backbone for automotive testing

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Clyde Stafford
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1 backbone for automotive testing Gerhard Spiegel Manager KÖNIG Prozessautomatisierungs GmbH Member of

2 Content Requirements What is EtherCAT? EtherCAT s strength Demo König

3 Requirements of measurement-/automation-systems High amount of data High bandwidth Deterministic timing One bus only

4 Content Requirements What is EtherCAT? EtherCAT s strength Demo König

5 What is EtherCAT? is Real Time Ethernet developed by

6 Configuration tool + Master + Slaves 3 items Configuration Tool Standard Ethernet IPC Slaves have: Real Time Ethernet + Controller + Slave Stack.. DVI Master has: Standard Ethernet Controller RTOS + Master Stack

7 7 Layer Structure with Real Time extensions Ethernet + Real Time Hardware Software Layer 5..7 Layer 4 Layer 3 Layer 1+2 IT-App.: HTTP SNMP DHCP TCP/UDP IP Timing-Layer Parameter Data Application Automation API Process Data Process Data Protocol Special Real Time Ethernet Controller

8 EtherCAT technology. EtherCAT Slave (taken from ETG) Real Time Ethernet Controller Ethernet Application Real Time Application TCP UDP IP Acyclic Data Mailbox EtherCAT MAC / DLL Process Data Ethernet PHY Ethernet PHY

9 EtherCAT technology. Data exchange (taken from ETG) Ethernet on the Fly Slave Device EtherCAT Slave Controller Slave Device EtherCAT Slave Controller Process data is extracted and inserted on the fly Frames return on the far end (full duplex) Higher bandwidth than Ethernet due to collision avoidance Deterministic behavior based on RTOS of master 100 MBd not being the end for Ethernet - is 8 times more than Profibus 10 times more than flexray 100 times more than CAN

10 Content Requirements What is EtherCAT? EtherCAT s strength Demo König

11 EtherCAT technology. High speed speed (taken from ETG, adapted to testing) Comparison 2000 Digital I/O 250 Byte 300 Analog In 600 Byte 300 Analog Out 600 Byte 1 Byte = 80ns 1514 * 80ns Telegram length 122µs 600 slaves, 500m cable Frame Cycle Time 276µs 44% Bus load

12 EtherCAT technology. Synchronous (taken from ETG) Reference clock Precise timing (<< 100ns!) IPC M t S S S.. DVI S S S S S

13 EtherCAT technology. Topology (taken from ETG) Topology type:.. IPC DVI Daisy Chain with Drop Lines Most widely used topologies: line (up to nodes) tree drop lines ring

14 EtherCAT technology. Topology Topology (taken from ETG, CAN extended) Gateways IPC.. DVI for using AK Protocol. configuration via DBC-files.

15 EtherCAT technology. Low costs (taken from ETG) Cheapest master and infrastructure Master: no dedicated plug-in card (co-processor), on-board Ethernet Port is fine Slave: - low-cost Slave Controller - FPGA, IP-Core or ASIC - for communication no powerful µc needed Infrastructure: - no Switches/Hubs required - Standard Ethernet cables + connectors

(IEC 61158, IEC 61784-2, ISO 15745-4) Slave Controller from several

16 EtherCAT technology. Openness (taken from ETG) Standard EtherCAT is IEC and ISO Standard (IEC 61158, IEC , ISO ) Slave Controller from several sources Master Stacks for various RTOS from several providers ETG organizes Plug-Fests and prepares Conformance Test

17 Greatest community 739 members (Status April 2008) EtherCAT technology. Openness (taken from ETG) Nov 03 Feb 04 Mai 04 Aug 04 Nov 04 Feb 05 Mai 05 Aug 05 Nov 05 Feb 06 Mai 06 Aug 06 Nov 06 Feb 07 Mai 07 Aug 07 Nov 07 Feb

18 EtherCAT technology. Summary High lights High-speed Deterministic timing behavior M t Different topology types I P C DVI.. Low cost for slave, infrastructure, master (in comparison with other RT Ethernet) Openness Nov 03 Feb 04 Mai 04 Aug 04 Nov 04 Feb 05 Mai 05 Aug 05 Nov 05 Feb 06 Mai 06 Aug 06 Nov 06 Feb 07 Mai 07 Aug 07 Nov 07 Feb

19 Content Requirements What is EtherCAT? EtherCAT s strength Demo König

20 Demo. Redundancy, Hot Plug, Slave 2 Slave Slave 7 Ch1 Ana In Slave 7 Ch1 Ana In Server Saw tooth application Premium Slave 3 Ch1 Ana In Slave 4 Ch1 Ana Out Slave 4 Ch2 Ana Out Slave To Slave (S2S)

21 Demo. Redundancy Topology Cable break detection Click on slave to see its settings

22 Demo. Hot-plug Mark slaves as pluggable Give them an unique address Connect/disconnect even during Operational Hot-pluggable slave plugged Hot-pluggable slave unplugged

23 Demo. Slave-to to-slave communication Outside PLC: output passes its value to input(s) Inside PLC: input passes its value to output(s)

24 Demo. 100µs s cycle, 17 byte, <1% CPU (Intel Pentium dual CPU E GHz)

25 Live demo. frame chart every 3rd cycle one acyclic exchange

26 Content Requirements What is EtherCAT? EtherCAT strength Demo König

27 EtherCAT company Products + Services 1. EtherCAT Studio configuration & diagnostic tool 2. König EtherCAT master adaptation and extension 3. EtherCAT slaves design and prototyping 4. EtherCAT consultancy concepts for implementations application architectures 5. EtherCAT trainings

28 Company. EtherCAT team EtherCAT team Management Sales, PM, Marketing Gerhard Spiegel Support & Training & Documentation Development Operating manager deputy Alexander Saposhnikov Victor Alexander Vysotski Mashentsev Vitaly Alexandra Bondarchuk Pavlova Studio and Master Anton Dmitry Sergey Dmitry Michail Tarasevich Minich Peniaz Markovich Kolesov (st) QA Slave- development and -project management Andrey Valeria Ivan Druk Kravchenko Konoplyanik (st) Pavel Jury Andrey Bakhur Osinenko Tsybulka Zakrevski Sergey

29 Automotive customers Customers in automotive testing

30 Company. Profile Profile Since 1986 About 60 engineers, IT scientists, mathematicians Planning/Service in Feucht near Nuremberg, Germany Development/Test in Minsk, Belarus Industrial communication (Profibus, CAN, EtherCAT) Working in a tight cooperation with main customer Atotech (subsidiary of Total)

31 Company. Production for printed circuit boards PCB lines with SCADA SCADA with worldwide software-installations from KÖNIG

32 Company. Activities Activities SCADA systems for copper deposition on Printed Circuit Boards (PCB) Soft PLCs according to IEC Pulse reverse power supplies with digital control Vision control systems Worldwide installations Configurators for (semi)-automatic creation of electro-schemas quotes

33 High lights of EtherCAT for automotive testing Highlights Redundancy in wiring Hot plug of devices Slave to Slave communication Raw CAN gateway Remote configuring of devices Different scan rates

34 Thank you!

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