. This allows users to efficiently integrate and analyze both highly dynamic processes and standard monitoring or diagnostic applications.
What are the benefits of cycle-accurate EtherCAT data acquisition?: Cycle-accurate data acquisition is essential for analyzing high-speed control and motion applications in modern automation systems. With ibaBM-eCAT, ibaPDA captures EtherCAT data synchronously at bus level, enabling precise time-correlated analysis of signal changes. This is particularly beneficial for motion control systems, drive diagnostics, and highly dynamic machinery. In addition, diagnostic information such as cycle times and telegram data can be evaluated to identify communication issues and performance deviations at an early stage.
Why is symbolic signal selection beneficial for PLC diagnostics?: Symbolic signal selection significantly simplifies data acquisition because variables can be accessed directly by their project names. With Request technology and the TwinCAT-Xplorer interface, ibaPDA provides convenient access to controller data through an integrated symbol browser. Signals can be added or modified flexibly without changing the PLC program or stopping the machine. This is especially valuable during commissioning, troubleshooting, and process optimization, as it reduces engineering effort and improves diagnostic efficiency.
When are polling-based interfaces suitable for industrial process monitoring?: Polling-based interfaces are ideal for applications where full cycle accuracy is not required. Using the TwinCAT-Xplorer interface, ibaPDA can cyclically request controller data over standard Ethernet connections without additional hardware or complex project modifications. This approach is well suited for process monitoring, condition monitoring, commissioning, and quick diagnostics of individual machines. At the same time, users benefit from cost-efficient integration and high flexibility in signal selection.
What role does flexible PLC connectivity play in modern automation environments?: Flexible PLC connectivity enables unified data acquisition across different controller platforms and forms the foundation for centralized process analysis. In addition to TwinCAT systems, ibaPDA supports controllers from Siemens, ABB, Allen-Bradley, Mitsubishi, OMRON, B&R, and other vendors through its Xplorer interfaces. This allows heterogeneous automation environments to be integrated without complex additional solutions. Combined with ibaAnalyzer, the acquired data can then be used for root cause analysis, performance monitoring, and long-term optimization projects.