EtherCAT Introduction

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Dylan Rogers
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1 Industrial EtherCAT Introduction EtherCAT: Control Automation Technology 1

2 EtherCAT for Control and Automation Technology EtherCAT is ultra Fast: 1000 dig. I/O: 30 µs, 100 servo s: 100 µs EtherCAT is : Standaard at I/O level EtherCAT is Flexible: Star, line, drop, with or without switch EtherCAT is Inexpensive: ethernet is mainstream technology, therefore inexpensive EtherCAT is Easy: everybody knows, it is simple to use

Functional Principle: on the Fly Analogy Fast Train: Train ( Frame) does not stop Even when watching train through narrow window one sees the entire train Car

3 Functional Principle: on the Fly Analogy Fast Train: Train ( Frame) does not stop Even when watching train through narrow window one sees the entire train Car (Sub-Telegram) has variable length User can extract or insert single persons (Bits) or entire groups even multiple groups per train EtherCAT: Control Automation Technology 3

4 Pass-through telegram access saves time from Master to Master Data is modified and/or added while telegram passes through without buffering, storing or disassembly / assembly. Telegram delay per terminal: 60 ns Optimal performance EtherCAT: Control Automation Technology 4

5 Functional Principle: on the Fly Slave Device EtherCAT Slave Controller Slave Device EtherCAT Slave Controller Process data is extracted and inserted on the fly Process data size per slave almost unlimited (1 Bit 60 Kbyte, if needed using several frames) Compilation of process data can change in each cycle, e.g. ultra short cycle time for axis, and longer cycles for I/O update possible In addition asynchronous, event triggered communication EtherCAT: Control Automation Technology 5

6 Functional Principle: Virtual ring structure Unit Master MAC 1 Unit Slave 1 Slave 2 Slave N Slave N EtherCAT: Control Automation Technology 6

7 Functional Principle: on the Fly Minimal protocol overhead via implicit addressing IPC.. DVI HDR FH EH Data WKC EH Data WKC EH Data WKC CRC Optimized telegram structure for decentralized I/O Communication completely in hardware: maximum performance no switches needed if only EtherCAT devices in the network Outstanding diagnostic features -compatibility maintained EtherCAT: Control Automation Technology 7

8 EtherCAT Distributed Clocks Precise Synchronization (<< 1 µs!) by exact adjustment of distributed clocks IPC M t S.. DVI S S S S S S S EtherCAT: Control Automation Technology 8

9 EtherCAT is Industrial! EtherCAT: only Standard Frames (IEEE 802.3) Master: MAC without co-processor or special HW Fully transparent for other protocols Internet Technologies (TCP/IP, FTP, Web server etc.) without restricting the real time capabilities, even with 100µs cycle time no large time gaps for rare traffic needed Full Tool-Access to devices at real time operation with and without TCP/IP 48 Bit 48 Bit 16 Bit 16 Bit 32 Bit Destination Source EtherType Header CRC Embedded in Standard Frame, EtherType 0x88A4 11 Bit Length 1..n EtherCAT Datagrams 1 Bit 4 Bit Res. Type EtherCAT: Control Automation Technology 9

Switchport can be implemented as device feature, seperate device or software

10 EtherCAT is Industrial! Connection to any device via Switchport Access to web server with standard browser Switchport can be implemented as device feature, seperate device or software functionality in master Switchport allows for hard real time capability with parallel communication of any kind IP C.. DVI Switchport EtherCAT: Control Automation Technology 10

11 EtherCAT is most flexible Flexible tree structures arbitrarily extendable Line without limitations through cascaded switches or hubs 100 m between two nodes, up to nodes in one segment branches can be connected/removed at run time ( Hot Connect ) Straight or crossed cables automatic detection IP C.. DVI EtherCAT: Control Automation Technology 11

12 Fieldbus Gateways EtherCAT Performance allows for: EtherCAT instead of PCI no card slots required any more maximum system expandability with low cost fieldbus gateways seamless integration of fieldbus devices protects your investment smooth migration path from fieldbus to EtherCAT EtherCAT: Control Automation Technology 12

Safety over EtherCAT: Features TÜV certified technology Developed according to IEC 61508 Protocol meets Safety

for functional safe motion control Variable CRC size for minimal overhead Safe Parameter Download at boot-up:

13 Safety over EtherCAT: Features TÜV certified technology Developed according to IEC Protocol meets Safety Integrated Level (SIL) 4 Device implementations typically SIL 3 Suitable for functional safe I/O as well as for functional safe motion control Variable CRC size for minimal overhead Safe Parameter Download at boot-up: most simple device exchange possible Safety devices already available EtherCAT: Control Automation Technology 13

14 Safety over EtherCAT: Routing Can be routed via non-safe gateways Can be routed via fieldbus systems One Safety Technology for (almost) all bus systems Fipio EtherCAT: Control Automation Technology 14

15 Without Redundancy: Cable Failure Unit Master MAC 1 Unit Slave 1 Slave M-1 Slave M+1 Slave N EtherCAT: Control Automation Technology 16

16 With Redundancy: Cable Failure Unit Master Unit MAC 1 MAC 2 Only 2nd Port required no special Interface Card Slave 1 Slave M-1 Slave M+1 Slave N EtherCAT: Control Automation Technology 17

17 EtherCAT is simpler to Addressing: No manual address setting required Addresses can be kept no new addressing if nodes are added Topology: Automatic topology target/actual comparison possible Diagnosis: Diagnosis information with exact localization Network planning: Performance independent of slave implementation (e.g. stack features, µc performance) Performance widely independent from topology (no switches/hubs) Performance more than sufficient - therefore no tuning required any more, default settings do the job EtherCAT: Control Automation Technology 18

18 EtherCAT is lower costs Master: no dedicated plug in card (co-processor), on-board Port is fine Slave: - low cost Slave Controller - FPGA or ASIC - no powerful µc needed Infrastructure: - no Switches/Hubs required - Standard Cabling EtherCAT: Control Automation Technology 19

19 EtherCAT is well proven In series applications since end of 2003 EtherCAT: Control Automation Technology 20

20 EtherCAT is an open technology Protocol is published completely: EtherCAT is IEC Specification (IEC/PAS 62407) EtherCAT is part of ISO Integration in IEC 61158, IEC and IEC on the way Slave Controller from several suppliers Slave Controller provide interoperability ETG organized Plug-Fests, and prepares conformity tests EtherCAT: Control Automation Technology 21

EtherCAT is an open technology Foundation: November 2003 Tasks: Support, Advancement and Promotion of EtherCAT Already more than 565* member companies from 25 countries in

21 EtherCAT is an open technology Foundation: November 2003 Tasks: Support, Advancement and Promotion of EtherCAT Already more than 565* member companies from 25 countries in Europe, America and Asia/Pacific: Device Manufacturers End Users Technology-Provider Membership is open to everybody * as of August 2007 EtherCAT: Control Automation Technology 22

ETG: Active Members April 2006: more that 200 implementation kits sold to ETG members (26% Master, 74% Slaves) Hannover Fair 2006: 41 Exhibitors, more than

22 ETG: Active Members April 2006: more that 200 implementation kits sold to ETG members (26% Master, 74% Slaves) Hannover Fair 2006: 41 Exhibitors, more than 80 different EtherCAT devices at EtherCAT joint booth among those: 20 drives and 8 different master shown in function EtherCAT: Control Automation Technology 23

23 EtherCAT: versatile System Architecture Master to Slave, Slave to Slave, Master to Master Transparent tool access to all nodes Open interfaces Master.. IPC DVI Master IPC M/M M/S M/S Switch.. DVI M/S S/S EtherCAT: Control Automation Technology 24

24 Typical EtherCAT application fields All fast applications, e.g.: packaging machines high speed presses injection molding machines woodworking machines machine tooling (CNC) robotics All widely distributed applications, e.g.: materials handling, logistics data acquisition EtherCAT: Control Automation Technology 25

25 Typical EtherCAT application fields And, Due to low cost master and simple wiring as well: Small embedded Controller Small PLCs Any PC based control application with or without real time requirements EtherCAT allows one to apply fieldbus technology where cost issues require direct wiring today. EtherCAT: Control Automation Technology 26

EtherCAT Performance Example 40 Axis (each 20 Byte Input- and Output-Data) 50 I/O Station with a total of 560 EtherCAT Bus Terminals 2000 Digital + 200 Analog I/O, Bus Length 500 m Performance

26 EtherCAT Performance Example 40 Axis (each 20 Byte Input- and Output-Data) 50 I/O Station with a total of 560 EtherCAT Bus Terminals 2000 Digital Analog I/O, Bus Length 500 m Performance EtherCAT: Cycle Time 276µs at 44% Bus Load, Telegram Length 122µs For comparison: Profinet IRT 763 µs, Powerlink V2 2347µs*, Profinet RT 6355 µs in spite of this cycle time still 56% bandwidth remaining, e.g. for TCP/IP * Quelle: Powerlink Spec V 2.0, App.3 EtherCAT: Control Automation Technology 27

27 Summary - EtherCAT is Ultra Fast: 1000 dig. I/O: 30 µs, 100 servo s: 100 µs - EtherCAT is : Standaard at I/O level - EtherCAT is Flexible: Star, line, Daisy Chain, with or without switch - EtherCAT is Safe: Safety signals, Redudancy - EtherCAT is Easy: No adressing, standaard ethernet tools for debugging, everybody knows, it is simple to use. - EtherCAT is Inexpensive: is mainstream, therefore inexpensive - EtherCAT is Well Proven: Lot of applications, Lot (active) ETG members. EtherCAT: Control Automation Technology 28

Functional Principle and the resulting Benefits.

Functional Principle and the resulting Benefits. 10.11.2010 EtherCAT Functional Principle: Ethernet on the fly Slave Device EtherCAT Slave Controller Slave Device EtherCAT Slave Controller Process data