21.04.23 1

ITW: EtherCAT

21.04.23 2

ITW: EtherCAT

Basics → Michael, Martin

Diagnostics → Josef

Hands on → Martin, Itzko

ITW 2009 - EtherCAT

EtherCAT is faster!

Bandwidth Usage of Ethernet for I/O and Drives:

Ethernet Header Data: ≥46 Bytes CRC I/O

Request with output data

User data:e.g. 2Bit…6Byte

4 Bytes22 Bytes

IPG

12 Bytes

I/OResponse with input data

Ethernet Header Data: ≥46 Bytes CRC IPG

node reaction

time

Ethernet Frame: ≥ 84 Bytes (incl. Preamble + IPG Inter-Packet Gap)

- with 4 Byte input + 4 Byte output per node:

- 4,75% application data ratio at 0µs reaction time/node

- 1,9% application data ratio at 10µs reaction time/node

ITW 2009 - EtherCAT

Difference EtherCAT – Real Time Ethernet

TCP/IP(original Windows Stack)

I/O System

NDIS Protocol Process Images

NDIS MiniportNDIS Miniport TwinCAT I/O TwinCAT I/O

EthernetController

EthernetController

e.g. Profibus Master

TwinCAT I/O with Y-Driver

similar core technology on the Master

Windows TwinCAT

ITW 2009 - EtherCAT

Difference EtherCAT – Real Time Ethernet

Real Time Ethernet EtherCAT

Switch Delay:10..300 µs depends on Switch and data size

Different Technology on the Slave site –> no switch

Topic Today

ITW 2009 - EtherCAT

Slave Device

EtherCAT Slave Controller

Slave Device

EtherCAT Slave Controller

Functional Principle: Ethernet „on the Fly“

Process data is extracted and inserted on the fly

Process data size per slave 1 Bit…60 Kbyte

In addition asynchronous event triggered communication

ITW 2009 - EtherCAT

Functional Principle: Ethernet „on the Fly“

Minimal protocol overhead via implicit addressing

Advantages:

Optimized telegram structure for decentralized I/O

Communication completely in hardware: maximum performance

no switches needed if only EtherCAT devices in the network

Outstanding diagnostic features

Ethernet-Compatibility maintained

DVI

IPC

....

Ethernet HDR EH Data CRCFH WKC

ITW 2009 - EtherCAT

Demo: Working Counter

Demo

WC Konfiguration

Example: EL2008 disconnected WC Alarm

ITW 2009 - EtherCAT

Demo: Working Counter

Demo

WC Konfiguration

WC=0 because of expected WC Value

ITW 2009 - EtherCAT

Demo: Working Counter

Demo

WC Konfiguration

WC=1 because of msising Slave

ITW 2009 - EtherCAT

Functional Principle: Ethernet „on the Fly“

Minimal protocol overhead via implicit addressing

DVI

IPC

....

Ethernet HDR EH Data CRCFH

WK

C

EH Data WK

C

EH Data WK

C

Diagnostic areas on one cable with Sync Units

ITW 2009 - EtherCAT

Demo: Sync Unit

Demo

Sync Unit Konfiguration

Example: disconnected EL3102 influences EL1008

ITW 2009 - EtherCAT

Demo: Sync Unit

Demo

Sync Unit Konfiguration

Group with EL3102 disconnected no valid data from EL1008!

ITW 2009 - EtherCAT

Demo: Sync Unit

Demo

Sync Unit Konfiguration

give own SyncUnit for EL1008 and EL3102

ITW 2009 - EtherCAT

Demo: Framesize & MTU

Demo

ITW 2009 - EtherCAT

EtherCAT Performance

* Source: Ethernet Powerlink Spec V 2.0, App.3

40 Axis (each 20 Byte Input- and Output-Data)

50 I/O Station with a total of 560 EtherCAT Bus Terminals

2000 Digital + 200 Analog I/O, Bus Length 500 m

Performance EtherCAT: Update-Time 276µs at 44% Bus Load, Telegram Length 122µs

56% bandwidth remaining,

e.g. for TP/IP

ITW 2009 - EtherCAT

Topology – Line Topology

DVI

IPC

....

Arbitrary number of devices in a line

Up to 65.535 devices

EK1100EtherCAT Coupler

EK1110EtherCAT Extension

ITW 2009 - EtherCAT

Topology – Bus

DVI

IPC

....

ITW 2009 - EtherCAT

21.04.23 19

EtherCAT Cables: ZB9010/20, ZK1090-9191-00xx

ZB9010/ZB9020 ZB9010 Industrial EtherCAT / Ethernet cable, standard cable, CAT 5e, 4 wires

ZB9020 Industrial EtherCAT / Ethernet cable, trailing cable, CAT 5e, 4 wires

ZK1090-9191-0xxx pre-assembled Ethernet / EtherCAT cables with

RJ 45 plug enables fast, easy wiring inside the control cabinet for short distances on the machine PUR cables in robust industrial quality distinguish themselves from office cables by both their

mechanical and their EMC characteristics 0.5m to 10 m

ITW 2009 - EtherCAT

21.04.23 20

EtherCAT Connector: ZS1090-0003 & ZS1090-0005

ZS1090-0003

EtherCAT / Ethernet connector, RJ45, four-pole, IP20, for field assembly

ZS1090-0005 CAT6 EtherCAT / Ethernet plug suitable for gigabit due to 8-pole implementation robust IP 20 die-cast zinc housing is made of only two parts and can be assembled in the field

without special tools Cables from AWG 22-26 can be connected fits the cables

ITW 2009 - EtherCAT

Topology – Bus with drop lines

DVI

IPC

....

Diagnostic

ITW 2009 - EtherCAT

Topology – Tree structure

DVI

IPC

....

ITW 2009 - EtherCAT

Topology – Star Topology with real time

DVI

IPC

....

EK1122EtherCAT junction

EK1101EtherCAT coupler with ID-Switch

ITW 2009 - EtherCAT

Identification for a group of Hot Connect“ devices:

EEprom -> Secondary Slave Address

Process Image (Hardware ID Switch, EK1101)

EtherCAT Hot Connect

Demo

ITW 2009 - EtherCAT

Demo: Hot Connect

Demo

Define Hot Connect Group

Right Klick on Coupler - Bottom Up, own SyncUnits are defined

ITW 2009 - EtherCAT

Hot Connect Application: FERAG

Flexible and modular bundling of magazines

ITW 2009 - EtherCAT

Topology – Star Topology with LWL

DVI

IPC

....

EK15211-Port EtherCATmultimode LWL junction

LWL

EK1501EtherCAT coupler with ID-Switchmultimode LWL connection

ITW 2009 - EtherCAT

Topology - EtherCAT over multimode LWLITW 2009 - EtherCAT

Cable redundancy

Only a second Ethernet Port is required on the master – possible with all EtherCAT slave devices

DVI

IPC

....

Redundancy with EK1122 ?-> NO

Demo

ITW 2009 - EtherCAT

Demo: Cable Redundancy

Demo

Configure Redundancy Adapter

Licence needed! Select Redundancy Port if possible!

ITW 2009 - EtherCAT

Demo: Cable Redundancy

New diagnosis variables

- Detect location of error

- Detect missing link

Only ONE failure at time!

Demo

ITW 2009 - EtherCAT

Redundant optical ring with EK1501 and EK1521

≤ 2 km

≤ 2 km

≤ 2 km

≤ 2 km

ITW 2009 - EtherCAT

Redundant optical ring with EK1501 and EK1521

Example: Snow Blower Control

Berchtold, Austria:

System with up to 1000 snow makers

ITW 2009 - EtherCAT

Interfaces of / to all important Bus Systems

InterbusEthernet(netzwork variables)

+ any CAN protocols

+ further PB protocols

(MC)

Demolater

ITW 2009 - EtherCAT

Topology – EtherCAT Bridge

DVI

IPC

....

DVI

IPC

....

DVI

IPC

....

Power Supply

EL6692EtherCAT Bridge Terminal

M1

M2

M3

• 480 Byte each direction• DC-Sync• EtherCAT Slave

SnapIn/PlugIn

Demo

ITW 2009 - EtherCAT

Demo: EL6692 Bridge

Demo

Check documentation for features!

- transport time

- DC synchronisation not supported in TwinCAT 2.10

ITW 2009 - EtherCAT

Port Multiplier and Star Topology

DVI

IPC

....

No MAC address will be used

Several (real time) Ethernet protocols are possible on one master port

Star Topology with real time support

CU2508Echtzeit Ethernet Port multiplier

ITW 2009 - EtherCAT

EtherCAT Memory Terminal for flexible Machine Concepts

EL6080

128kByte NOVRAM

Parameter & Recipes

cyclic data like: production counters hours of operation counter

Applications: modular machine counter

Basis for„Dongle-Terminal“ ?

ITW 2009 - EtherCAT

EtherCAT Switchport

Switchport Terminal – EL6601 + EL6614

• Interface to each Ethernet device in the network

• Ethernet Frames will be included in the EtherCAT protocol

• „Ethernet over EtherCAT“

Ethernet PHY

EtherCAT MAC / DLL

Process DataMailbox

Ethernet PHY

µC

Ethernet MAC PHY

Fragementation

ITW 2009 - EtherCAT

Switchport Terminal – EL6601 + EL6614

EtherCAT Switchport

EtherCAT MAC / DLL PHYPHYProcess DataMailbox

µC

Ethernet MAC PHY

Fragmentation

TX1TX2TX3

TX

TX2TX3TX1

RX RX4RX1 RX2 RX3

Interface to each Ethernet device in the network

Ethernet Frames will be included in the EtherCAT protocol

„Ethernet over EtherCAT“

ITW 2009 - EtherCAT

EtherCAT is Industrial Ethernet!

• Any Ethernet Device can be connected to the Switchport

• Access to web server with standard browser

DVI

IPC

....

virtual Ethernet Switch

Functionality Switchport

ITW 2009 - EtherCAT

EtherCAT and Wireless Communication

DVI

IPC

....

Switchport

Networ

k Var

iable

Proto

col

• Wireless Devices can be connected to Switchport • Wireless does not reduce the performance

in the EtherCAT segment • Protocol:

EtherCAT network variables• Wireless segment transparent

for the master

ITW 2009 - EtherCAT

Keep your ESI & Systemmanager Extensions up to date !ITW 2009 - EtherCAT

Version Identification – Software

ESC(ASIC

orFPGA)

µC

E²PROM

Device identification,Description, Process Image

Communicationand Diagnosis Functionality

Terminal specific functionse.g. Analog Input, SSI etc.(only at complex terminals)

FPGA Terminal specific functione.g. Encoder

ITW 2009 - EtherCAT

E²PROMITW 2009 - EtherCAT

FPGAITW 2009 - EtherCAT

µC

Attention!

ITW 2009 - EtherCAT

Increase of the Machine Efficiency through XFC XFC – eXtreme Fast Control Technology

XFC Basics

Fast IO, Time Stamp, Oversampling,Micro Increments

Application Examples: Control Engineering Machine with two transitions Demonstration Examples

EtherCAT & TwinCAT: AgendaXFC – eXtreme Fast Control Technology

Increase of the Machine Efficiency through XFC XFC – eXtreme Fast Control Technology

XFC-ComponentsXFC – eXtreme Fast Control Technology

XFC-Technology

Distributed-Clocks

Time-Stamp

Oversampling

Fast I/Os

XFC – eXtreme Fast Control Technology

Micro Increments

Fast I/O-Terminals 1µs TON/TOFF

Signal

Minimum reaction time

Time

Input: EL1202

Output: EL2202

85 µs 185 µs

XFC – eXtreme Fast Control Technology

Demo

Demo: Distributed Clocks

See special documentation for DC basics

XFC – eXtreme Fast Control Technology

Demo: Distributed Clocks

New Datagrams appear if DC is used – see documentation for settings

XFC – eXtreme Fast Control Technology

Demo: Distributed Clocks

Special dialog if Slave supports DC

See online diagnosis for quality reasons

XFC – eXtreme Fast Control Technology

Time-Stamp Terminal

Exact Reaction Time

Input: EL1252

Output: EL2252

Signal

Time

Exact Time Resolution

Time equidistant reactions

XFC – eXtreme Fast Control Technology

Demo

Oversampling-Terminals

Oversampling – extreme measurements

SPS-cycle SPS-cycle

Measuring cycle

Fast signal scanning

Analog value collection

XFC – eXtreme Fast Control Technology

Oversampling-Terminals

Exact output pulse

Output: EL2262

Signal

Time

XFC – eXtreme Fast Control Technology

Fast signal scanning

Output short impulses

Demo

Micro Increments (MI)

Encoder Signal

PLC / Bus Cycle

XFC – eXtreme Fast Control Technology

1 2 3 4 5 6 7

3 4 5 6 7

3,05 4,6 5,8 6,8 7,6

internal counter

Value without MIValue with MI

Time of rising and falling edge is used to calculate the micro increments (256 bit).

Micro Increments (MI) XFC – eXtreme Fast Control Technology

without Micro Increments:

Cycle Time Position t Position t+1 ∆ Position Speed

1 0 3 3 3

1 3 4 1 1

1 4 5 1 1

1 5 6 1 1

1 6 7 1 1

with Micro increments:

Cycle Time Position t Position t+1 ∆ Position Speed

1 0 3,05 3,05 3,05

1 3,05 4,6 1,55 1,55

1 4,6 5,8 1,2 1,2

1 5,8 6,8 1 1

1 6,8 7,6 0,8 0,8

Micro Increments (MI)

Micro Increments:

Better position resolution at low speeds with standard encoder

More accurate speed calculation

No filter needed (NC)

filter causes delay in the reaction time

Result:

machine runs more smoothly

coupled axes: better synchronization (by less delay)

Will be implemented in: EL5101 and EL5151

XFC – eXtreme Fast Control Technology

Micro Increments (MI)XFC – eXtreme Fast Control Technology

Micro Increments (MI)XFC – eXtreme Fast Control Technology

Microincrements in EL51xx: Enabled by CoE

Demo

I/O Response Timing: Control Cycle Usage

Tresp (average) = 2.5-3 cycle

CPU Time

Tresp (average) = 1.5 cycle

Tresp, PROFIBUS

PLC

.

t

Input

Output

PROFIBUS

K-Bus

EtherCAT-In

PLC

t

Input

Output

EtherCAT-Out

Tresp, EtherCAT

PROFIBUS-Timing

XFC-Timing

Demo

XFC – eXtreme Fast Control Technology

Demo: Separate Input UpdateXFC – eXtreme Fast Control Technology

Default: 1 (or more) Ethernet frames, sent when Task finished

Demo: Separate Input UpdateXFC – eXtreme Fast Control Technology

Additional Input frame(s):

- at “CPU Limit” when BaseTime = TaskTime

- at “PreTicks” when BaseTime < TaskTime