Industrial Ethernet Comparison for Motion Control Applications
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1 Industrial Ethernet Comparison for Motion Control Applications Sari Germanos Technology Marketing Ethernet POWERLINK Standardization Group
2 Topology comparison - Conventional structure PLC Bus 1 Motion Bus 2 controller Drive Drive Drive Drive <1ms jitter <5ms cycle time Bus 3 I/O I/O >100 bytes Bus 4 Sensor Sensor <10$ Bus 5 Vision >1Mbits/s Many bus systems Different engineering tools Complex diagnostics and maintenance
3 Cycle time requirements > CNC, robotics = 200 to 400 µs > Fast IO = 200 to 400 µs > Motion control = 800 to 1200 µs > IO = 2 to 10 ms Typical cycle time ranges from 200 µs to 10 ms
4 Topology comparison - Integrated automation PLC Drive Drive Drive Drive I/O Sensor I/O Sensor 100ns jitter 100µs cycle time 1 to 1490 bytes 100 Mbit/s <10$ Vision One technology Unmatched performance Unlimited freedom in machine design Easy diagnostics and maintenance
5 Everything Connected to one network Ideal Network an Integrated System Architecture PLC Robotic Pneumatics Visualization Vision remote I/Os Sensor Safety Robotic Motion Systems
6 Fieldbus Technology Traditional fieldbuses RS485 or CAN based Reliable, field proven Cheap Very limited bandwidth Need a faster solution: Industrial Ethernet
7 Why Ethernet Ethernet is a safe investment for your communication networks Ongoing evolution since 1972 Available in all microprocessors Manufacturer independent technology Access to web technologies (TCP/IP, web server) Higher Productivity
8 CSMA/CD Ethernet Medium access: CSMA/CD Carrier-Sense Multiple Access with Collision Detection Collisions generate repeat after random delay Induces unpredictable delays Standard Ethernet is not deterministic Designed for office application
9 Switched Ethernet Switched Ethernet networks Traffic separation in collision domains Messages managed in queues Collisions are moved from network to queues Queues generate delay Packets are dropped in case of congestion Switches introduce latency thus not deterministic!
10 Ethernet Network Types TCP/IP based Networks Profibus Ethernet/IP Sum frame based Networks (token ring concept) Sercos III EtherCAT Hybrid Networks POWERLINK
11 Ideal Network Requirements 1. Real-time performance, high efficiency 2. Large asynchronous bandwidth 3. One single Network for all automation 4. Flexible network topology 5. Hot pluggable 6. High availability 7. Electromagnetic Compatibility (EMC) 8. Easy commissioning, maintenance and diagnostic
12 POWERLINK Concept Network master 1 Managing Node (MN) Network slaves Up to 239 Controlled Nodes (CN)
13 Ideal Network Requirements 1. Real-time performance, high efficiency 2. Large asynchronous bandwidth 3. One single Network for all automation 4. Flexible network topology 5. Hot pluggable 6. High availability 7. Electromagnetic Compatibility (EMC) 8. Easy commissioning, maintenance and diagnostic
14 Requirements 1 & 2 Performance & Efficiency Basic and robust mechanism No complex time synchronization Ideal for motion control
15 Ideal Network Requirements 1. Real-time performance, high efficiency 2. Large asynchronous bandwidth 3. One single Network for all automation 4. Flexible network topology 5. Hot pluggable 6. High availability 7. Electromagnetic Compatibility (EMC) 8. Easy commissioning, maintenance and diagnostic
16 Requirement 3 Direct slave to slave communication Fast drive to drive reaction time Centralized or decentralized architecture Multiplexed slot assignment No need to exchange all data at fastest cycle time Ideal for Integrated Automation
17 Efficient technology Poll Response Chaining Position Control Loop Current Control Loop
18 Ideal Network Requirements 1. Real-time performance, high efficiency 2. Large asynchronous bandwidth 3. One single Network for all automation 4. Flexible network topology 5. Hot pluggable 6. High availability 7. Electromagnetic Compatibility (EMC) 8. Easy commissioning, maintenance and diagnostic
19 Requirements 4 & 5 Hot Plug Higher productivity, modular system concepts Topology flexibility 100% free choice of star, tree, ring, or daisy chain No limits on system extensions
20 Ideal Network Requirements 1. Real-time performance, high efficiency 2. Large asynchronous bandwidth 3. One single Network for all automation 4. Flexible network topology 5. Hot pluggable 6. High availability 7. Electromagnetic Compatibility (EMC) 8. Easy commissioning, maintenance and diagnostic
21 Requirement 6 High Availability Ring redundancy Full medium redundancy Redundant master
22 Ideal Network Requirements 1. Real-time performance, high efficiency 2. Large asynchronous bandwidth 3. One single Network for all automation 4. Flexible network topology 5. Hot pluggable 6. High availability 7. Electromagnetic Compatibility (EMC) 8. Easy commissioning, maintenance and diagnostic
23 Requirement 7 Electromagnetic Compatibility New machines include noisy electric power components
24 Ideal Network Requirements 1. Real-time performance, high efficiency 2. Large asynchronous bandwidth 3. One single Network for all automation 4. Flexible network topology 5. Hot pluggable 6. High availability 7. Electromagnetic Compatibility (EMC) 8. Easy commissioning, maintenance and diagnostics
25 Requirement 8 Network Diagnostics Unambiguous diagnostics Total view of the network No data manipulation on path-transmission Standard office diagnostic-tools PC with on-board Ethernet interface using Wireshark, Omnipeak, etc.
26 POWERLINK Frame Structure POWERLINK frame Fully compliant with IEEE Ether Type = 0x88AB
27 POWERLINK OSI model POWERLINK OSI model POWERLINK sits on top of the standard Ethernet MAC layer Full integration with TCP/IP
28 Performance Timing characteristics 0.1 µs system synchronization 100 µs cycle time High capacity High data throughput 239 Controlled Nodes 480 synchronized axes 460,000 digital I/O data points Exceptional performance Example : 17 stations, 800 digital I/O, 180 analog I/O, 24 axes -> cycle time of µs
29 The fastest network in the world! 728 axes in 400µs
30 CANopen Reference Model POWERLINK interface is CANopen over Ethernet Same device profiles CANopen application layer Same mechanisms (PDO, SDO, Object Dictionary )
31 Standards EPSG is an open vendor group Technology not owned by a single company POWERLINK is an open protocol No license fees No patents Free specification: Open-source protocol stack available Open standards IEEE IEC
32 POWERLINK implementation Any HARDWARE Any operating system
33 openpowerlink Open-source POWERLINK stack (MN and CN) BSD license Developed for Linux Ported to Windows and VxWorks Other platforms under development Project hosted at SourceForge.net:
34 Market Share 3,100 OEMs developing POWERLINK systems More than one Million POWERLINK systems deployed Source IMS Research 2013
35 Government Recommended Standard Industrial Ethernet National Standard GB/T-27960
36 Benefits of opensafety Fieldbus-independent safe communication PLC opensafety I/O Current fieldbus Available Worldwide use in series machines since 2008 Manufacturer-independent EPSG (Ethernet POWERLINK Standardization Group) Open source Without any restrictions
37 End user acceptance Available safety protocols ProfiSafe CIPSafety Profibus Profinet Ethernet/ IP FSoE Safety Net p Proprietary protocol from PILZ Others POWER- LINK SERCOS III EtherCAT Modbus TCP/IP UDP
38 End user acceptance Available safety protocols Profibus Profinet Ethernet/ IP Others POWER- LINK SERCOS III Covers 100% of the market CANopen Modbus TCP/IP UDP
39 opensafety One safety standard for the whole production line
40 opensafety is certified TÜV certification IEC SIL3, PL e Certified safe motion profiles IEC International safety standard IEC certified product
41 End user acceptance Stefano Pasquali Commercial Part Technical Manager Bryan Griffen Head of Electrical & Automation Engineering Christian Kervenec Vice President Technology helps us reduce the number of components and the overall complexity of the system SIDEL allows communication of safety data across the entire production line, independent of the system used NESTLÈ opensafety is the only c o m p l e t e l y o p e n a n d independent safety standard ALSTOM
42 Industrial Ethernet Facts Comparison of 5 major Industrial Ethernet technologies Available at
43 POWERLINK news
44 Thank you for your attention! Sari Germanos Technology Marketing Ethernet POWERLINK Standardization Group
opensafety The open safety standard for all communication protocols
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