Safety over EtherCAT Overview - EtherCAT Technology …€¦ · Part 3: Profiles for ... Device 1...
Transcript of Safety over EtherCAT Overview - EtherCAT Technology …€¦ · Part 3: Profiles for ... Device 1...
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OverviewSafety over EtherCAT
EtherCAT Technology Group
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety over EtherCAT
• Requirements• Safety over EtherCAT Technology
– Architecture– Definitions– State Machine– Telegram– Summary
Applications
© EtherCAT Technology Group Safety over EtherCAT 2
• Conformance• Applications
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
International Standards for Safetybus Systems
• BGIA Test principles GS-ET-26– Test principles of the German Institute for Occupational
Safety and Health – Scope: Bus systems for safety related communication
• IEC 61784-3– DIGITAL DATA COMMUNICATIONS FOR
Applications
© EtherCAT Technology Group 3
MEASUREMENT AND CONTROLPart 3: Profiles for functional safety communications in industrial network - General rules and profile definitions
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
IEC 61784-3
Applications
© EtherCAT Technology Group 4Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety communication as part of a safety system
Sensor(s) Logic Actor(s)
Safety communication
1%
Safety Function
Bus Bus
Safety communication
1%
Applications
© EtherCAT Technology Group 5
• Probability of failure for the safety system:– PFHSafetyfunction = PFHSensor + PFHLogic + PFHActor + 2x PFHBus
< 10-8…10-7 /h for SIL 3 (IEC 61508)
• The IEC 61784-3 highly recommends that the safety communication channel does not consume more than 1 % of the maximum PFD or PFH of the target SIL for which the functional safety communication profile is designed:
– PFHBus < 10-9 /h for SIL 3
• More than 100.000 years communication without an undetected Error!Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety over EtherCAT
• 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).
Applications
© EtherCAT Technology Group 6
• The protocol is approved by an independent Notified Body (TUV Sued Rail GmbH).
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety over EtherCAT | Hardware Architecture
• 1-channel communication systemModel A according to IEC 61784-3 Annex A
Controller ASafety
Protocol
Controller BSafety
Protocol
Device 2
Controller BSafety
Protocol
Controller ASafety
ProtocolController ASafety
Protocol
Controller BSafety
Protocol
Device 1
Controller ASafety
Protocol
Controller BSafety
Protocol
Applications
© EtherCAT Technology Group 7
Protocol ProtocolProtocol Protocol
PHY
Magnetics Magnetics
PHY
EtherCATSlave Controller
PHY
Magnetics Magnetics
PHY
EtherCAT Slave Controller
RJ45 RJ45 RJ45 RJ45
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety over EtherCAT | Software Architecture
• Black channel approachwith safety and non-safety data on the same bus
Device 1
Safety Application
St d d
Device 2
Safety Application
St d dApplications
© EtherCAT Technology Group 8
Safety overEtherCATProtocol
StandardApplication
Safetyover
EtherCAT
EtherCATDLL and AL
EtherCAT Telegram
Safety data container (FSoE Frame)
Safety overEtherCATProtocol
StandardApplication
EtherCAT Communication Interface
EtherCAT Communication Interface
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety over EtherCAT | System Example
• Decentralized Safety-Logic• Standard PLC routes the safety messages
Standard PLC
Safety Inputs Safety Sensors
Applications
© EtherCAT Technology Group 9
Safety Logic
Safety Outputs
Safety Drives
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
FSoE | Master / Slave Connection
FSoE Master
Master of a FSoEConnection. The Master initiates the communication.
The FSoE Master sends a FSoE Master Frame, which contains the SafeOutputsApplications
© EtherCAT Technology Group 10
SafeOutputs.
A FSoE Master can manage one or many FSoE Slaves.
FSoE Master
SafeOutputs inFSoE Master Frames
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
FSoE | Master / Slave Connection
FSoE Slaves
SafeInputs inFSoE Slave Frames
FSoE Slave
Slave of a FSoEConnection.
The FSoE Slave sends a FSoE Slave Frame, after receiving a valid FSoE Master Frame.
The FSoE Slave FrameApplications
© EtherCAT Technology Group 11
FSoE Master
SafeOutputs inFSoE Master Frames
The FSoE Slave Frame contains the SafeInputs.
A FSoE Slave belongs to one FSoE Master.
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
FSoE | Communication Cycle
FSoE Cycle
The FSoE Cycle consists of theFSoE Master Frame confirmed by aFSoE Slave Frame.
The FSoE Master sends a FSoE Master Frame to h FS E SlApplications
© EtherCAT Technology Group 12
the FSoE Slave.
With sending theFSoE Master Frame the Master starts a Watchdog-Timer for guarding theFSoE SlaveFSoE Master Frame
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
FSoE | Communication Cycle
FSoE Slave Frame
FSoE CycleFSoE Cycle
The FSoE Cycle consists of theFSoE Master Frame confirmed by aFSoE Slave Frame.
The FSoE Master sends a FSoE Master Frame to h FS E SlApplications
© EtherCAT Technology Group 13
The FSoE Master only generates a new FSoEMaster Frame after receiving a valid FSoESlave Frame.This starts a new cycle.
the FSoE Slave.
With sending theFSoE Master Frame the Master starts a Watchdog-Timer for guarding theFSoE Slave
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
FSoE | Watchdog Time
FSoE Watchdog Time FSoE Watchdog Time
Every device guards that the partner sends a new FSoE Frame within the configured FSoEWatchdogzeit
If the Watchdog expires, the devices change to the Reset State
Applications
© EtherCAT Technology Group 14
the Reset State.
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
FSoE | Connections
FSoE Connection
The FSoE Connection is a logical connection between an FSoEMaster and an FSoESlave.
It shall be a unique Connection-ID in the system This must be
Connection-ID 1Connection-ID 3
Applications
© EtherCAT Technology Group 15
system. This must be checked within the configuration.
Connection-ID 2
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
FSoE | Unique Address
FSoE Slave Address
Beside the Connection-ID every FSoE Slave has in the scope of the system a unique 16-Bit FSoE Slave Address
This address can be adjusted at the Device
FSoE Slave Address
Applications
© EtherCAT Technology Group 16
adjusted at the Device, e.g. via a DIP-Switch.
Up to 65.535 Devices can be addressed.
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
FSoE State Machine per Connection
• Every FSoE Connection is handled by an FSoEState Machine.
• The FSoE Master manages a
• single FSoE State Machine per FSoESlave.
Reset
Session
Reset_ok
Session_okApplications
© EtherCAT Technology Group 17
• After Power-On the FSoE Master and the FSoE Slave are in the State Reset.
• The Safe Outputs can only be set in the state Data.
Connection
Parameter
Data
Conn_ok
Param_ok
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
FSoE State Machine | Error
• In case of an error the devices change to the Reset state.
• Master:An internal detected Error (communication error or application error)
Reset
Session
Applications
© EtherCAT Technology Group 18
• Slave:An internal error is detected orafter receiving a Reset telegram from the Master
Connection
Parameter
Data
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
FSoE – Frame
Ethernet Header
EtherCATHeader
1. Data-gram
2. Data-gram FSC
Ethernet-Telegram FSoE Frame
The FSoE Frame is mapped as a Container in the process data of the device.
Each device detects a new FSoE Frame, if at least one Bit in the
FSoE Frame
Applications
© EtherCAT Technology Group 19
CMD SafeData CRC_0 Safe
Data CRC_1 SafeData CRC_n Conn ID
at least one Bit in the FSoE Frame is changed.
Every 2 Byte SafeData are checked by a 2 Byte CRC
The maximum number of SafeData is therefore not restricted by the protocol.
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety over EtherCAT | Safety Measures
MeasureError
Sequence Number Watchdog Connection
IDCRC
Calculation
Unintended repetition
Loss
Insertion
Incorrect sequence
Corruption Applications
© EtherCAT Technology Group 20
Corruption
Unacceptable delay
Masquerade
Repeating memory errors in Switches
Incorrect forwarding between segments
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety over EtherCAT | Features
• The FSoE specification has no restrictions according to:– Communication layer and interface– Transmission speed– Length of safe process data
• Routing via unsafe gateways, fieldbus systems or backbones is possible.
Applications
© EtherCAT Technology Group 21Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety over EtherCAT | Features
• Residual Error Probability R(p) < 10-9/h
• The protocol is developed according to IEC 61508 Safety Integrity Level SIL 3
• The protocol is approved by TÜV Süd Rail GmbH (Notified body)
Applications
© EtherCAT Technology Group 22
( y)
• Certified products with Safety over EtherCAT are available since 2005
• Safety-over-EtherCAT is submitted to IEC 61784-3 Functional safety fieldbuses – Release date 2010
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety over EtherCAT | Features
• 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
C f f f S SApplications
© EtherCAT Technology Group 23
• 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
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety over EtherCAT | Conformance Test
• Protocol test for the devices– Connection via EtherCAT Interface– Black box Test
• Test suite available for device manufactures– Test suite can be used during device development– No special Hardware necessary
Applications
© EtherCAT Technology Group 24
p y
• Independent Test Laboratory for confirmation of conformity
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Certification Process | Proposal
Device Development with Safety over EtherCAT (FSoE)according to IEC 61508 or relevant Product Norm
FSoE Conformance Test
EMC Tests(Increased Levels) IEC 61508 Approval
Applications
© EtherCAT Technology Group 25
Conformance Test(Increased Levels)
Device Certification
EMC-Lab EtherCAT Test Center Notified Body
Notified Body
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
FSoE Conformance Test | FSoE Slave
Equipment under Test(EuT)
XML Test Configuration
FSoE Slave
XML
FSoESlave Information File (ESI)
Applications
© EtherCAT Technology Group 26
EtherCAT
Test Report
Test Logic
EtherCAT Master
EtherCAT Slave
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety engineering in modern automation
Applications
© EtherCAT Technology Group 27
• Mixed network for standard and safety functions• Standard network with a decentralized safety island• Separate networks for standard and safety functions
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety engineering in modern automation
FSoE Slave deviceSFSoE Master deviceM
M
FSoE Slave FrameFSoE Master Frame
Applications
© EtherCAT Technology Group 28
• Configured Master-Slave Connections• Communication routed via Standard-PLC
S Connection-ID 1
M
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety engineering in modern automation
FSoE Slave deviceSFSoE Master deviceMFSoE Slave Frame
FSoE Master Frame
MApplications
© EtherCAT Technology Group 29
• Configured Master-Slave Connections• Communication routed via Standard-PLC
S Connection-ID 2
M
S
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety engineering in modern automation
SConn-ID 3
S Conn-ID 4
FSoE Slave deviceSFSoE Master deviceM
MApplications
© EtherCAT Technology Group 30
• Multi Master networks• Safety groups with group failsafe possible.
S MConn-ID 2
Conn-ID 1M
S
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety engineering in modern automation
FSoE Slave deviceSFSoE Master deviceM
M SApplications
© EtherCAT Technology Group 31
• "Master-Master" Communication possible with Master & Slave implementation in the Master device
• Unique Conn-ID• Used for plant concatenation
MConn-ID 5
M S
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Application | Tire and wheel testing machine
Applications
© EtherCAT Technology Group 32Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Application | Tire and wheel testing machine
• Advantages for the costumer:• Integration of Safety functions in the TwinSAFE system
– Emergency stop– Safety fence monitoring
• Small switch box directly at the safety fence• Optimum interaction between standard automation and
safety technologyApplications
© EtherCAT Technology Group 33
y gy– Reduced engineering and hardware costs– Simplified wiring– Modifications are easy to implement
• Only one tool needed for Standard and Safety functions– TwinSAFE software editor conveniently integrated in the
TwinCAT system
Safety over EtherCAT
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Requirements
Safety over EtherCAT
- Architecture
- Definitions
- State Machine
- Frame Structure
- Summary
Conformance
A li ti
Safety over EtherCAT
www.ethercat.org
Applications
© EtherCAT Technology Group 34
EtherCAT Technology GroupDr. Guido Beckmann
Ostendstr. 19690482 Nuremberg, [email protected]
Safety over EtherCAT