Post on 16-Mar-2020
Xilinx Smarter Connected Control Solutions
XILINX CONFIDENTIAL.
Industry Mega Trends
Page 2
Cyber-Physical
Systems
Communicating
Devices
Cloud, Connected
Everything
Machine 2 Machine Industry 4.0 Internet of Things
XILINX CONFIDENTIAL.
Market Enterprises Strategy Talents
The 4
Advantages
New Info
Technology
Numerical
Control Tools
Aerospace
Equipment
High-Tech
Ships
Railway
Equipment
Energy
Saving
New
Materials
Medical
Devices
Agricultural
Machinery
Power
Equipment
The 10 Key
Sectors
Source – People’s Daily Online, 05/22/2015
Made in China 2025
XILINX CONFIDENTIAL.
Smart Factory B
Merging of Virtual
and Physical Worlds
– Cyber-Physical Systems CPS
Give Birth to the “Smart Factory”
concept
– Real-time quality, time, resource
cost advantages
• Flexible
• Self-adaptable
• Learning
• Fault tolerance
Services provide added Values
Page 4
Industry 4.0 Smart Factory PipelineCloud-based Secure Networks
Smart Factory A
Smart
Machine
Smart
Machine
M2M –
Communication
Cyber-Physical Production Systems
Smart
Materials
Smart
Products
Secure
Cloud Networks
Source: DFKI 2012
Services
XILINX CONFIDENTIAL.
Page 5
Attributes of Smarter Factories
Dynamically Adaptable Machines
Smarter Sensors Smarter Controls Smarter Connectivity
XILINX CONFIDENTIAL.
An Example of Smart Factory
XILINX CONFIDENTIAL.
Scores of Industrial Networks...
Page 7
Enterprise LAN
GigE
Fieldbus
devices
Historic Data
OPC Server
Workstation
PLCPACMotion Controller
Fieldbus
Master
HMI
Servo
Drives
I/Os
Light
Curtain
Sensor
Drive
Machine Vision
Camera Many optimized
networks
None is compatible
to the other!
but
XILINX CONFIDENTIAL.
consequently
... and you must support them all!
I/O Drive Sensor
Controller
Different Factories
use equivalent equipment in different networks
must support Many ProtocolsYour Product
XILINX CONFIDENTIAL.
S
Program-
mable
Logic
Controller
(PLC)
Industrial EthernetIndustrial Network is the Backbone
Sensors
Actuators
S
SS
No automation without real-time Network
Modern Industrial Networks are on Ethernet
S
M
S
= Master
= Slave (e.g. IO module)
Photoelectric
Sensor Pressure
Sensor
Motor
M I n d u s t r i a l N e t w o r k o n E t h e r n e t
XILINX CONFIDENTIAL.
Industrial EthernetMarket Share by installed nodes
other, 3%Ethernet,
8%Discrete Machine
Safety, 7%
Industrial Ethernet,
9%
Fieldbuses, 74%
Industrial Ethernet
and Fieldbuses,
780 millions of nodes
connected in 2014
(installed base)
Profinet25%
EtherNet/IP24%
Modbus-TCP13%
Powerlink7%
EtherCAT6%
Sercos III1%
other24%
54 millions of Industrial Ethernet
nodes connected in 2014 (installed base)
Based on forecast data for 2014 from http://www.imsresearch.vom
"The World Market for Industrial Ethernet & Fieldbus Technologies(...) - 2013 edition", Chapter 2
XILINX CONFIDENTIAL.
Industrial EthernetChoices are growing
Sponsor Siemens Rockwell Schneider El. Beckhoff B&R Bosch
Consortia
Profibus User
Organization
(PNO)
Open DeviceNet
Vendors
Association
(ODVA)
Modbus
Organization
EtherCAT
Technology
Group (ETG)
Ethernet
Powerlink
Standardization
Group (EPSG)
Sercos
International
e.V.
Installed base
(nodes) 2014*24,600k 23,900k 13,200k 6,000k 6,400k 1,200k
New nodes
connected
2014*
(CAGR 2011-
16)*
6,700k
(CAGR 17%)
6,200k
(CAGR 15%)
3,300k
(CAGR 16%)
1,700k
(CAGR 18%)
1,500k
(CAGR 12%)
260k
(CAGR 13%)
Max. nodes in a
network**
Almost
Unlimited
Almost
Unlimited
Almost
Unlimited65,536 240 511
Sub millisecond
cyclesYes No No Yes Yes Yes
Focus Industrial I/O Industrial I/O UniversalAutomation,
PLC to Device
Machine
Building
Automation,
Drives
* Source: Based on 2012 data from http://www.imsresearch.com/, "The World Market for Industrial Ethernet & Fieldbus Technologies (...) - 2013 edition, chapter 2".
** Source: Wikipedia, Definition of Industrial Ethernet
XILINX CONFIDENTIAL.
Protocol Differentiators
• Different classes with different complexity (Conformance Class A, B and C)
• Seamless integration with Profibus available
• Optimized for cyclic traffic (cycles down to 12.5 µs)
• With optimized MAC layer in hardware
• 100% standard 802.3 MAC Layer and Data Link Layer.
• Half-duplex - all information is boradcasted.
• Open protocol (BSD license)
• Short cycle times, ideal for drive applications
• Slave-to-slave communication
• Can runs on standard UDP/IP
• Optional DLR for lower latency and enhanced synchronoization
• Software based, uses TCP/IP port 502
• Open protocol
• No hard real-time
Industrial EthernetDifferentiators of the most important protocols
XILINX CONFIDENTIAL.
Industrial Ethernet Generic Architecture and Building Blocks (1/2)
Communi-
cation
Processor
HALSwitch + MAC +
Synchronization
Direct I/O
Process Data Interface (PDI)
Host
Processor
Protocol Stack Application
PHY
PHY
IE Network
Hardware
Software
General Purpose
(internal or
external)
AMS
Function in PL
Xilinx
AXI
xMII
GPIO
Legend:
Analog in
XILINX CONFIDENTIAL.
Communication ProcessorRuns protocol stack.
Forwards information between network and Process Data Interface.
Can be a hard core, soft core or dedicated logic.
Switch+MAC+Sync
Provides two network ports
Functionality for filtering and fast forwarding with interrupt and sync signal
Time-stamping
HALHW Abstraction Layer as a shim between and (typically with AXI slave).
Gateway between two clock domains, optionally with DMA
Direct I/OLatch or sample/hold functionality.
Can built AMS functionality with access to XADCs.
Process Data Interface
Communication with the user application on host processor.
Provides µC specific interface (often AXI, sometimes (Q)SPI or other).
Interrupt request control
Host ProcessorFor user application and higher layer services
Industrial Ethernet Generic Architecture and Building Blocks (2/2)
Full diagram: see slide before
XILINX CONFIDENTIAL.
Introducing Anybus embedded
– one solution for all
networks
XILINX CONFIDENTIAL.
• Multi-Protocol suite for Industrial Ethernet on Zynq
• From HMSProduct
• FPGA IP + Protocol Stack
• License = Security Chip from HMSDelivery
• No NRE *), charge per Security Chip
• MoQ = 500 + One-time low quantity option for ramp upPricing
• HMS's established support structures for Anybus
• Documentation, Reference System on ZedboardSupport
Anybus IP on Xilinx
*) unless features beyond standard model are ordered
Page 17
Industrial NetworkingIP Cores from Alliance Partner Program
XILINX CONFIDENTIAL.
Xilinx Alliance Partner Program
customer-specific
adaptations possible
flexible licensing models
Main model:
Source code buyout
Alternative:
One-time-fee for binaries
Xilinx Alliance
Partner Program
Multi protocol Single Protocol
Profinet IRT
EtherCAT
sercos III(Spartan-6)
Powerlink
EtherNet/IP,
Modbus-TCP,
Powerlink(SW porting upon customer
request as design service)
Note: is also multi protocol
supplier for Xilinx. Focus: SW stacks for
Zynq
Mechatrolink-III
CC-Link IE
XILINX CONFIDENTIAL.
Example 1: Xilinx Partner Beckhoff - EtherCAT
Zynq-7000 EtherCAT System
EtherCAT with 31.25 µs on Zynq
ISM-NET
XILINX CONFIDENTIAL.
Example 2: Xilinx partner Enclustra
Functional Safety with Profinet IRT in Zynq
XILINX CONFIDENTIAL.
Protocol Type Features / Conditions ProviderGeneral
Availability
Device Family
Support
Profinet RT/IRT Device
- Conformance class C
- Proven SDK from Molex
- Application in A9 or MicroBlaze
- Source code buyout option
- Volume independent license
Enclustra
ZHAW InES
available (RT)
Q2/2015 (IRT)
Zynq-7000, Artix-7
Profinet IO Device
- Conformance Class A
- Pure Software solution
- Very small stack size
- Volume independent license
port GmbH availableZynq-7000,
Spartan-6
Profinet RT/IRT Device
- Conformance class C
- with integrated soft core
processor for the protocol stack
- Royalty model
Softing available Zynq-7000, Artix-7
Ethernet/IP Adapter
- Proven SDK from Molex
- 3 port switch in FPGA fabric
- Linux driver support for real-time
and non-real-time traffic
- Volume independent license
Enclustra
ZHAW InESQ2/2015 Zynq-7000, Artix-7
Industrial Ethernet from Xilinx Alliance Program Partners (1/3)
XILINX CONFIDENTIAL.
Protocol TypeFeatures / Conditions
Provider AvailabilityDevice Family
Support
EtherCAT Slave
- Ethernet Slave Controller
- Comprehensive configuration
options supported by GUI
- Source code for slave stack
development available for ETG
members
- Volume independent model or
mixed annual fee/royalty model
available
Beckhoff availableZynq-7000, Artix-7,
Spartan-6
EtherCAT Master
- Based on proven stack from
acontis
- Compliant to the EtherCAT Master
Class Directive according to
ETG.1500
- Independent from operating
system
- Royalty model
IXXAT available Zynq-7000
Ethernet
POWERLINK
Controlled
Node
- OpenPOWERLINK with openMac
- Implemented in uBlaze for cross
platform compatibility and to free
up A9s for application use
B&R availableZynq-7000, Artix-7,
Spartan-6
Ethernet
POWERLINK
Controlled
Node +
Managing
Node
- openPOWERLINK for Cortex A9
- software solution for standard
Ethernet infrastructure
B&R availableZynq-7000, Artix-7,
Spartan-6
Industrial Ethernet from Xilinx Alliance Program Partners (2/3)
XILINX CONFIDENTIAL.
Protocol Type Features / Conditions Provider AvailabilityDevice Family
Support
Modbus-TCP Slave
- OS-independent software
- Runs as an application on a
socket
API on TCP layer
- Compatible with all Ethernet
hardware
Ixxat on requestZynq-7000, Artix-7,
Spartan-6
Sercos IIISlave +
Master
- Self-contained and lean FPGA IP
core
- Less than 5.000 LUTs
Sercos International
e.V.available Spartan-6
CC-Link IE Slave- Annual license fee (volume
independent)inrevium on request Zynq-7000
Mechatrolink IIISlave +
Master
- Annual license fee (volume
independent)inrevium available Zynq-7000
Industrial Ethernet from Xilinx Alliance Program Partners (3/3)
XILINX CONFIDENTIAL.
– Avnet Supported Kit
– EtherCAT slave TRD
– LX150T base board +
ISMNET card
– Phasing out!
Industrial Ethernet Kits
– Positioned as “platform”
– Customer buys
hardware pieces
individually
– Qdesys MC reference
design with EtherCAT
– Go to Qdesys for D/L
and support
– Various boards for CC-Link, Powerlink, Mechatrolink, EtherCAT
– Sold as kits or individual boards that can be assembled for complete network evaluation
– Expanding to global presence
Inrevium Boards For Industrial Networking
Avnet Spartan-6
IEK
$1,895
Zynq Intelligent
Drives
$1,145+
– Spartan-6 LX75T
– Basis for S6 Motor Control Kit
– Can add ISMNET
– Larger device good for
EtherCAT, bridging apps
– Driving ref. designs towards
this
Avnet LX75T Board
$425
$250
ISMNET
+
$TBD
FMC
+
Avnet ZedBoard
– Produced by Avnet
– Zynq 7Z020
– New FMC with motor
control and dual
Ethernet
– Driving all new IE ref.
designs on Zynq to this
Industrial Ethernet Switches for High AvailabilityHSR/PRP switches, IEEE1588-2008 solutions
XILINX CONFIDENTIAL.
Problem: Network outage can impact whole plants
Solution: Recovery with HSR and PRP protects the networks
Ethernet High Availability (1/2)
PRP(Parallel Redundancy Protocol)
HSR(High Availability Seamless Redundancy Ring)
Node
#1
Node
#3
Node
#2
Node
#4
Node
X
Node
Y
Network
A
Network
B
Protection in a RING Protection via PARALLEL paths
Widely used for communication between substation networks
SoCe has solution with lowest latency - exclusively for Xilinx!
XILINX CONFIDENTIAL.
Ethernet High Availability (2/2)
HSR / PRP
Switch
IEE
E1
58
8
Tra
nsp
are
nt C
lock
A B
uplink
PHYPHY
PHY
Xilinx Alliance Partner:
Protection with zero packet loss
3 port switch for Ethernet
IEEE1588 for synchronization over network
Target markets
– Energy (i.e. IEC 62439)
– Industrial
– Transportation
For Zynq and Spartan-6
XILINX CONFIDENTIAL.
Ethernet High AvailabilityHSR/PRP Switch IP-Core
Differentiators
Cut through mode
– Constant and Low latency times:
– <3 µs for FE / <500 ns for GE
– (Competitor: 106 µs @ 1280 byte frame)
No need for CPU or software stack
– 1588 and Supervision Frames managed by hardware
– (Competitor: always need a CPU)
1GE HSR - Forwarding Time Latency
Comparison
0
2000
4000
6000
8000
10000
12000
14000
16000
256 512 1024 1280
Payload Size (Bytes)
La
ten
cy (
ns)
- L
ow
er
is b
ette
r
Theoretical Min.
HSR/PRP Switch-Xilinx
FRS-Alteracompetition
HSR/PRP Switch is a HDL IP Core for the implementation of both the HSR (IEC 62439-3-
Clause 5) and PRP (IEC 62439-3-Clause 4) protocols in a single device.
XILINX CONFIDENTIAL.
Ethernet High AvailabilityHSR/PRP Switch IP-Core
100M / 1GE / Copper - Fiber
Full IEEE 1588-2008 V2 support
Fully scalable in number of ports and features
RSTP, VLAN, SNMP, DAN, RedBox, Quadbox
Reference Designs for Spartan-6 and Zynq devices
Single flag switches between PRP and HSR modes
Area optimized for low cost FPGA devices
– Example: RedBox with Transparent Clock
– 5.250 slices (15.000 LUTs, 11.300 registers), 64 RAMB16, 20 RAMB8
Commercial conditions
– Project license with netlist: 34K€, +6K€ annual support and maintenance
– Site license with encrypted HDL and royalty-based model: on request
Contact:
– industrial@soc-e.com
HSR/PRP Switch, further information
XILINX CONFIDENTIAL.
Ethernet High AvailabilityNETBox (Development Kit)
NETbox is an all-in-one solution to develop FPGA based
Industrial Networking Solutions. It includes the NEToem
pluggable OEM module and a NETcarrier board.
– On-board LAN9303 Ethernet Switch to combine
Reliable Ethernet with regular Ethernet
– UART/GPIO/GPS Clock/JTAG/PMOD connectors
for versatile connectivity
– User programmable OLED Graphic Display
– EHIZtari PC HSR/PRP Network Analysis and
Testing tool availableRJ45
RJ45
RJ45
RJ45
RJ45
RJ45
NEToemModule
(FPGA)
I2C
SDA SCL
Fast Ethernet Switch
SERIAL
JTAGOLED
PMOD GPIO
LPDDR
FLASH
Tº Sensor
Board-to-board connector
Debug Connector
F.E PHY F.E PHY F.E PHY F.E PHY
GPIOS
x40
MII x5
XILINX CONFIDENTIAL.
Individual Products – Many CPU variants, OS and API
Lack of Security, Reliability
Smart Grid Automation – Current Generation Architecture
Power Supply CPU
Backplane
MCUNo OS
CPLD
CPU
OS a
FPGASwitch
CPU
OS b
FPGA
Protection
Relay
DSP b
FPGA
Measurement
Unit
DSP a
FPGA
I/O
MCU
FPGA
XILINX CONFIDENTIAL.
IIoT Factors Contributing to Smart Grid
– New Feature >> Highest Reliability - HSR/PRP
» Lowest latency
» Sub 4 ms recovery time IED to IED
– New Requirements >> Robust Security
>> Functional Safety
Smart Grid Automation – Next Generation Architecture
Power Supply
HSR/PRP, IEEE1588 IP
+
+
CPU
HSR/PRP
EtherCAT
Module nModule 2
EtherCATEtherCAT
DSP
I/O
EtherCAT
DSP
I/O
Module 1
EtherCAT
DSP
I/O
Multi-axis Motion Control for CNC & Robotics
XILINX CONFIDENTIAL.
Page 37
Worldwide Industrial Robots Shipment
CAGR (2012-17)
6.5%
34.2%
2.2%
6.0%
3.7%
The actual number
by CRIA is 57,000
XILINX CONFIDENTIAL.
Two Categories of Industrial Machines
Small size, small power
Large size, high power
Collaborative Robot
6-axis Industrial Robot CNC
Laser Cutting Machine
SCARA Robot Delta Robot
XILINX CONFIDENTIAL.
Robot Controller Architecture Consideration
Motor Drivers
Integrated
Discrete
Motor Drivers
Main
CPU
2nd CPU Servo Ctrlr
CPU
Typically DSP/PowerPC
Position control
Axis computing
Typically X86 Typically FPGA
CPUServo
Ctrlr
- Multiple chips
- Single chip like Zynq/MPSoC
- Suitable for
Desktop collaborative robot
Mobile Robot
Robot ARM
- Suitable for
Traditional industrial robot
High-end collaborative robot
XILINX CONFIDENTIAL.
Single Chip for multi-axis servo drive + network
Processing System
Programmable Logic
Drive12%
ZC-7010
Processing System
Programmable Logic
ZC-7020
Drive4%
Processing System
Programmable Logic
Drive22%
ZC-7010
Processing System
Programmable Logic
ZC-7020
Drive7%
TWO MOTORS
ONE MOTOR
Drive12%Processing
System
Programmable Logic
ZC-7020
4 FULL DRIVES + EtherCAT®
60%
XILINX CONFIDENTIAL.
Basic building blocks
– Fifteen control functions, all modular
– DSP48 centric
– Dynamic operation with minimum footprint
– CLARKE, PARK, PID, ATAN2, SIN/COS, SMO, SVM,
RPFM, filters, etc.
High precision
– 48bit operations, 18bit precision
30...40 times faster than µC
– Freescale: 55 µs @ 96MHz for torque control loop
– QDESYS IP: 1.6 µs @ 50MHz
Low EMI– innovative RPFM power modulation algorithm
All Motor data and parameters via XML descriptors– scalable, wide range motor current measurement
Available today
– One-time fee @ 5K USD
Motor Control IP for Xilinx FPGA
...
Xilinx-exclusive Motor Control IP for Performance and Extensibility
XILINX CONFIDENTIAL.
Model-based Design for Motor Control
MATLAB and Simulink
Algorithm and System Design
HDL IP Core
Generation
Embedded System
Integration
SW Interface
Model Generation
FPGA Bitstream SW Build
Processor-
in-the-loop
Code Generation with Mathworks
System Design
– Simulink for model based design
HDL Worflow Advisor with
– HDL Coder for RTL code
– Embedded Coder
– Mathworks support packages for Xilinx
platform
Bitstream compilation and
programming from within Simulink
– using Xilinx design suite
Processor-in-the-loop for fast
iterations
More information:
– www.mathworks.com/xilinx
– www.mathworks.com/zynq
Lo
ng
-liv
ing
P
latf
orm
Ec
on
om
ica
l S
olu
tio
nH
igh
Pro
du
cti
vit
y
Code Generation for fastest optimization
XILINX CONFIDENTIAL.
Page 43
Industrial Robot Controller Software Architecture
Hardware
OS
RT Extension
Libraries
Applications
Motion Ctrl NetworkingUI
Processor Memory Sensor I/O
SMP -
Non Hard RT: Windows, Linux
Hard RT: Vxworks, QNX
AMP –
Linux + Baremetal/RTOS
INTime for Windows
RTAI/Xenomai for Linux
X86
ARM
PPC
…
Force
Camera
Anti-collision
…
Sensor
Encoder
Ethernet
CAN
Serial
USB
Operation 1 Operation N…
Safety
SoftPLC OPC UA
Operation 2
…Security
XILINX CONFIDENTIAL.
Zynq-based Motion Controller Solution by B&R
Page 44
Z7010
Linux
XenomaiPowerlink
Eclipse-based IDE
Core board
CNC & Robotics
XILINX CONFIDENTIAL.
Zynq-based SoftPLC/SoftMotion Solution from Phoenix Contact SW
XILINX CONFIDENTIAL.
Page 46
Integrated Control & Drive System Partition
Field
Bus
Access
High-
level
Control
Trajectory
Planning
IO
Trajectory
Integration
P/V/I
ControllerPWM
Drive
Non-Real-Time Real-Time
Motion Control Drive Control
High-level Control
Trajectory Planning
Trajectory Integration
Position Control
Velocity Control
Current Control FPGA
CPU
FPGA
CPU
FPGA
CPU
FPGA
CPU A
CPU B
FPGA
CPU A
CPU B
FPGA
DSP
CPU
A B C D E F G
Flexibility
Performance
XILINX CONFIDENTIAL.
Page 47
Zynq-based Integrated Control & Drive Solution
XILINX CONFIDENTIAL.
Time Division Multiplexing in PL for Multi-axis
XILINX CONFIDENTIAL.
Implemented utilization
Resource Utilization
XILINX CONFIDENTIAL.
Co-Simulation
XILINX CONFIDENTIAL.
Collaborative Robots
Collaborative Robots going to reach >40.000 units in 2020
– ASP of $25,000 each
– $1B market
– Make production more feasible – lower cost
Use mode is in collaboration with humans
– Space becomes an issue
• Controls and power supplies need high degree of integration
– Sensors are attached and deeply embedded into control
Functional Safety is critical
XILINX CONFIDENTIAL.
Collaborative Robot Platform with Integrated Drive
A53 A53
R5
R5
TC
M
OCM
Peripherals
Cache
FPGA
Region 1
Safety
Ind. Ethernet
FPGA Region 2
SDSoC accel
FPGA Region 3
Communication
Sensor Preprocessing
Mvision accel
A53 A53
Zynq® – Smart MV Camera
A9 A9
FPGA
Zynq® – Smart MV Camera
A9 A9
FPGA
Zynq® – Smart MV Camera
A9 A9
FPGA
FPGA
Region 1
MOSFET MOSFET MOSFET MOSFET MOSFET
Ax
is 1
Ax
is 2
Ax
is 3
Ax
is 4
Axis
20
Motion Control for multi axis
Embedded Safe Motion
EtherCAT Master stack with Safety
Layer
Safety Requirements: Ple CAT 4
HMI
Display
FPGA
Region 1
FPGA
Region 1
FPGA
Region 1
FPGA
Region 1
Multi Axis power stage with min. drive
capabilities and safety
MOS FET or SiC driver stage
Digital Encoder
Safety requirements: Ple CAT 4
Sensors
Robotics Control
Meta data processing from
- Sensors
- Vision Sensors
Robot Motion Planning & Safe Motion
Motion controller
Sensor bus management
Camera bus management, GigE Vision etc. or
Ind.Ethernet like EtherCAT, Profinet, Powerlink
HMI
Safe motion safety requirements: PLd CAT3
…
XILINX CONFIDENTIAL.
Xilinx Functional Safety Value Proposition
Page 53
Zynq
Sa
fety
A9
Spartan-6/
Artix-7
Cost & Profitability Compliance & Reliability Flexibility &
Innovation
Integration of Safe and
Non-Safety functions
Certified Tools,
Methodologies, Reports
Isolation Design Flow
Updates to Non-Safety
Integration of Cortex A9
and FPGA
Safety Manual, Reliability
Report
Highest availability
through lowest SEU
failure rates
IEC61508
ISO26262
Certified by
Isolation Design Flow
Sa
fety
A9
XILINX CONFIDENTIAL.
Page 54
4 Devices 3 Devices 2 Devices$$ 1 Device $
Customer Time To Revenue depends on
completeness of the certified solution
Zynq and Zynq MPSoC
Functional Safety Reference Design
Accelerates customer TTR by 12 to 18 month
Unique Xilinx Functional Safety Solution we have a strong value proposition