AM437x Industrial Communications. Sitara ARM Processors

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1 AM437x Industrial Communications Single Chip Drive Embedded Processing Sitara ARM Processors 1

2 Agenda AM437x Overview & Communications Device & IDK Overview Industrial Communications AM437x Motor Control Industrial Field Oriented Control Position Feedback Sigma Delta Modulator AM437x Tools & System Advantages Software Development Kit (SDK) Industrial Subsystem Solutions & Advantages

3 AM437x Overview & Communications AM437xIndustrialCommunications Single Chip Drive 3

4 Integration Single Chip Drive Solution Field Oriented Control providing variable frequency drive motor control Control Integration of a Multiprotocol feedback interface Connect Certified multi protocol industrial Ethernet integration enabling real time deterministic communication Communicate 4

5 Integration Single Chip Drive Solution: AM437x Safety MCU AM437x Solution time sync Field Oriented Control Power Power Industrial Ethernet Control MPU Feedback Integration M Industrial Ethernet Integration Feedback Feedback I/O 5

6 AM437x Single Chip Drive Controller Industrial Ethernet Service Port Fieldbus T = µs Eth Phy 1 Eth Phy 2 MII Eth RGMII Phy 3 RS 485 UART AM437x ICSS 2 port Industrial Ethernet 2 port 1Gb Ethernet MAC/switch Time Sync ARM Cortex A9 Up to 1000 MHz 256K L2 RAM 256K Shared RAM PWMSS SD Filter 2x SAR ADC ecap(pwm) T = µs 6 channel PWM 9 channel Sinc3 Isolation Power Stage 1 Power Stage 2 Resolver 3 phase System Interfaces ICSS 32 bit DDR3, NAND, NOR, MMC 1xPRU UARTs, QSPI, McSPI, McASP, CAN RS 485 IEP, SCU edma, ecap, eqep, epwm, Timer 1..2 Position Feedback IF GPIOs M FB M FB SPI Safety Power MCU 3 Safety Stage 1 MUC 1 Functional Safety over Industrial Ethernet Position Feedback Control Legend: ICSS Industrial Communication Subsystem SD Sigma Delta (Sinc1/2/3) IEP Industrial Ethernet Peripheral MII Media Independent Interface FB Feedback (Absolute Encoder)

7 Cortex A9 delivers up to 2500 DMIPs 20% higher h than Cortex A8 VFP unit 10 times faster than Cortex A8 256KB RAM configurable as either L2 cache or L3 SRAM, providing up to 512KB of internal L3 RAM 256 KB L3 RAM (AM335x has 64KB) 32b DDR memory interface increases bandwidth (vs 16b in AM335x) Simplified power sequencing for flexible power design System cost savings AM437x Differentiation from AM335x QSPI interface enables execute in place (XIP) from low cost NOR flash Enables DDR less applications ARM Cortex A9 Up to 1 GHz 32K/32K L1 256K L2 / L3 64K RAM Graphics Acceleration SGX530 Display Subsystem 24bit LCD Touch Screen Controller Quad Core PRU ICSS 45nm Industrial Communications + Motor Feedback Protocols + Sigma Delta 2 x ICSS (AM335x has 1) for industrial protocol acceleration enables simultaneous industrial Ethernet protocols and motor feedback protocols. Display processing offloads CPU from tasks such as overlay, etc. Contributes to higher performance than AM335x Processing: 256KB L3 Shared RAM Overlay, Resizing, Security Color Space AccelerationPac 32 bit Conversion, etc. LPDDR2/DDR3/DDR3L Crypto, Secure boot Secure boot enables IP protection, anti cloning, System Services and take over protection Simple Pwr Seq EDMA Debug 12 Timers SyncTimer32K WDT RTC 2x 12 bit ADCs EMAC 2 port switch 10/100/1G w/1588 QSPI Camera I/F (2x Parallel) USB2 Dual Role +PHY x2 Connectivity and IOs CAN x2 ecap/ eqep x3 HDQ PWM x6 SPI x5 I2C x3 McASP x2 GPIO UART x6 NAND /NOR (16bit ECC) 3 MMC/ SD/SDIO More SPI, Timers, PWMs, and ADC channels to support Industrial applications New HDQ / 1 Wire interface for sensors and battery monitor Single/Dual camera port for apps such as data terminals, barcode scanners, etc.

8 AM437 Industrial Development Kit (IDK) 8

9 AM437 IDK Evaluation Module (EVM) +24V DCPower Mini USB B XDS100v2 emulator support JTAG Camera I/O Expansion AM437x ADC Interface Sigma Delta I/F 9 PWMs microsd Expansion slot for additional storage 3 phase motor PWM Output QEP Input Dedicated 24V Motor Supply RS485 EnDAT 2.2 I/F 8x Digital I/Os 1 GHz Sitara AM4379 Cortex A9 Gig B Ethernet Industrial Communications LEDs Ind. Ethernet PORT1 Ind. Eh Ethernet PORT0 9

10 Industrial Communications Ethernet for Control Automation Technology (EtherCAT): Large IO systems and drives, getting momentum in Asia Industrial Ethernet based on Profibus Real Time (Profinet RT) / Isochronous Real Time (Profinet IRT) Factory automation including network connected drives Ethernet Industry Protocol (Ethernet/IP): IEEE compliance, Common Industrial Protocol, CIPSync for drives, strong in Process Automation Powerlink: Open technology, popular p in inverters Sercos III: Optimized technology for drives Protocol Platform Availability Stack Partner Key Sponsor AM335x Certified BeckHoff SSC (Open EtherCAT Slave Beckhoff AM437x Certified* Source) Profibus Slave AM335x Certified* TMG Siemens AM335x Certified KalkiTech, Rockwell Automation EtherNet/IP Slave AM437x In Development Molex Schneider Electric AM335x RT Certified, IRT in Dev ProfiNet Slave Molex Siemens AM437x RT & IRT in Dev Powerlink Slave AM335x Certified PORT B&R Automation * Firmware certified on primary development platform Sercos III Slave AM335x Certified Automata Rexroth Bosch Group Schneider Electric 10

11 Industrial Protocols: 3P Engagement Model (For active links, refer to the PDF attachment) Protocol 3P Initial Engagement Production Profibus TMG: Klaus Peter Willems Production license : 1 time karlsruhe.de 5000 fee plus maintenance Profinet EtherCAT Ethernet/IP SERCOS III EtherCAT Master IEC61850 High availability Seamless Redundancy (HSR) Parallel Redundancy Protocol (PRP) Molex: Bieber, Thierry Thierry.Bieber@molex.com Interniche stack: sales@iniche.comcom EtherCAT Technology group (ETG) Stack also available from Port: Christian Bornschein cb@port.de ESD: Dirk Flege sales@esd.eueu Molex: Bieber, Thierry Thierry.Bieber@molex.com Cannon Automata: Christoph Melzer chmelzer@automata.de Koenig: Gerhard Spiegel Gerhard.Spiegel@koenig pa.com Acontis: Stefan Zintgraf s.zintgraf@acontis.com com Triangle Microworks: Joe Stevens jstevens@trianglemicroworks.com Netmodule: Rainer Fehr rainer.fehr@netmodule.com Netmodule: Rainer Fehr rainer.fehr@netmodule.com Evaluation license included in TI SDK Request the free Sercos III limited evaluation binary for ICE Not yet included in TI SDK Not yet included din TI SDK Contact Molex and Interniche Available for free with ETG membership which is also free. Support from ETG Contact Molex Contact: p _ sit ara_1_en Contact Triangle Microworks License will be included? License will be included? Powerlink Port: Christian Bornschein cb@port.de Contact Port

12 EtherCAT Overview EtherCAT is a real time, low latency industrial field bus protocol that is becoming popular in industrial automation and motor control applications. Emerging Real time Ethernet Standard Driven by Beckhoff Automation Accepted as physical layer for other standards Technical Features Based on IEEE802.3 Ethernet Standard 100 Mbps Full duplex Distributed Clocks and Synchronization Standards IEC 61158, IEC and IEC IEC for Safety over Ethernet TwinCAT, CANopen, SERCOS application layers Applications Industrial Drives Distributed I/O Industrial Computing and Control Supported by the EtherCAT Technology Group (ETG) Drives development of EtherCAT Founded in 2003 by Beckhoff Automation Beckhoff assigned rights to EtherCAT to ETG Free membership Global presence Members from 50 countries Active Worldwide training i centers Plug fests Technical committees Working groups 12

13 EtherCAT Slave ISO/OSI Reference Model Video over Ethernet File over Ethernet Ethernet over Ethernet CAN over Ethernet FieldBus Memory Management Unit Service Data Objects Process Data Objects The EtherCAT master sends a telegram that passes though each node. Each EtherCAT slave reads the data addressed to it on the fly and inserts its data in the stream as the frame moves downstream. This increases the effective data to over 90% of the Ethernet bandwidth. The real time communications operations are performed by the PRU ICSS exchanging output and input information with the communications stacks managed by the ARM. The Application layer is supported by the ARM. EtherCAT can provide the physical layer for application protocols like CAN (CoE), Servo drive (SoE), Slide courtesy of ETG

14 Communications Example: EtherCAT TI has worked with Beckhoff Automation to streamline the process of integrating EtherCAT with the Sitara AM335x or AM437x processors. All the tools and software code required to integrate an EtherCAT slave application are available in the industrial software development kit (SDK). The SDK includes firmware for: EtherCAT protocol Software drivers Hardware initialization routines Adaptation layer for the stack API EtherCAT protocol stack Application The documentation describes how to integrate Industrial communication functionality into a customer application Customers become ETG members (required to market EtherCAT products no charge) Entitled to obtain a free copy of the Beckhoff stack directly via the ETG website. A binary copy of the Beckhoff EtherCAT stack is included in the TI Industrial SDK for evaluation, development and test purposes. 14

15 AM437x Motor Control AM437xIndustrialCommunications Single Chip Drive 15

16 Overview of Drive Architecture Three major functions: Communication Integration with the field network directly or through PLC or motion controllers Application Manage connect, control, feedback and communication Control Control motor speed versus torque & efficiency i to maintain i noiseless 16 operation and a operating life

17 Field Oriented Control Loop Example A diagram of a velocity and position field oriented control loop for a permanent magnet synchronous motor. 17

18 Field Oriented Control Loop The field oriented control loop is performed by the AM437x Cortex A9 ICSS 1 supports the EtherCAT operations ICSS 0 implements the EnDat 2.2 interface and ADC data acquisition 18

19 Single Chip Drive Processing Model AM437x Layer 7 Application Industrial Application API API SYSBIO OS State Machine Protocol Stack PWM API Sigma Delta API EnDAT API API Protocol Driver Bootloa ader, Too ls ARM API API API Layer 2 Data Link Protocol Firmware Protocol Firmware Protocol Firmware PRUSS Layer 1 Physical PWM Sigma Delta EnDAT Ethernet Phy TI Example Customer Developed Third Party or Customer TI 19

20 AM437x Control Cycle EtherCAT communication consists of cyclic and acyclic communications. The cyclic communications contain process information. These are initiated by the PLC master or motion controller at a periodic intervals. These can include position sequences and other control information. The information that is returned to the PLC or motion controller can include measurements and status information. The received cyclic position sequences are translated into three motion control sequences each communications cycle by the field oriented control algorithm that generates 3 phase PWM motor control commands. The field oriented control algorithm uses position and current feedback inputs from an EnDAT 2.2 encoder and a Delta Sigma modulator. Status and error information from these operations are returned to the motion controller or PLC during the next communications cycle. This processing uses only a fraction of the ARM s processing capacity. This permits the ARM to support other acyclic (non periodic) communications and processing functions such as a web server for other remote status, control and programming operations. 20

21 AM437 FOC Control with EnDAT Position Data Straight forward implementation; Performance was not optimized Critical Function Timeline Processing Time Level 4 (closed speed loop) Level 5 (closed position loop) ADC Sampling and Conversion PRU us SYSBIOS Interrupt Latency * A us FOC Close Current/Torque loop to PWM update A us Elapsed time Sample to PWM update us 25% Head room us Elapsed Time + 25 % Headroom for customer tailoring us Worst case Maximum operational rate (worst case one channel) khz Cortex 600 MHz PWM Loading EtherCAT 100 us communication interval KHz Level 5 (closed position loop) Single drive motor control 47 68% 408 Mcycles * As a reference the low level starterware interrupt latency is 600 ns.

22 Digital Encoder Interfaces Industrial drives require accurate, high reliability, and low latency position feedback. The AM437x supports several high speed digital encoder interfaces for position and rotary encoders Encoder d Data (EnDAT) 2.2, HIgh PERformance InterFACE Digital Servo Link( HiperFace DSL) Bidirectional Serial Synchronous Continuous (BiSS C). These interfaces transfer position information and additional physical quantities such as number of turns, temperature, and diagnostics i to the control system. Support of legacy Encoder interfaces like QEP

23 Digital Encoder Interfaces Protocol EnDAT HiperfaceDSL BiSS C Owner Heidenhain (Germany) Sick (Germany) ic Haus (Germany) License /specification Free / NDA Free / NDA Free / Open Source Phy Interface RS 485 RS 485 RS 422/485 Speed 100kbit 8/16 Mbit Mbit 1/2/5/10 Mbit Reach 100 meter, 300m at lower speed. 100 meter 100 meter Cable 4 wire 2 wire, motor integrated 4 wire Max frame length ~ bit Continuous frame 117 bit 64 bit / frame Delay compensation Yes Yes yes Oversampling 8x 8x 8x Overhead channels Two additional 8 V frames 1 bit per frame Synchronization Start pulse bit time Async Pulse (13 ns) Start pulse bit time Host interface Own API function compatible Register compatible register compatible Functional Safety Yes, may change No Yes (early) ICSS ICSS_L / M_v2 Mv21 3 chan ICSS_L / Mv2,(225MHz),1 M_v2, ICSS v1 1 channel chan

24 Sigma Delta Current Measurement Sigma Delta Dlt Current tmeasurement provides: Fast conversion for over current protection Higher resolution measurements for precision motor control Good isolation from high side voltages 24

25 Delta Sigma Modulator Interface to Sitara PRU AMC1304 CLOCK (up to 20Mhz) Sitara TM +/ 50mV or +/ 250mV INP INM CLOCK DATA DATA (1 bit) SD_CLKOUT SD_CLKIN SD_DATA_IN0 SD_DATA_IN1. SD_DATA_IN8 PRU_ ICSS0 The conversion of the one bit AMC1304 Sigma Delta Modulator output to a 24 bit binary signal is performed by the Sitara PRU using a SINC filter. The filter is combination of PRU hardware and firmware: Integration is performed in the hardware accumulators Differentiation is done in PRU firmware. 25

26 Delta Sigma Modulator Current Sensing in 3 Phase Inverters: System Block Diagram NOTE: Only one half bridge shown Isolated high side IGBT gate driver power supply 8V +16V 24V Isolated DC/DC ISO SDM Power Supplies For IGBT Gate Drivers 24Vin, Isolated Outputs 3.3V P/S cold side ±50 mv Gain 4..18V IN LDO ΔΣ Isolation Barrier AM437x with SINC decimation filter R SHUNT AC Motor AMC1304 Isolated Current Shunt and Voltage Measurement for Motor Drives Using AM437x ti /t

27 Isolated Current Shunt & Voltage Measurement for Motor Drives Using AM437x

28 Tools & System Advantages AM437xIndustrialCommunications Single Chip Drive 28

29 Industrial SDK (ISDK) Architecture Requirements Applications Communication Stacks SYS BIOS DAL/Platform Drivers PRU Firmware Hardware (AM437x IDK) 29

30 ISDK for Sitara Available in Windows install package, which includes the following: Protocol firmware, libraries lb and headers: objects Drivers for platforms: source format Starterware: source format Example projects: source format HW Setup GELs Code Composer Studio v6 AM437x emulation support (XDS560 and XDS100v2) GNU Code Generation Tools NOTE: IA SDK requires BIOS and XDCTOOLS versions defined in release notes and getting started guide.

31 IA SDK Releases Ongoing releases Download latest release: ind sitara Getting Started t Guide: G Release Notes (release dependent): User Guide (release dependent): Industrial SDK The ISDK should be installed in a location that is aligned with the placement of the CCS and SYS/BIOS paths. For example, in the current CCS directory. 31

32 The AM437x Advantage High performance Cortex A9 with enhanced industrial connectivity and real time processing Why was this device developed? Expand the Sitara portfolio with a higher performance Cortex-A9 Enhanced PRU-ICSS to support multiple real time operations and opening new applications such as Industrial Single Chip Drives Contains a higher level of integration versus AM335x with Camera, Display Subsystem, 512-kB of on-chip memory, QSPI-NOR flash interface, simplified power sequencing Advanced security features What differentiates the AM437x? The two ICSSs with their combined 4 PRUs are the largest differentiator Provide a solution for applications needing ultra-low latency and deterministic, real-processing These can replace FPGAs/ASICs and save BOM cost Integrated Sinc3 filter for higher precision delta sigma ADC Low power consumption for portable applications and end equipment where thermal performance is a concern Small package size

33 AM437x Single Chip Drive Controller Industrial Ethernet Service Port Fieldbus T = µs Eth Phy 1 Eth Phy 2 MII Eth RGMII Phy 3 RS 485 UART AM437x ICSS 2 port Industrial Ethernet 2 port 1Gb Ethernet MAC/switch Time Sync ARM Cortex A9 Up to 1000 MHz 256K L2 RAM 256K Shared RAM PWMSS ΔΣ Filter 2x SAR ADC ecap(pwm) T = µs 6 channel PWM Current feedback Isolation Power Stage 1 Power Stage 2 Resolver 3 phase System Interfaces ICSS 32 bit DDR3, NAND, NOR, MMC 1xPRU UARTs, QSPI, McSPI, McASP, CAN RS 485 IEP, SCU edma, ecap, eqep, epwm, Timer 1 2 Position Feedback IF GPIOs M FB M FB SPI Safety Power Safety MCU 3 Stage 1 MUC 1 Functional Safety over Industrial Ethernet Position Feedback Control Legend: ICSS Industrial Communication Subsystem SD Delta Sigma (Sinc1/2/3) IEP Industrial Ethernet Peripheral MII Media Independent Interface FB Feedback (Absolute Encoder)

34 AM437x Multi Axis Drive Controller Industrial lethernett Service Port Fieldbus T = µs Eth Phy 1 Eth Phy 2 MII Eth RGMII Phy 3 RS 485 UART AM437x ICSS 22 port ICSS Industrial Ethernet 2 port 1Gb Ethernet MAC/switch Time Sync ARM Cortex A9 Up to 1000 MHz 256K L2 RAM 256K Shared RAM ICSS 1xPRU IEP GPMC QSPI/McSPI T = µs custom IF PIF SIF Isolation Power Stage 1 Power Stage 2 Power Stage n 3 phase System Interfaces ICSS 32 bit DDR3, NAND, NOR, MMC 1xPRU RS 485 UARTs, QSPI, McSPI, McASP, CAN SCU transceiver edma, ecap, eqep, epwm, Timer 1 3 Position Feedback IF GPIOs M FB M FB M FB SPI Safety Power MCU 3 Safety Stage 1 MUC 1 Functional Safety over Industrial Ethernet Position Feedback Control Legend: ICSS Industrial Communication Subsystem IF Interface SIF Serial Interface PIF Parallel Interface SCU Serial Capture Unit IEP Industrial Ethernet Peripheral MII Media Independent Interface

35 For More Information Overview for Sitara ARM Processors: AM437x Technical Reference Manual For questions regarding topics covered in this training, visit the support forums at the TI E2E Community website. 35

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