SERCOS III Universal Real-Time Communication for Automation

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Howard York
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1 SERCOS III Universal Real-Time Communication for Automation MOF 2010 / Summit, Tokyo /Japan November 19,2010 Peter Lutz, Managing Director, SERCOS International e.v.

2 SERCOS III : Next Evolution Step for SERCOS SERCOS III = SERCOS + Ethernet Innovation by Combining SERCOS and Ethernet Utilization of Standard Ethernet as real-time network Re-use of well-defined and proven SERCOS mechanisms : Time-slot protocol for collision avoidance Hardware synchronization Protocol in the real-time channel Motion control profile SERCOS stands for 25 Years Experience Performance, Determinism and Robustness 2.5 Million Real-Time nodes No. 2

3 Application Areas of SERCOS Cycle times Synchronization Application Areas SERCOS I-III Standard Ethernet communication Not cyclic Not synchronized Positioning drives, FCs, I/Os ms > 4 ms Controller-to- Controller Comm. & Synchr ms < μs SERCOS III Coordinated drives, High-Speed-I/Os. 250 μs... 4 ms < 1 μs SERCOS I SERCOS II Multi-axes drive concepts with centralized signal processing 31,25 μs μs < 1 μs No. 3

4 SERCOS III: Topologies Line Topology Ring Topology Master Master CAT5e Full-Duplex Ethernet, Fiber optic or Copper Wire Baudrate 100 Mbit/s, Cycle time: 31,25 µs 65 ms Synchronization Accuracy: << 1 µs No. 4

5 SERCOS III Ring Redundancy Redundancy, e.g. in case of Cable break Hot plugging of devices Master Full-Duplex Ethernet, Fiber optic or Copper Wire Baudrate 100 Mbit/s, Cycle time: 31,25 µs 65 ms Synchronization Accuracy: << 1 µs Recovery Time : < 20 µs Hot plug device No. 5

6 SERCOS III for modular machines and systems C2C Master 1 Master 2 Slave Master Slave Master CC Controller-to-Controller Communication (C2C) and Cross Communication (CC) No. 6

7 SERCOS III: Communication Cycle, RT and NRT Channel Synchronization: Once per Cycle MDT AT MDT H D R M S T H D R M S T H D R M S T Real-Time Channel (SERCOS III Frames, Ethertype 0x88CD) Non-real-time Channel (any Ethernet frame, Ethertype 0x88CD) Communication Cycle (discrete cycle times: 31,25 µs; 62,5 µs; 125 µs; 250 µs; 500 µs 65 ms) MDT, AT and non-real-time data is embedded in Standard Ethernet frames No. 7

8 SERCOS III Ethernet Connecitivity (1) primary or secondary channel Master P1 P2 Line Slave 1 P1 P2 Slave 2 P1 P2 Slave 3 P2 P1 IP SERCOS III and other Ethernet frames Collision Buffer PC Non-real-time frames only Collision Buffer is available in each SERCOS III device PC receives S III frames and other (non-real-time) frames PC transmits non-real-time frames only (Ethernet, IP, ) No. 8

9 SERCOS III Ethernet Connecitivity (2) PC1 Ethernet (Plant / Office) Line IP Master P1 P2 PC3 PC2 I/O No. 9

10 SERCOS III Ethernet Connecitivity (3) PC1 Ethernet (Plant / Office) IP Master Ring PC2 P1 P2 I/O No. 10

11 SERCOS III Ethernet Connecitivity (4) IP I/O Download/Upload via NRT-channel in non-real-time mode in line topology Every SERCOS III device has a MAC address PC is connected to a unused port No. 11

12 NRT-Communication NRT services define exchange of SERCOS III data with and without established SERCOS III communication TFTP (trivial file transfer protocol) Standard protocol based on UDP TCP / IP Stack isn t necessary used for firmware download SERCOS Internet Protocol S/IP Standard protocol between nodes Based on TCP/IP used to modify and setup parameters in the slave Security measures need to be considered for the NRT channel only SERCOS device profiles already include security functions (e.g., password protection, access restrictions) No. 12

13 International Standard Drive Profiles, IEC IEC series Adjustable speed electrical power drive systems IEC Device profile guideline IEC Generic interface and use of profiles for power drive systems IEC Interface definition Generic PDS interface specification Annex A Mapping of Profile type 1 (CiA 402) Annex B Mapping of Profile type 2 (CIP Motion) Annex C Mapping of Profile type 3 (PROFIdrive) Annex D Mapping of Profile type 4 (SERCOS) IEC Profile specifications IEC IEC IEC IEC Profile type 1 (CiA 402) Profile type 2 (CIP Motion) Profile type 3 (PROFIdrive) Profile type 4 (SERCOS) IEC Mapping of profiles to network technologies IEC IEC IEC IEC Mapping of profile type 1 to: CANopen EtherCAT ETHERNET Powerlink Mapping of profile type 2 to: DeviceNet ControlNet EtherNet/IP Mapping of profile type 3 to: PROFIBUS PROFINET Mapping of profile type 4 to: SERCOS I + II SERCOS III EtherCAT No. 13

14 CIP Safety on SERCOS SI adopts CIP Safety as its functional safety protocol for SERCOS Compatible safety protocol for SERCOS III and CIP-based protocols ODVA and SI develop and establish joint conformance testing CIP Safety on SERCOS SERCOS safety Profile CIP Safety CIP Safety Profile Routing between networks Adaptation of CIP Safety SERCOS interface SERCOS Gateway CIP SERCOS III SERCOS III SERCOS III Ethernet/IP SERCOS III SERCOS III Ethernet/IP No. 14

FDT/DTM for SERCOS III FDT unifies the communication between field devices and the engineering systems. FDT thus makes it possible to call any devices using any protocols via any engineering tool.

15 FDT/DTM for SERCOS III FDT unifies the communication between field devices and the engineering systems. FDT thus makes it possible to call any devices using any protocols via any engineering tool SERCOS III Devices Device #2 Device #3 Device #1 DD Device #2 (SDDML) DTM Device #3 Option 1 Option 2 Option 3 DD: Device Description SDDML: SERCOS Device Description Language FDT Tool (Framework) DTM Device #1 DTM Device #2 DTM Device #3 commdtm FDT: Field Device Tool DTM: Device Type Manager No. 15

16 Summary SERCOS III is a high-performance, real-time communication standard (IEC 61784/61158) for the automation of machines and machine systems is designed in such a way that it meets the requirements of innovative machining concepts (Motion, Safety and I/O over one wire) supports NRT traffic (e.g., TCP/IP, UDP/IP) in parallel to the real-time communication without affecting the real-time behaviour of the network supports security mechanisms on a device-level uses accepted standards (e.g. TCP/IP, UDP/IP, CIP Safety, SERCOS Drive Profile, FDT/DTM) to support and improve the information cooperation No. 16

Real-Time Ethernet Technology Comparison

Real-Time Ethernet Technology Comparison SERCOS Seminar Atlanta September 16, 2009 Peter Lutz, Managing Director SERCOS International e.v. Real-Time Ethernet Competition No. 2 Overview on Real-Time Ethernet