EtherCAT Introduction

Cover Slide – Read and Delete EtherCAT is:

- Faste aster r - Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy

EtherCAT Introduction: This slide set intends to provide an overview over the most important features of the EtherCAT technology. Please do not forward the slides in PPT format – only as PDF! It is allowed to modify the slides according to own preferences and presentation style – e.g. by deleting some slides or adding information regarding own EtherCAT products. It is, however, prohibited explicitly to use slides or elements from the slides (e.g. pictures) for any other purpose than to introduce and promote the EtherCAT technology. The animations have been developed with and for Microsoft PowerPoint 2003. Some elements will not work with earlier versions. For comments regarding the slides please contact [email protected]

- Vers Versat atilile e

Nuremberg, May 2009, EtherCAT Technology Group

The Ethernet Fieldbus.

Why Ethernet for Automation? Automation? EtherCAT is:

- Faste aster r - Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

• Today at controller level: state-of-the-art • Advantages for fieldbuses: – – – –

lower costs because the use of commodity technology Ethernet technology is driven by the office sector access to internet technology (e.g. webserver) reduction of interfaces

• But: Common Ethernet does not achieve fieldbus requirements as… – Low cost, performance, deterministic (real time),…

EtherCAT - The Ethernet Fieldbus. EtherCAT is:


• • • •

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!

EtherCAT is faster EtherCAT is:


• Transmission Rate: – 2 x 100 Mbit/s (Fast Ethernet, Full-Duplex)

• Update Times: – – – – –

256 digital I/O in 11 µs 1000 digital I/O distributed to 100 nodes in 30 µs = 0.03 ms 200 analog I/O (16 bit) in 50 µs, 20 kHz Sampling Rate 100 Servo-Axis (each 8 Byte In + Out) in 100 µs = 0.1 ms 12000 digital I/O in 350 µs


- Faste aster r - Synchr Synchron oniza izatio tion n

• Bandwidth Usage of Ethernet for I/O and Drives: – Ethernet Frame:

84 Bytes incl. Preamble + IPG (interpacket gap) ≥

- Industrial Industrial Ethernet Ethernet - Flex Flexib ible le

Data pay load: e.g. 2 Bit..6 Byte

- Easi Easier er to conf config igur ure e 22 Bytes

- Cost Cost effe effect ctiv ive e

Ethernet Header

- Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty

4 Bytes

Master

Data: ≥46 Bytes

CRC

12 Bytes

IPG

Request with output data

I/O

Response with input data Ethernet Header

Data: ≥46 Bytes

CRC

IPG

- Redun Redundan dancy cy - Vers Versat atilile e

– with 4 Byte input + 4 Byte output per node: • 4,75% application data ratio at 0 µs reaction time/node • 1,9% application data ratio at 10 µs reaction time/node

Node reaction time


- Faste aster r - Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le - Easi Easier er to conf config igur ure e

• Bandwidth Usage Comparison: – At 4 Byte user data per node: • Polling / Timeslicing: ~ 2..5 % – From 2 Bit user data per node: • EtherCAT: ~ 80..97 % (Full Duplex, 2 x 100 MBit/s)

- Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt

100

- Well Well prov proven en

90

- Open

80

- Confor Conforman mance ce

70

- Safe Safety ty - Redun Redundan dancy cy

60 50 40


30 20 10 0

Polling / Timeslicing

EtherCAT

Functional Principle: Ethernet „on the fly“ EtherCAT is:

- Faste aster r - Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le - Easi Easier er to conf config igur ure e

Car 27

- Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

• 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


- Faste aster r

Slave Device

Slave Device

EtherCAT Slave Controller


- Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

• Process data is extracted and inserted on the fly: – Process data size per slave almost unlimited

(1 Bit…60 Kbyte, if needed using several s everal frames) cycl e, e.g. – Compilation of process data can change in each cycle, ultra short cycle time for axis, and longer cycles for I/O update possible – in addition asynchronous, event triggered communication


- Faste aster r

Master

- Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en

Ethernet Header

ECAT HDR

1 R D H

PLC Data

2 R D H

NC Data

2 R D H

Data n

Ethernet

- Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

• 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

Performance: Application Example EtherCAT is:

- Faste aster r - Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e

• 40 Axis (each 20 Byte Input- and Output-Data) • 50 I/O Station with a total total of 560 EtherCAT Bus Terminals • 2000 Digital + 200 Analog I/O, Bus Length 500 m • Performance EtherCAT: Cycle Time = 276 µs at 44 % Bus Load, Telegram Length = 122 µs

- Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty

276 µs

EtherCAT

in spite of this cycle time still 56% bandwidth remaining, e.g. for TCP/IP for TCP/IP

479 µs

SERCOS III


763 µs

Prof inet IRT

2347 µs

Pow erlink erlink

6355 µs

Profinet I/O

0

1000

2000

3000

4000

5000

6000

7000

‘Slow’ Control Systems benefit, too EtherCAT is:

• Reaction time with legacy fieldbus I/O:

- Faste aster r - Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet

I

PLC Task

O

I

PLC Task

O

I

PLC Task

O

I

PLC Task

O

I

PLC Task

- Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e

Tmpd

- Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

- Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

best case reaction time worst case reaction time

- Vers Versat atilile e Input

Input

(worst case)

(best case)

Output Tmpd: Master Processing Delay TI/O: Local I/O Update Time (local Extension Bus + Firmware)


• System Architecture with EtherCAT:


I

PLC Task

O

I

PLC Task

O

I

PLC Task

O

I

PLC Task

O

I

PLC Task

- Flex Flexib ible le - Easi Easier er to conf config igur ure e

no dedicated Master Device any more


Tmpd

- Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

- Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

on underlying extension bus any more

TI/O

TI/O

TI/O

TI/O


• System Architecture with EtherCAT:


I

PLC Task

O

I

PLC Task

O

I

PLC Task

O

I

PLC Task

O

I

PLC Task

- Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open

TDMA (NIC)


TEtherCAT Cycle

TDMA = Tim Time fo for Data r Data Transfer from/to Ethernet Controller via Direct Memory Access: Memory Access: neglectible


• Reaction Time with EtherCAT:


I

PLC Task

O

I

PLC Task

O

I

PLC Task

O

I

PLC Task

O

I

PLC Task

- Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce

best case

worst case

EtherCAT Bus Cycle

Input

Input

(worst case)

(best case)

Output

- Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

– 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

Fieldbus: requires Mapping in Control System EtherCAT is:


• Traditional fieldbus system generate physical process image • This has to be mapped to logical process image(s)

- Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt

Control System, e.g. IPC

- Well Well prov proven en DPRAM


Fieldbus Scanner/Master

Node 1

Node 1 Data n s e g PLC Data a m i s s e c NC Data o r p l a c i g o l

Node 2

Node 3

Node 2

Node 3

Node 4

Node 4 Mapping

Fieldbus: requires Mapping in Control System EtherCAT is:


• The same applies to control system with just one process image • Resorting of process data (“Mapping”) is required, too

- Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt

Control System, e.g. IPC

- Well Well prov proven en DPRAM

- Open

Fieldbus Scanner/Master


Node 1


e g a Process m i Data s s e c o r p l a c i g o L

Node 2

Node 3

Node 1

Node 2

Node 3

Node 4

Node 4 Mapping

EtherCAT: Mapping moved into Slave Devices Master

EtherCAT is:

- Faste aster r - Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy

e t y B G 4 o t p u s e g a Data n m i s s PLC Data e c o r p l a NC Data c i g o l

Ethernet Header

ECAT HDR

1 R D H

PLC Data

Datagram 1

2 R D H

NC Data

Datagram 2

2 R D H

Data n

Ethernet

Datagram n


• Control System is unburdened, master becomes very simple • Data is transmitted according to the application requirements: extremely fast, flexibly and efficiently

Direct Memory Access saves time EtherCAT is:

- Faste aster r - Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le

• Fieldbus cards: up to 30% of CPU time for data copying

PC Control with Fieldbus cards PC RAM Scanner card, DP RAM

Control task PCI

- Easi Easier er to conf config igur ure e

CPU

memcopy

bus


• EtherCAT: MAC is PCI Bus master, data is provided by DMA directly to PC RAM: CPU relieved more performance

PC Control with EtherCAT PC RAM CPU

PCI

MAC

DMA bus

Control task

EtherCAT Propagation Delay Measurement (1) EtherCAT is:

- Faste aster r



• EtherCAT Node measures time difference between leaving and returning frame

- Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en

EtherCAT Frame Processing Direction

- Open

EtherCAT Frame


Forwarding Direction


EtherCAT Propagation Delay Measurement (2) EtherCAT is:

- Faste aster r



• EtherCAT Node measures time difference between leaving and returning frame

- Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

IPC Master

Distributed Clocks EtherCAT is:

- Faste aster r



• Precise Synchronization (<< 1 µs!) by exact adjustment of Distributed Clocks

- Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le

M

- Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e

IPC Master

S

∆t

- Easi Easier er to imp imple leme ment nt - Well Well prov proven en

S


S

S

S

S

S

External Clock Synchronization: IEEE 1588 • Switchport with integrated IEEE 1588 Boundary Clock

EtherCAT is:

- Faste aster r



IEEE 1588 Grandmaster

- Synchr Synchron oniza izatio tion n - Industrial Industrial Ethernet Ethernet - Flex Flexib ible le

M


Boundary Clock

S

Master

- Easi Easier er to imp imple leme ment nt - Well Well prov proven en

S


S

S

S

S

S

Distributed Clocks EtherCAT is:

- Faste aster r - Synchr Synchron oniza izatio tion n



• Long Term Scope View of two separated devices • 300 Nodes in between, 120m Cable Length

- Industrial Industrial Ethernet Ethernet - Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

Simultaneity: ~15 ns Jitter: ~ +/-20ns

EtherCAT is Industrial Ethernet! EtherCAT is:

- Faste aster r



- Synchr Synchron oniza izatio tion n



- Industrial Industrial Ethernet Ethernet

• EtherCAT uses Standard Ethernet Frames: IEEE 802.3 • Alternatively via UDP/IP (if IP Routing is needed) • no shortened frames

- Flex Flexib ible le Standard Ethernet Frame

- Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty

48 Bit

48 Bit

16 Bit

DA

SA

EtherType

Ethernet Header

0..32 Byte 32 Bit

48 -1498 Byte

Header DatagramEthernet 1 DatagDaten ram 2

Embedded in Standard Ethernet Frame, EtherType 0x88A4


16 Bit

…

Datagram n

Pad.

CRC

Pad.

CRC

EtherCAT Telegram

160 Bit

64 Bit

16 Bit

IP Header

UDP H.

Header

Or: via UDP/IP UDP Port 0x88A4 11 Bit

1 Bit

4 Bit

Length

Res.

Type

48 -1470 Byte EtherCAT Data


- Faste aster r






- Industrial Industrial Ethernet Ethernet - Flex Flexib ible le - Easi Easier er to conf config igur ure e

• fully transparent for TCP/IP • all Internet technologies (HTTP, FTP, Webserver,…) available without restricting the real time capabilites! • full tool access to devices at real time operation – with and without TCP/IP


EtherCAT Slave Device

- Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy

Standard TCP/IP Stack

Ethernet Application Application TCP

Real Time Application Application

UDP Acyclic Data

IP

- Vers Versat atilile e Mailbox

Process Data

EtherCAT MAC / DLL Ethernet PHY

Ethernet PHY


- Faste aster r






• Any Ethernet Device can be connected connected to Switchport • Access to Webserver with Webserver with Standard Browser

- Industrial Industrial Ethernet Ethernet - Flex Flexib ible le

Virtual Ethernet Switch Functionality

- Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

Master

Webserver Switchport


- Faste aster r






• Virtual Ethernet Switch routes any Ethernet Frame • From inside as well as from outside the segment

- Industrial Industrial Ethernet Ethernet - Flex Flexib ible le Virtual Ethernet Switch Functionality

- Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt

Switchport

Master

- Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

Ethernet Switch

Switchport: Any Ethernet Protocol EtherCAT is:

- Faste aster r







• Interface to any Ethernet Device or Network • Ethernet Frames are inserted into EtherCAT Protocol: – ‘Ethernet over EtherCAT’


EtherCAT Switchport


Ethernet MAC

PHY

- Well Well prov proven en - Open RX1

- Confor Conforman mance ce - Safe Safety ty

RX RX3 RX2TX µC

RX4

Fragmentation

- Redun Redundan dancy cy Mailbox

- Vers Versat atilile e PHY TX2 TX3 TX1

Process Data

EtherCAT MAC / DLL TX2 TX3 TX1

PHY

Vertical Integration (1) • …via Switchport

EtherCAT is:

- Faste aster r







Master

- Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en

Switchport


• + any Ethernet Protocol can be used • + requires only one Ethernet Port (at IPC/Controller) • + EtherCAT performance is not limited

Vertical Integration (2) • ...via 2. Ethernet Port

EtherCAT is:

- Faste aster r







Master


2nd Ethernet Port


• + any Ethernet Protocol can be used • + EtherCAT performance is not limited • but: requires second Ethernet Port (at IPC/Controller)

Vertical Integration (3) • …via Switch

EtherCAT is:

- Faste aster r







Master


Ethernet Switch


• + any Ethernet Protocol can be used • + requires only one Ethernet Port (at IPC/Controller) • but: performance reduced by switch delay (and generic Ethernet traffic)

EtherCAT wiring is more flexible • Standard Ethernet Topology: Star

EtherCAT is:

- Faste aster r

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




- Flex Flexib ible le - Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

EtherCAT wiring is more flexible • Flexible tree structures – arbitrarily extendable

EtherCAT is:

- Faste aster r










– Topology variants like Line, Star, Tree, Daisy Chain

+ Drop Lines possible; can be used in any combination! – Up to 65.535 nodes for each EtherCAT segment – Standard Ethernet cabling Line

- Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce

Master


Star/Tree

Drop Line

EtherCAT wiring is more flexible • Ethernet Signal Variants of EtherCAT:

EtherCAT is:

- Faste aster r









- Flex Flexib ible le

– 100BASE-TX (up to 100 m between 2 nodes) – 100BASE-FX (longer distances between 2 nodes) – LVDS (for modular devices)


LVDS* 100 m

- Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce

Master


Ethernet on 100BASE-TX up to 100 m with transformer coupling

Ethernet on LVDS* physical layer: for modular devices

• Any number of number of physical layer changes layer changes allowed *LVDS: Low Voltage Differential Signaling according to ANSI/TIA/EIA-644, ANSI/TIA/EIA-644, also used in IEEE 802.3ae 802.3ae (10Gigabit (10Gigabit Ethernet)

Ethernet on 100BASE-FX (fibre optics) for longer distances

EtherCAT Extra Large System Test EtherCAT is:

- Faste aster r

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





10.056 EtherCAT Nodes

EtherCAT instead of PCI EtherCAT is:

- Faste aster r

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




• • •

Protection of your investment your investment smooth migration path from legacy fieldbus to EtherCAT seamless integration of existing fieldbus devices, e.g.: – – – – – – – – – – – – – – – –


•

AS-Interface CAN, CANopen CC-Link ControlNet DeviceNet Ethernet/IP FIPIO Interbus IO-Link Lightbus LONWorks Modbus Plus, RTU, TCP MPI PROFIBUS PROFINET IO …

maximum maximum system expandab expandability ility with low cost cost fieldbus fieldbus gateways gateways

EtherCAT instead of PCI • Update Times (examples):

EtherCAT is:

- Faste aster r










– Process image update-time

via PCI (500 Bytes input and output data each): 400 µs – Process image update-time via EtherCAT (1.500 Bytes input and output data): 150 µs

EtherCAT instead of PCI EtherCAT is:

- Faste aster r









• No Slots in Control System (IPC or PLC) required any more • Nevertheless maximum expandability


EtherCAT

EtherCAT is easier to configure • Addressing

EtherCAT is:

- Faste aster r

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







- Easi Easier er to conf config igur ure e - Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

– No manual address setting required automatically – Addresses can be assigned automatically – Addresses can be kept • no new addressing if nodes are added

EtherCAT is easier to configure • Topology:

EtherCAT is:

- Faste aster r

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








target/actual comparison – Automatic topology target/actual

• Diagnosis: – Diagnosis with exact localization


• Network planning: – Performance independent of: • Slave implementation • Topology (no Switches/Hubs) Switches/Hubs)

EtherCAT is lower costs (1): Engineering • Implementation / Tools:

EtherCAT is:

- Faste aster r

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










- Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open

– Standard Network Monitor Tools, e.g. MS Network Monitor

or Wireshark: free of charge – Parser Software: free of charge

• 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

EtherCAT is lower costs (2): Hardware • Master:

EtherCAT is:

- Faste aster r

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










- Cost Cost effe effect ctiv ive e - Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce

– 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 needed


• Infrastructure: – no Switches/Hubs required C onnectors – Standard Ethernet Cabling + Connectors

32 Bit µC

EtherCAT is easier to implement: Slave • Slave Implementation:

EtherCAT is:

- Faste aster r

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


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- Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

– 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

EtherCAT Slave Controller Features: ASIC (1) EtherCAT is:

- Faste aster r


















- Easi Easier er to imp imple leme ment nt

Name

ET1100

ET1200

netX5

Type

ASIC

ASIC

ASIC

Package

BGA128 0,8mm Pitch

QFN48 0,5mm Pitch

BGA201 0,8mm Pitch

Size

10 x 10 mm

7 x 7 mm

13 x 13 mm

serial/parallel (8/16-bit, async)*

serial*

serial (SPI), parallel (8/16/32-bit, async)

32

8-16*

16

8 kByte

1 kByte

6 kByte

SyncManager

8

4

8

FMMUs

8

3

8

Yes

Yes

Yes

2-4 (MII/E-bus)*

2-3 (E-bus/max. 1xMII)*

2 (MII)

Routable with standard PCB

-

Multi Protocol Support

Hardware Supplier

µC Interface


Digital I/O DPRAM

Distributed Clocks No. Of Ports Specials

* configurable

EtherCAT Slave Controller Features: ASIC (2) EtherCAT is:

Name

netX 100

netX 500

netX50

Type

ASIC

ASIC

ASIC

Package

BGA345 1mm Pitch

BGA345 1mm Pitch

PBGA 1mm Pitch


Size

22x22 mm

22x22 mm

19x19 mm


µC Interface

µC-Bus (internal, 32-bit)



16 (GPIO)

16 (GPIO)

32 (GPIO)

256/400 Byte (Mailbox/Process Data)

256/400 Byte (Mailbox/Process Data)

6 kByte

SyncManager

4

4

8

FMMUs

3

3

8

Yes

Yes

Yes

2 (100BASE-TX)

2 (100BASE-TX)

2 (100BASE-TX)

Multi Protocol Support, Integrated: PHYs, ARM-9 µC



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Hardware Supplier

Digital I/O


DPRAM


Distributed Clocks No. Of Ports Specials

EtherCAT Slave Controller Features: FPGA EtherCAT is:

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Name

ET1810/ET1811/ET1812

ET1815/ET1816/ET1817

Type

FPGA + IP Core

FPGA + IP Core

Cyclone I+II+III, Stratix I+II+III+IV+GX+II GX, Arria GX

Spartan 3+3E+3A+3AN+3ADSP, Virtex II+II Pro+II Pro X+4+5

Hardware Supplier

Supported Chips


Package

FPGA dependent

FPGA dependent


Size

FPGA dependent

FPGA dependent

µC Interface

serial/parallel (8/16-bit, async) AVALON®*

serial/parallel (8/16bit, async) OPB®*

8-32*

8-32*

1...60 kByte*

1...60 kByte*

SyncManager

0…8*

0…8*

FMMUs

0…8*

0…8*

Distributed Clocks

Yes*

Yes*

2 (MII)

2 (MII)

Several IP Core License models available

Several IP Core License models available


Digital I/O DPRAM

No. Of Ports Specials

EtherCAT is easier to implement: Master • Master Implementation:

EtherCAT is:

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- Easi Easier er to imp imple leme ment nt - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

– e.g. with Master Sample Code (Source) – EtherCAT Configuration Tool – XML Data format of ESI and ENI

EtherCAT is easier to implement: Master • Example: Master with just one process image

EtherCAT is:

– typical e.g. for small controllers with one control task – up to 1488 Byte Process data size c onstant – Header for Process Data communication remains constant

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Ethernet Header


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DA

SA

Type

- Easi Easier er to imp imple leme ment nt 

6 Bit

6 Bit

2 Bit

ECAT Frame EtherCAT HDR HDR 10 Bit 2 Bit

EtherCAT Telegram Data 0….1486 Byte

Ethernet C K Pad. W

2

FCS

0…32 4 Byte


constant header

completely sorted (mapped) process data

Working Counter: constant

Padding Bytes and CRC generated by Ethernet Controller (MAC)

– Master can be implemented with minimal effort – No separate communication processor required (e.g. on

plug-in card) – Much simpler that legacy fieldbus systems – Very much simpler than competing Industrial Ethernet approaches…

EtherCAT is well proven EtherCAT is:

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- Easi Easier er to imp imple leme ment nt  - Well Well prov proven en - Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e

• In series production since 2003 • Numerous applications • Great product variety of available EtherCAT products

EtherCAT Architecture + Device Profiles EtherCAT is:

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EtherCAT Device File System, Bootloader

- Open

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TCP


UDP IP

Ethernet FoE

The CANopen Standard

IDN

Object Dictionary

Service Channel

SDO

IEC 61800-7-204 IEC 61800-7-304

EN 50325-4 IEC 61800-7-201 IEC 61800-7-301

File Access


DEVICE Application

The SERCOS* Standard

- Easi Easier er to imp imple leme ment nt  - Well Well prov proven en

HTTP, FTP,…

EoE

SoE

CoE

Mailbox

Process Data

PDO Mapping

AT MDT

CoE/SoE Process Data


Ethernet Physical Layer

*SERC *SE RCOS OS inte interfa rface™ ce™ is a trad tradema emark rk by SI e.V

Typical EtherCAT Device Architecture Device Architecture EtherCAT is:

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EtherCAT Device HTTP, FTP,…

optional Device Profile Profile Device Definitions Definitions

TCP

UDP IP


DEVICE Application

Ethernet

Parameters Asynchronous Asynchronous Communication (Explicit Addressing) Addressing)

EoE

CoE/SoE Mailbox EtherCAT Slave Controller


Cyclic Synchronous Communication (Implicit Addressing) Addressing)

CoE/SoE Process Data

IEC 61491 EtherCAT Servodrive Architecture Servodrive Architecture EtherCAT is:

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EtherCAT Device HTTP, FTP,…

Servodrive Applicatio Servodrive Application n

SERCOS*

Drive Profile TCP

UDP IP

IDN Service Channel


IEC 61800-7204 is the

optional

Ethernet

Process Data: AT / MDT

Servodrive Profile IEC 61800-7-204 Mapping to EtherCAT: IEC 61800-7-304 61800-7-304

EoE

SoE Mailbox

SoE Process Data



*SERCOS interface™ is a trademark by SI e.V.

EtherCAT in IEC 61800-7 EtherCAT is:

IEC 61800-7: Generic Interface and use of profiles for power for power drive systems

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IEC 61800-7-1: Interface Definition Annex A: Mapping to DS402

- Open - Confor Conforman mance ce

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Annex C: Mapping to PROFIdrive

Annex D: Mapping to SERCOS*

IEC 61800-7-200: Profile Specifications Specifications


Annex B: Mapping to CIP

IEC 61800-7-201: Profile CiA 402

IEC 61800-7-202: Profile CIP Motion

IEC 61800-7-203: Profile PROFIdrive

IEC 61800-7-204: Profile SERCOS*

- Safe Safety ty - Redun Redundan dancy cy

IEC 61800-7-300: Mapping of Profiles to Network Technologies

- Vers Versat atilile e IEC 61800-7-301 Mapping to Mapping to Mapping to CANopen EPL EtherCAT

B ...

C ...

IEC 61800-7-304 Mapping to Mapping to Mapp Mappin ing g to SERCOS I/II SERCOS III EtherCAT

*SERC *SE RCOS OS inte interfa rface™ ce™ is a trad tradema emark rk by SI e.V. e.V.

EtherCAT is an open technology EtherCAT is:

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• Foundation: November 2003 • Tasks: Support, Advancement and Promotion of EtherCAT • The worlds largest organization dedicated to Industrial Ethernet • more than 940* member companies from 45 countries in 6 continents: – Device Manufacturers – End Users – Technology Providers

• Membership is open to everybody

EtherCAT is an open technology • Protocol is disclosed completely:

EtherCAT is:

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– 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

EtherCAT is an open technology EtherCAT is:

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• Master Stacks for various for various RTOS available*, including Open / Shared Source! – – – – – – – – – – – – – – – – – – – –

eCos Intime Linux with RT-Preempt MICROWARE OS-9 On Time RTOS-32 PikeOS Proconos OS Real-Time Java RMOS RT Kernel RT-Linux RTXC Quadros RTAI Linux QNX VxWin + CeWin VxWorks Windows CE Windows XP/XPE with CoDeSys SP RTE Windows XP/XPE with TwinCAT RT-Extension XENOMAI Linux

EtherCAT Technology Group and IEC EtherCAT is:

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• Management Board of IEC has approved Liaison of EtherCAT Technology Group with IEC SC65C WG 11/12/13 + JWG10 (SC65C: Digital Communication)

• Thus ETG is official IEC Standardization Partner

ETG Team Worldwide EtherCAT is:

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- Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy

ETG Office Japan

- Vers Versat atilile e ETG Office North America Austin, TX

ETG Headquarters Tokyo Germany ETG Office ETG Office Nuremberg China Korea Beijing Seoul

ETG Membership Development • As of April 2009: 1000 Members

EtherCAT is:

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1000 940

900

881 820

800

766 696


1000

700

634 600

575 515



- Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e 33 3 0 v o N

500

458 404 357 321 285 240 214 188 169 136 117 59 89

400 300 200 100

4 0 y a M

4 0 v o N

5 0 y a M

5 0 v o N

6 0 y a M

6 0 v o N

7 0 y a M

7 0 v o N

8 0 y a M

8 0 v o N

9 0 y a M

0

Members from 45* Countries, 6 Continents EtherCAT is:

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Australia

Austria

Belarus

Belgium

Denmark

Bosnia and Herzegovina

Finland

Brazil

Canada

China

Croatia

Czech Rep

Hungary

India

Israel

Italy

Japan

Korea

Liechtenstein

Lithuania

Mexico

Netherlands

New Zealand

Norway

Poland

Portugal

Romania

Russia

France

Germany

Greece




- Open - Confor Conforman mance ce - Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e Serbia

Singapore

Slovakia

Slovenia

South Africa

Spain

Sweden

Switzerland

Taiwan

Thailand

Turkey

Ukraine

United Kingdom

USA

ETG: Active Members EtherCAT is:

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• Much more important than membership figures: How many are active, how many implement the technology? • Dec 2008: More than 690 Implementation Kits sold to ETG Members (25% Master, 75% Slaves), plus there are Open + Shared Source masters! • SPS/IPC/Drives 2008: 60 Vendors with over 180 different EtherCAT Devices at ETG booth: – 25 different drives from

16 manufacturers jointly operating in one network – 15 different functional Masters in one setup, using 10 different operating systems – Safety devices (master + slave devices) from 2 manufacturers operating in one system – Master to Master and redundancy live demo

EtherCAT: Large Product Selection EtherCAT is:

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I/O, Controller, HMI, Servo Drives, Variable Speed Drives Sensors, Slave + Master Development Kits Control Panels, Hydraulic Valves and Pneumatic Valves, …

Conformance and Interoperability EtherCAT is:

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

Safety over EtherCAT: Features (1) EtherCAT is:

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• 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 protocol is developed according according to IEC 61508 61508 – 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)


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• FSoE Frame is mapped in the cyclic PDOs – Minimum FSoE Frame-Length: 6 Byte – Maximum FSoE Frame-Length: depending on the number of

safe process data of the Slave Device – Therefore the protocol is suitable for safe I/O as well as for functional safe motion control

• Confirmed transfer from the FSoE Master to the FSoE Slave and vice versa. • Safe Device Parameter can be downloaded from the Master to the Slave at Boot-Up of a FSoE Connection • Certified products with Safety over EtherCAT are available since 2005.


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• 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

Safety over EtherCAT: over EtherCAT: Routing EtherCAT is:

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• Can be routed via non-safe gateways • Can be routed via fieldbus systems • One Safety technology for (almost) all bus systems

Safety over EtherCAT: Software Architecture • Black channel approach

EtherCAT is:

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– with safety and non-safety data on the same bus

Device 1

Device 2

Safety Application

Safety Application




- Open

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Standard Application

Standard Application

Safety over EtherCAT Protocol

Safety over EtherCAT Protocol

EtherCAT Communication Interface

EtherCAT Communication Interface

EtherCAT Telegram

Safety data container (FSoE Frame)

Safety over EtherCAT EtherCAT DLL and AL

Safety over EtherCAT: Hardware Architecture • One channel communication system

EtherCAT is:

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– Model A according to IEC 61784-3 Annex A

Device 1 Controller A Safety Protocol

Controller A Safety Protocol

Device 2

Controller B Safety Protocol






PHY

PHY

Magne Ma gnetic ticss Ma Magne gnetic ticss

RJ45

RJ45

PHY

PHY

Magne Mag netic ticss Ma Magne gnetic ticss

RJ45

RJ45



Safety over EtherCAT: Frame Structure • Ethernet telegram

EtherCAT is:

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Ethernet Header

EtherCAT Header

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- Open

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2. Datagram FS FSC

Safety over EtherCAT over EtherCAT frame


1. Datagram

CMD

SafeData

CRC_0

SafeData

CRC_1

Conn ID

over EtherCAT frame – Safety over EtherCAT • The FSoE Frame is a data container mapped in the process data of the devices • A new FSoE Frame is recognized if at least one bit has changed according to the last frame • For every 2 Byte SafeData a 2 Byte CRC is calculated • Up to n Byte SafeData can be transmitted

Safety over EtherCAT: Safety Measures EtherCAT is:

Measure

Sequence Number

Watchdog

Connection ID

CRC Calculation

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Error


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Unintended repetition




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Loss

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

Insertion



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Incorrect sequence



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- Open

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 



Corruption



Unacceptable delay



Masquerade



Repeating memory errors in Switches Incorrect forwarding between segments









Safety over EtherCAT: over EtherCAT: Implementation Example EtherCAT is:

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• Decentralized Safety-Logic • Standard PLC routes the safety messages Standard PLC

Safety Inputs


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Safety Outputs

- Safe Safety ty - Redun Redundan dancy cy - Vers Versat atilile e S S S

Safety Drives

Safety Logic

S

Safety over EtherCAT: over EtherCAT: Advantages • Fully integrated solution:

EtherCAT is:

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– 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

EtherCAT: High availability • Cabling redundancy

EtherCAT is:

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– 2nd Ethernet port needed on master side only

• Hot Swap of devices • Hot Connect of network segments • Master Redundancy with Hot Swap Master

Hot Connect Group

Without Redundancy: Normal Operation EtherCAT is:

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RX Unit

TX Unit




RX

TX


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EtherCAT Master

MAC 1




- Open

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- Safe Safety ty

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RX

TX

☺

☺

☺

Slave 1

Slave 2

Slave N

RX

TX

RX

TX

... TX

RX

RX

TX

TX

RX

... TX

RX

Without Redundancy: Cable Failure EtherCAT is:

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RX Unit

TX Unit


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RX

TX


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EtherCAT Master

MAC 1




- Open

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

- Safe Safety ty




RX

TX

☺

☺





Slave 1

Slave 2

Slave N-1

Slave N

RX

TX

RX

TX

RX

TX

... TX

RX

RX

TX

TX

RX

... TX

RX

TX

RX

Without Redundancy: Node Failure EtherCAT is:

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RX Unit

TX Unit




RX

TX





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EtherCAT Master

MAC 1




- Open

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

- Safe Safety ty




RX

☺

☺

Slave 1

Slave 2

RX

TX

RX

TX

TX





Slave N-2

Slave N-1

Slave N

RX

RX

TX

TX

... TX

RX

RX

TX

TX

RX

... TX

RX

TX

RX

TX

RX

With Redundancy: Normal Operation EtherCAT is:

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RX Unit

TX Unit


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RX

TX


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MAC 1

MAC 2

EtherCAT Master




- Open

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

- Safe Safety ty

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RX

TX

RX

Only 2nd Ethernet Port required – required – no special Interface Card

TX

☺

☺

☺

Slave 1

Slave 2

Slave N

RX

TX

RX

TX

... TX

RX

RX

TX

TX

RX

... TX

RX

With Redundancy: Cable Failure EtherCAT is:

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RX Unit

TX Unit


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RX

TX


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MAC 1

MAC 2

EtherCAT Master




- Open






- Safe Safety ty




RX

TX

RX

TX

☺

☺

☺

☺

Slave 1

Slave 2

Slave N-1

Slave N

RX

TX

RX

TX

RX

TX

... TX

RX

RX

TX

TX

RX

... TX

RX

TX

RX

With Redundancy: Node Failure EtherCAT is:

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RX Unit

TX Unit




RX

TX


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MAC 1

MAC 2

EtherCAT Master




- Open






- Safe Safety ty




RX

☺

☺

Slave 1

Slave 2

RX

TX

RX

TX

TX

RX

TX

☺

☺

Slave N-2

Slave N-1

Slave N

RX

RX

TX

TX

... TX

RX

RX

TX

TX

RX

... TX

RX

TX

RX

TX

RX

EtherCAT: various system architecture EtherCAT is:

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• • •

Master to Slave Slave to Slave Master to Master M2S

Switchport




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- Safe Safety ty

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- Redun Redundan dancy cy

Master M2M Switch Gateways




M2S Master

S2S

EtherCAT and Wireless Communication EtherCAT is:

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• • •

Wireless Devices can be connected via Switchport Wireless segment does not slow down EtherCAT communication Protocol: EtherCAT Automation EtherCAT Automation Protocol – Pushed and/or Polled and/or Polled Process Data Exchange

•

Wireless Segment transparent for Master for Master Device Master

Switchport l c o o o t o P r o n o o i t m a o o t u T A A C r C t e E h


e.g. RFID Reader

Why do Companies choose EtherCAT? • High Performance

EtherCAT is:

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– EtherCAT is the fastest Industrial Ethernet technology

• Flexible Topology – Benefit not only for widely distributed applications

• Ease of Use – Easy configuration and maintenance

• Low Cost – Inexpensive implementation & infrastructure

• Functional Safety – Safety communication integrated

• Product Variety – Great variety of available EtherCAT products

EtherCAT Application Fields • Fast applications, e.g.:

EtherCAT is:

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– – – – – – – –

packaging machines high speed presses injection molding machines woodworking machines machine tooling (CNC) test beds robotics …

• Widely distributed applications, e.g.: – – – –

materials handling logistics data acquisition …

EtherCAT Application Fields • Due to low cost master and simple wiring as well:

EtherCAT is:

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– Small Embedded Controller – Small PLCs – Any PC based Control Application • with or without real time requirements

• EtherCAT allows one to apply fieldbus technology where cost issues require direct wiring today

EtherCAT - The Ethernet Fieldbus. Please visit

EtherCAT is:

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www.ethercat.org for more for more information


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- Safe Safety ty

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EtherCAT Technology Group ETG Headquarters

Ostendstr. 196 90482 Nuremberg, Germany Phone: +49 911 54056 20 [email protected]

EtherCAT Introduction

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