The Ethernet Fieldbus.

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1 The Ethernet Fieldbus.

2 Ethernet for Real-Time Communication Main Performance Problems: 1. Bandwidth Utilization 2. Stack Delays 3. Switch Delays EtherCAT Technology Group

3 1. Industrial Ethernet Bandwidth Utilization Minimum Ethernet Frame: 84 Bytes Example: with 4 Bytes Process Data (32 I/O): 4/84 = 4,75% Application Data Ratio 84 Bytes, regardless which Protocol 14 Bytes Process Data, e.g Bytes 4 B. 14 Bytes Ethernet HDR Process Data Ethernet Frame Payload: min. 46 Bytes FCS CRC Interpacket Gap 84 Bytes, e.g. with 14 Bytes 20 Bytes 8 Bytes 20 Bytes Payload e.g. 4 Bytes 4 B. 14 Bytes Ethernet HDR IP HDR UDP HDR Ethernet/IP CIP HDR Process Data FCS CRC Interpacket Gap EtherCAT Technology Group

4 Industrial Ethernet Bandwidth Utilization EtherCAT Technology Group

I/O) CIP Network & Transport Implicit Msg CIP Message Encapsulation IP

5 2. Industrial Ethernet Stack Delays I/O Ports Device Profile Application Objects (e.g. I/O) CIP Network & Transport Implicit Msg CIP Message Encapsulation IP Encapsulation TCP UDP IP Ethernet MAC Explicit Msg Industrial Ethernet Protocol Stacks are BIG Processing then needs TIME EtherCAT Technology Group

6 Stack Performance Comparison (I) Stack performances of the Ethernet technologies differ substantially, due to the different complexity of the stacks Softing, a German specialist for field bus technology published* the following comparison of the stack delay times: Stack Time Profinet IO Ethernet/IP EtherCAT Average 0.58 ms 1.89 ms 0.11 ms Max: 0.74 ms 2.96 ms 0.18 ms Min: 0.54 ms 1.23 ms 0.05 ms All three protocols were implemented on the same hardware (interface board with FPGA + Softcore CPU) and by the same team, so they are indeed comparable * Source: Einer für alle; Flexible Real-Time-Ethernet Anschaltung mit FPGA, messtec drives Automation Real-Time Ethernet Sonderheft 2010, by Frank Iwanitz, Business Development Manager Real-Time Ethernet at Softing GmbH, Munich, Germany EtherCAT Technology Group

Stack Performance Comparison (II) Softing stack

EtherCAT Slave Stack Code (SSC*) EtherCAT (SSC)

0,5 1 1,5 2 2,5 3 * SSC Stack Delay time measured on

Serial Process Data Interface and a 40 MHz 16 Bit

7 Stack Performance Comparison (II) Softing stack performance data shown in a diagram, + Beckhoff EtherCAT Slave Stack Code (SSC*) EtherCAT (SSC) EtherCAT Ethernet/IP Min Max Average Profinet IO 0 0,5 1 1,5 2 2,5 3 * SSC Stack Delay time measured on EL9800 EtherCAT Evaluation Kit using the 10 Mhz Serial Process Data Interface and a 40 MHz 16 Bit PIC CPU; 2 Byte Output Data, min 15µs, max 20µs EtherCAT Technology Group

3. Industrial Ethernet Switch Delays Switch Buffer Delay: Unpredicable by Nature Buffer delay depends on buffer load @ frame arrival.

8 3. Industrial Ethernet Switch Delays Switch Buffer Delay: Unpredicable by Nature Buffer delay depends on buffer frame arrival. QoS (Quality of Service) eases the pain by introducing multiple priorities (and buffers), but does not resolve the issue. EtherCAT Technology Group

9 3. Industrial Ethernet Switch Delays Almost all Switches use Store & Forward Line Topology means cascaded Switches Substantial accumulated delay and jitter even without buffer delay (if switches are idle). Typical Store & Forward Delay per switch: Frame length (7 122µs) + 3µs. Example: Full frame, 20 nodes in line topology: 2,5 ms Switch Internal Switches Switch Internal Switch Internal Switch EtherCAT Technology Group

option=com_docman&task=doc_view&gid=28 Quote: When tested up to 80 percent network bandwidth utilization, using both managed and unmanaged switches, the

10 Ethernet for Real-Time Communication? 20ms 8ms Quote: RT in Profinet provides similar Real-Time properties like Profibus Source: Profibus International Quote: When tested up to 80 percent network bandwidth utilization, using both managed and unmanaged switches, the system managed 16 position configured axes with an 8 ms coarse update rate. Source: Rockwell Automation, White Paper: Scalability-The Best Approach to Change, Aug EtherCAT Technology Group

11 EtherCAT: Performance Breakthrough harvepino - Fotolia.com EtherCAT Technology Group

EtherCAT: highest Performance The fastest Industrial Ethernet Technology 1000 distributed digital I/O in 30µs 100 Servo-Axis every 100 µs EtherCAT directly to the I/O Slice, no Sub-Bus

12 EtherCAT: highest Performance The fastest Industrial Ethernet Technology 1000 distributed digital I/O in 30µs 100 Servo-Axis every 100 µs EtherCAT directly to the I/O Slice, no Sub-Bus Optimal Usage of the Standard Ethernet Port in the Controls, no extra hardware Reason for this unique performance: The EtherCAT Functional Principle (Ethernet on the Fly) EtherCAT Technology Group

Functional Principle: Ethernet on the fly Car 27

stop Even when watching Train through narrow window

variable length One can extract or insert single

13 Functional Principle: Ethernet on the fly Car 27 Analogy Fast Train: Train (Ethernet Frame) does not stop Even when watching Train through narrow window one sees the entire Train Car (Sub-Telegram) has variable length One can extract or insert single persons (Bits) or entire groups (Bytes) even multiple groups per train

14 Functional Principle: Ethernet on the Fly Efficient: Typically only one Ethernet Frame per Cycle Ideal Bandwidth Utilization for maximum Performance EtherCAT Technology Group

15 Functional Principle: Ethernet 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

16 Functional Principle: Ethernet on the fly Master Ethernet Header ECAT HDR HDR 1 PLC Data 1 HDR 2 NC Data HDR 2 PLC Data 2 CRC Minimal protocol overhead via implicit addressing Optimized telegram structure for decentralized I/O Communication completely in hardware: maximum (+ predictable!) performance No switches needed if only EtherCAT devices in the network Outstanding diagnostic features Ethernet-compatibility maintained

17 EtherCAT resolves the Performance Problems Main Performance Problems: 1. Bandwidth Resolved! Utilization 2. Stack Delays Resolved! 3. Switch Delays Resolved! EtherCAT Technology Group

18 EtherCAT - The Ethernet Fieldbus. EtherCAT is real time down to the I/O level No underlying sub-systems any more

19 EtherCAT - The Ethernet Fieldbus. Other technologies need local I/O cycles + gateways Driver Fieldbus Controller RAM CPU Flash RAM Master for Local Extension Bus I/O I/O I/O I/O Driver Fieldbus Controller CPU I/O Flash

20 EtherCAT - The Ethernet Fieldbus. EtherCAT: Real time down to the I/O Driver EtherCAT Controller EtherCAT Controller EtherCAT Controller EtherCAT Controller EtherCAT Controller

21 EtherCAT - The Ethernet Fieldbus. EtherCAT is real time down to the I/O level No underlying sub-systems any more No delays in gateways In- and outputs, sensors, actuators, drives, displays: everything in one system!

22 Slow Control Systems benefit, too Reaction time with legacy fieldbus I/O: I PLC Task O I PLC Task O I PLC Task O I PLC Task O I PLC Task T mpd Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O best case reaction time worst case reaction time Input (worst case) Input (best case) Output T mpd : Master Processing Delay T I/O : Local I/O Update Time (local Extension Bus + Firmware)

23 Slow Control Systems benefit, too System Architecture with EtherCAT: I PLC Task O I PLC Task O I PLC Task O I PLC Task O I PLC Task no dedicated Master Device any more T mpd Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O T I/O on underlying extension bus any more

24 Slow Control Systems benefit, too System Architecture with EtherCAT: I PLC Task O I PLC Task O T DMA (NIC) T EtherCAT Cycle I PLC Task O I PLC Task O I PLC Task T DMA = Time for Data Transfer from/to Ethernet Controller via Direct Memory Access: neglectible

25 Slow Control Systems benefit, too Reaction Time with EtherCAT: I PLC Task O I PLC Task O I PLC Task O I PLC Task O I PLC Task worst case best case EtherCAT Bus Cycle Input (worst case) Input (best case) Output Reaction time reduced significantly with the same controller performance no underlying local I/O cycles and extension bus delays any more Due to the very simple protocol no dedicated master systems (e.g. plug-in cards) required

26 Fieldbus: requires Mapping in Control System Traditional fieldbus system generate physical process image This has to be mapped to logical process image(s) logical process images Control System, e.g. IPC Data n PLC Data NC Data Feldbus Scanner/ DPRAM Master node 1 node 2 node 3 node 4 node 1 node 2 node 3 Mapping node 4

27 Fieldbus: requires Mapping in Control System The same applies to system with just one process image Resorting of process data ( Mapping ) is required, too logical process image Control System, e.g. PLC Feldbus Scanner/ DPRAM node 1 node 2 node 3 node 4 Master node 1 node 2 node 3 Mapping node 4

28 EtherCAT: Mapping moved into Slave Devices Master logical process images up to 4 GByte Data n PLC Data NC Data Ethernet Header ECAT HDR HDR 1 PLC Data NC Data Data n Ethernet HDR 2 Datagram 1 Datagram 2 Datagram n HDR 3 Control System is unburdened, master becomes very simple Data is transmitted according to the application requirements: extremely fast, flexibly and efficiently

29 Synchronization Synchronization Synchronization Source: konflikty.pl

30 Timing Synchronous with Frame Position Signal = x Sampling error because of jitter Gradiant = velocity equidistant Sample Point ~4 µs Master Jitter 108 µs 94 µs 101 µs 104 µs 100 µs Cycle Time Error due to sample deviation Velocity = x EtherCAT Out In Calc. Out In Calc. Out In Calc. Out In Calc. Out In D/A D/A D/A D/A D/A A/D A/D A/D A/D A/D Not in sync with IN

31 Timing Synchronous with Frame Problems of this approach I/O signal timing depends on Master Modern (multicore) CPU systems will always jitter in the range of µs Measuring error due to sample deviation: May need special Hardware in the Master Solution Timing with Distributed Clock (DC) System

32 EtherCAT Propagation Delay Measurement (1) EtherCAT Node measures time difference between leaving and returning frame EtherCAT Frame Processing Direction EtherCAT Frame Forwarding Direction

33 EtherCAT Propagation Delay Measurement (2) EtherCAT Node measures time difference between leaving and returning frame Master IPC

34 Distributed Clocks Precise Synchronization (<< 1 µs!) by exact adjustment of Distributed Clocks Master IPC M t S S S S S S S

35 Distributed Clocks Long Term Scope View of two separated devices 300 Nodes in between, 120m Cable Length Simultaneousness: ~15 ns Interrupt Node 300 Interrupt Node 1 Jitter: ~ +/-20ns

36 Synchronous with Distributed Clocks Position Signal = x Sample Point DC Sync 100 µs 100 µs 100 µs 100 µs equidistant Velocity = x 100 µs Cycle Time No sampling Error EtherCAT Calc. Out Sync In Sync Out In Calc. Out In Calc. Out In Calc. Out In D/A D/A D/A D/A A/D A/D A/D A/D

37 Synchronization of multiple Networks EtherCAT networks can be coupled via EtherCAT Bridge Bridge provides hardware synchronization of several networks 1 MASTER 1 SLAVE 2 SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE MASTER 2 SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE 3 MASTER 3 SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE

38 Synchronization of multiple Networks EtherCAT networks can be coupled via EtherCAT Bridge Bridge provides hardware synchronization of several networks S Y N C H R O N O U S MASTER 1 MASTER 2 MASTER 3 SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE S Y N C H R O N O U S SLAVE SLAVE SLAVE

39 External Clock Synchronization: IEEE 1588 Switchport with integrated IEEE 1588 Boundary Clock Master M S S S S S Boundary Clock IEEE 1588 Grandmaster S S

40 EtherCAT is Industrial Ethernet! fully transparent for TCP/IP all Internet technologies (HTTP, FTP, Webserver, ) available without restricting the real time capabilities! EtherCAT Slave Device Standard TCP/IP Stack Ethernet Application TCP UDP Real Time Application IP Acyclic Data Mailbox Process Data EtherCAT MAC / DLL Ethernet PHY Ethernet PHY

41 EtherCAT is Industrial Ethernet! Any Ethernet Device can be connected to Switchport Access to Webserver with Standard Browser Master Virtual Ethernet Switch Functionality Switchport Webserver

42 Switchport: Any Ethernet Protocol Interface to any Ethernet Device or Network Ethernet Frames are inserted into EtherCAT Protocol: Ethernet over EtherCAT PHY EtherCAT Switchport Ethernet MAC µc Fragmentation PHY Mailbox Process Data EtherCAT MAC / DLL PHY

43 Vertical Integration (1) via Switchport Master Switchport + any Ethernet Protocol can be used + requires only one Ethernet Port (at IPC/Controller) + EtherCAT performance is not limited

44 Vertical Integration (2)...via 2. Ethernet Port Master 2nd Ethernet Port + any Ethernet Protocol can be used + EtherCAT performance is not limited - but: requires second Ethernet Port (at IPC/Controller)

45 EtherCAT wiring is more flexible Standard Ethernet Topology: Star

46 EtherCAT wiring is more flexible Flexible topologies arbitrarily extendable Topology variants like Line, Star, Tree, Daisy Chain + Drop Lines possible; can be used in any combination! Up to nodes for each EtherCAT segment Standard Ethernet cabling Master Line Star/Tree Drop Line

47 EtherCAT Extra Large System Test EtherCAT Nodes

48 EtherCAT wiring is more flexible Ethernet Signal Variants of EtherCAT: 100BASE- (up to 100 m between 2 nodes) 100BASE-FX (up to 20 km between 2 nodes (single mode fibre) ) LVDS (for modular devices) 100 m LVDS* Master 20 km Ethernet on 100BASE- up to 100 m with transformer coupling Ethernet on LVDS* physical layer: for modular devices Ethernet on 100BASE-FX (fibre optics) up to 20 km Any number of physical layer changes allowed *LVDS: Low Voltage Differential Signaling according to ANSI/TIA/EIA-644, also used in IEEE 802.3ae (10 Gigabit Ethernet)

49 EtherCAT instead of PCI Protection of your investment Smooth migration path from legacy fieldbus to EtherCAT Seamless integration of existing fieldbus devices, e.g.: AS-Interface BACnet MS/TP CANopen CC-Link ControlNet DeviceNet Ethernet/IP FIPIO Interbus IO-Link Lightbus LonWorks Modbus Plus, RTU, TCP PROFIBUS PROFINET IO Maximum system expandability with low cost fieldbus gateways

50 EtherCAT instead of PCI No Slots in Control System (IPC or PLC) required any more Nevertheless maximum expandability EtherCAT

51 EtherCAT is easier to configure Topology: Automatic Topology Expected/Actual Comparison Diagnosis: M Diagnosis with exact Localization Every node constantly monitors checksum Bit errors are detected and localized Even Timing Errors (e.g. Time Window for Actual Values missed) are detected and stored locally in the chip

52 EtherCAT is easier to configure Network planning: Performance independent of: Slave implementation (no Stacks involved in Process Data Communication) Topology (no Switches/Hubs) Addressing No manual address setting required No IP- or MAC-Address Handling Required Addresses can be assigned automatically Addresses can be kept no new addressing if nodes are added

53 EtherCAT is lower costs (1): Engineering Less effort for Network planning: Simplified configuration Default settings will work, no network tuning Improved Diagnosis: Faster error handling leads to less downtime Faster Setup: No address setting required Implementation / Tools: Standard Network Monitor Tools, e.g. MS Network Monitor or Wireshark: free of charge Parser Software: free of charge

EtherCAT is lower costs (2): Hardware Master: no dedicated plug in card (co-processor) on-board Ethernet Port is fine Slave: low cost Slave Controller FPGA or

54 EtherCAT is lower costs (2): Hardware Master: no dedicated plug in card (co-processor) on-board Ethernet Port is fine Slave: low cost Slave Controller FPGA or ASIC for simple devices: no µc needed no powerful µc + lots of memory needed Infrastructure: no Switches/Hubs required Standard Ethernet Cabling + Connectors 32 Bit µc

55 EtherCAT is easier to implement Slave Implementation: All time critical functions implemented on ASIC or FPGA ESC handles Real-time Protocol in Hardware Integrated Communication State Machine Network Performance independent of Slave-µC Performance Protocol Stack For usage with or without µc (Host CPU) Integrated DPRAM (1 8kByte) Integrated Distributed Clock Handling Ultra precise interrupts to µc

56 New EtherCAT Slave Controller Chips Hilscher - Easier netx to implement 100/500 ESC10/20: Altera Cyclone -I March 2014 Beckhoff ET1200 IP-Core for Altera Cyclone -II Beckhoff ET1100 IP-Core Xilinx Spartan -3 Hilscher netx 50 IP-Core for Altera Cyclone -III IP-Core for Altera Stratix -IV IP-Core for Xilinx Spartan -6 IP-Core for Altera Cyclone -IV TI's Sitara µp family Hilscher netx 51/52/6 IP-Core for FPGA of Intel Atom E6x5C IP-Core for Altera Cyclone -V IP-Core for Xilinx Kintex -7 IP-Core for Altera Stratix -V Renesas R-IN32M3-EC Anybus NP40 IP-Core for Xilinx Artix -7 + Zync Innovasic Fido5000

57 EtherCAT is easier to implement: Master Master Implementation: e.g. with Master Sample Code (Source) EtherCAT Configuration Tool XML Data format of ESI and ENI EtherCAT Configuration Tool Process Data (PD) Image description Application Realtime.xml.xml Parser Process Data Image Mailbox Services EtherCAT Slave Information (ESI) Files EtherCAT Network Information (ENI) File init cyclic commands req. resp. acyclic commands optional; for online functionality (e.g. scanning for devices) Realtime EtherCAT Master Driver Ethernet Frames Network Driver Standard Ethernet MAC

20) Slave Controller from several sources available Slave Controller provides

58 EtherCAT is an open technology Protocol is disclosed completely: EtherCAT is IEC, ISO and SEMI Standard (IEC 61158, IEC 61784, ISO 15745, SEMI E54.20) Slave Controller from several sources available Slave Controller provides interoperability ETG organizes Interoperabilitly Testing ( Plug Fests ), Workshops and Seminars Conformance Testing + Certificates

59 EtherCAT in IEC IEC : Generic Interface and use of profiles for power drive systems Annex A: Mapping to CiA402 IEC : Profile CiA402 Mapping to CANopen** IEC Mapping to EPL IEC : Interface Definition Annex B: Mapping to CIP IEC : Profile CIP Motion Mapping to EtherCAT Annex C: Mapping to PROFIdrive IEC : Profile Specifications IEC : Profile PROFIdrive IEC : Mapping of Profiles to Network Technologies B... C... Mapping to SERCOS I/II IEC Mapping to SERCOS III Annex D: Mapping to SERCOS* IEC : Profile SERCOS* Mapping to EtherCAT *SERCOS interface is a trademark of SI e.v. **CANopen is a trademark of CAN in Automation e.v.

60 EtherCAT Architecture + Device Profiles File System, Bootloader File Access HTTP, FTP, TCP IP UDP Ethernet EtherCAT Device Mailbox The SERCOS* Standard IDN Service Channel IEC IEC EtherCAT Slave Controller DEVICE Application The CANopen** Standard Object Dictionary EN IEC IEC Process Data PDO Mapping AT MDT FoE EoE SoE CoE CoE/SoE SDO Process Data Ethernet Physical Layer *SERCOS interface is a trademark of SI e.v. **CANopen is a trademark of CAN in Automation e.v.

EtherCAT Master OS Technology Variety EtherCAT Masters implemented on wide

Microware OS-9 MQX TM On Time RTOS-32 Oracle Solaris (SunOS) PikeOS

RTAI-Linux SCALE-RT TKernel VxWin + CeWin + RTOS32Win +LxWin VxWorks

CoDeSys SP RTE Windows XPE/WES7/WES8 with TwinCAT RT-Extension Windows

61 EtherCAT Master OS Technology Variety EtherCAT Masters implemented on wide range of RTOS* ecos FreeRTOS INTEGRITY INtime Linux (with RT-Preempt) Microware OS-9 MQX TM On Time RTOS-32 Oracle Solaris (SunOS) PikeOS Proconos OS QNX RMOS ROS (Robot Operating System) RTKernel RTLinux R RC RTAI-Linux SCALE-RT TKernel VxWin + CeWin + RTOS32Win +LxWin VxWorks Windows CE Windows Embedded with IntervalZero R Windows XP/XPE with CoDeSys SP RTE Windows XPE/WES7/WES8 with TwinCAT RT-Extension Windows NT/2000/XP/Vista/7/8 with TwinCAT RT-Extension XOberon XENOMAI Linux µc/os-ii TM µitron *as of March 2014

organization More than 2900* member companies from 58 countries in 6

62 EtherCAT is an open technology Foundation: November 2003 Tasks: Support, Advancement and Promotion of EtherCAT The worlds largest fieldbus organization More than 2900* member companies from 58 countries in 6 continents: Device Manufacturers End Users Technology Providers Membership is open to everybody *as of

ETG Team Worldwide Thomas Rettig, GER Martin Rostan, GER Joseph P. Stubbs, USA Dr. Karl Weber, GER Key Yoo, KOR Dr. Guido Beckmann, GER Andrea Bock, GER Geng Cheng, CHN Bin (Beryl) Fan, CHN Prof Dr.

63 ETG Team Worldwide Thomas Rettig, GER Martin Rostan, GER Joseph P. Stubbs, USA Dr. Karl Weber, GER Key Yoo, KOR Dr. Guido Beckmann, GER Andrea Bock, GER Geng Cheng, CHN Bin (Beryl) Fan, CHN Prof Dr. Yong-Seon Moon, KOR Alessandro Figini, GER Dr. YanQiang Liu, CHN Burkart Lingner, GER Florian Häfele, GER Florian Hammel, GER Fengjiao (Jojo) Fu CHN Oliver Fels, GER Masanori Obata, JPN Michele Beers, USA Christiane Heubusch, GER Rainer Hoffmann, GER Makiko Hori, JPN Liliane Hügel, GER EtherCAT Technology Group

64 EtherCAT Technology Group Structure

ETG Membership Development 3000 As of October 2014: 2950 Members 2500 2000 Aug 2013 Aug 2014: + 407 1500 1000

Aug 07 Nov 07 Feb 08 May 08 Aug 08 Nov 08 Feb 09 May 09 Aug 09 Nov 09 Feb 10 May 10 Aug 10 Nov 10 Feb 10 May 11

65 ETG Membership Development 3000 As of October 2014: 2950 Members Aug 2013 Aug 2014: Nov 03 Feb 04 May 04 Aug 04 Nov 04 Feb 05 May 05 Aug 05 Nov 05 Feb 06 May 06 Aug 06 Nov 06 Feb 07 May 07 Aug 07 Nov 07 Feb 08 May 08 Aug 08 Nov 08 Feb 09 May 09 Aug 09 Nov 09 Feb 10 May 10 Aug 10 Nov 10 Feb 10 May 11 Aug 11 Nov 11 Feb 12 May 12 Aug 12 Nov 12 Feb 13 May 13 Aug 13 Nov 13 Feb 14 May 14 Aug 14 EtherCAT Technology Group

66 ETG Membership Distribution 100% 90% 80% 70% 60% EtherCAT Technology Group: a truly Global Organization America Asia 50% 40% 33 members Europe w/o Germany ~ 2900 members 30% Germany 20% 10% Germany Europe w/o Germany America Asia ROW EtherCAT Technology Group

67 Members from 58 * Countries, 6 Continents Argentina Australia Austria Belarus Belgium Bosnia and Herzegovina Brazil Bulgaria Canada China Columbia Croatia Czech Rep Denmark Finland France Germany Greece Hungary India Iran Ireland Israel Italy Japan Korea Lebanon Latvia Liechtenstein Lithuania Luxemburg Macedonia Malaysia Malta Mexico Netherlands New Zealand Norway Poland Portugal Qatar Romania Russia San Marino Serbia Singapore Slovakia Slovenia South Africa Spain Sweden Switzerland Taiwan Thailand Turkey Ukraine United Kingdom USA *as of

68 How many members invest in the technology? One indicator: implementation kits sold. Until now, Beckhoff alone has sold over 1800 kits (80% slave kits, 20%(!) master kits) + there are slave implementation kits + master stacks from many other vendors*, such as Slave Beck IPC Deutschmann EBV Elektronik Hilscher HMS anybus IXXAT Automation koenig-pa port Nagano OKI Red one technologies Soft Servo Systems STMicroelectronics Terasic Technologies TESSERA Xilinx Master acontis esd igh IXXAT Automation Kithara Koenig-pa MicroSys Electronics Profimatics Sybera * Only those listed that have entered their offering in the EtherCAT Product Guide at

Development Kits Control Panels, Hydraulic Valves and

69 EtherCAT: Largest Product Selection I/O, Controller, HMI, Servo Drives, Variable Speed Drives Sensors, Slave + Master Development Kits Control Panels, Hydraulic Valves and Pneumatic Valves, Official EtherCAT Product Guide:

70 Conformance and Interoperability Conformance and interoperability are very important factors for the success of a communication technology Conformity to the specification is an obligation to all users of the EtherCAT technology Therefore the EtherCAT Conformance Test Tool (CTT) is used Test Cases for the CTT are provided by the Working Group Conformance within the ETG community The EtherCAT Conformance Test proves conformance with issuing a certificate after passing the test at an official EtherCAT Test Center (ETC)

71 Safety over EtherCAT Material feeding Muting Two-Hand control Protection of workspace e.g. with Laser scanner Emergency stop Operator Diagnosis Safely-limited Position / Speed Door guarding with Interlocking Safety guard Setup / Maintenance

72 Modern Machine Safety Concepts

73 Safety over EtherCAT: Features Safety over EtherCAT (FSoE) defines a safety communication layer for the transportation of safety process data between Safety over EtherCAT devices. FSoE is an open technology within the EtherCAT Technology Group (ETG). The protocol is developed according to IEC It meets the Safety Integrity Level (SIL) 3 Residual Error Probability R(p) < 10-9 The protocol is approved by an independent Notified Body (TÜV) Certified products with Safety over EtherCAT are available since 2005

74 Safety over EtherCAT: Features (3) The FSoE specification has no restrictions according to: Communication layer and interface The communication layer is not part of the safety measures: black channel (assumed unsolved bit error rate: p = 10-2 ) Transmission speed Length of safe process data (lenght of safe process data is arbitrary) Routing via unsafe gateways, fieldbus systems or backbones is possible

75 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

76 Safety over EtherCAT: Software Architecture Safety Application Safety over EtherCAT Protocol Device 1 Standard Application EtherCAT Communication Interface EtherCAT Telegram Standard Application Device 2 Safety Application Safety over EtherCAT Protocol EtherCAT Communication Interface Safety over EtherCAT EtherCAT DLL and AL Safety data container (FSoE Frame) EtherCAT is used as a "black channel" It contains safety and standard information

77 Safety over EtherCAT: Hardware Architecture One channel communication system According to model A of IEC Annex A In Port RJ45 Controller A Safety Protocol Controller A Safety Protocol Magnetics PHY Device Controller B Safety Protocol Controller B Safety Protocol EtherCAT Slave Controller PHY Magnetics RJ45 Out Port

78 Safety over EtherCAT: Frame Structure EtherCAT Frame Ethernet Header EtherCAT Header 1. Datagram HDR Safety Application FSoE Protocol Device 1 EtherCAT Communication interface 2. Datagram FSoE Process Data Standard Application FSC FSoE Frame The FSoE Frame is embedded as a Container in the process data of the device. Each device detects a new FSoE Frame, if at least one Bit in the FSoE Frame is changed. Every 2 Byte SafeData are checked by a 2 Byte CRC FSoE Frame The maximum number of SafeData is therefore not restricted by the protocol. CMD Safe Data 0 CRC_0 Safe Data 1 CRC_1 Safe Data n CRC_n Conn ID

79 Safety over EtherCAT: Safety Measures Error Measure Sequence Number Watchdog Connection ID CRC Calculation Unintended repetition Loss Insertion Incorrect sequence Corruption Unacceptable delay Masquerade Repeating memory errors in Switches Incorrect forwarding between segments

80 Safety over EtherCAT: Advantages Fully integrated solution: safe and standard communication in one channel Reduction of fieldbuses and interfaces Central configuration, diagnosis and maintenance for safe and unsafe I/O in one tool Safety application makes full use of EtherCAT advantages: Short reaction times Almost unlimited number of nodes Large network extensions Cable redundancy options High Flexibility with Hot Connect

81 Safety over EtherCAT Open Solution Companies with Safety over EtherCAT interface* FSoE Master Baumüller, Beckhoff, Kuka, NUM, Sick, OMRON FSoE Drives AMK, Baumüller, Beckhoff, Kollmorgen, Kuka, Lenze, NUM, LTi, Stöber, Sensors, Safety I/Os Beckhoff, Baumüller, BBH, NUM, OMRON, Sick, TR electronic Stack Provider 3S (CodeSys), Ixxat Several additional machine manufacturer using Safety over EtherCAT internally in their devices: Printing machines, Tooling machines, NC Controller *available products or product announcements

82 Safety over EtherCAT: Implementation Example Decentralized Safety-Logic Standard PLC routes the safety messages Standard PLC Safety Inputs Safety Sensors Safety Outputs Safety Drives Safety Logic

83 Without Redundancy: Normal Operation EtherCAT Master Unit Unit MAC 1 Slave 1 Slave 2 Slave N......

84 Without Redundancy: Cable Failure EtherCAT Master Unit Unit MAC 1 Slave 1 Slave 2 Slave N-1 Slave N......

85 Without Redundancy: Node or Cable Failure EtherCAT Master Unit Unit MAC 1 Slave 1 Slave 2 Slave N-2 Slave N-1 Slave N......

86 With Redundancy: Normal Operation EtherCAT Master Unit Unit MAC 1 MAC 2 Only 2nd Ethernet Port required no special Interface Card Slave 1 Slave 2 Slave N......

87 With Redundancy: Cable Failure EtherCAT Master Unit Unit MAC 1 MAC 2 Slave 1 Slave 2 Slave N-1 Slave N Switchover time: < 15µs

88 With Redundancy: Node or Cable Failure EtherCAT Master Unit Unit MAC 1 MAC 2 Slave 1 Slave 2 Slave N-2 Slave N-1 Slave N......

89 EtherCAT: High availability Cabling redundancy 2nd Ethernet port needed on master side only Hot Swap of devices Hot Connect of network segments Master Redundancy with Hot Stand By Master Hot Connect Group

90 EtherCAT: versatile system architecture Master to Slave Slave to Slave Master to Master M2S Master M2M M2S Gateways Switchports Master S2S

91 EtherCAT Automation Protocol

92 EtherCAT and Wireless Communication Wireless Devices can be connected via Switchport Wireless segment does not slow down EtherCAT communication Protocol: EtherCAT Automation Protocol (EAP) Pushed and/or Polled Process Data Exchange Wireless Segment transparent for Master Device Master Switchport e.g. RFID Reader

Process Data Exchange Wireless Segment transparent for Master Device Master Switchport Master sees process

93 EtherCAT and Wireless Communication Wireless Devices can be connected via Switchport Wireless segment does not slow down EtherCAT communication Protocol: EtherCAT Automation Protocol (EAP) Pushed and/or Polled Process Data Exchange Wireless Segment transparent for Master Device Master Switchport Master sees process data of underlying system as local I/O data e.g. Card or RFID Reader Master with or without control application

94 EtherCAT - The Ethernet Fieldbus. Why go for something slower, just because it is more expensive?

95 EtherCAT - The Ethernet Fieldbus. Please visit for more information EtherCAT Technology Group ETG Headquarters Ostendstr Nuremberg, Germany Phone: info@ethercat.org

The Ethernet Fieldbus.

The Ethernet Fieldbus. Ethernet for Real-Time Communication Main Performance Problems: 1. Bandwidth Utilization 2. Stack Delays 3. Switch Delays EtherCAT Technology Group 1. Industrial Ethernet Bandwidth