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SERCOS III – 3rd Generation Hard Real TimeNew functions create new opportunities and additional potential

Position Data 4000 Times Per Second“Making music” from your servo motor with SERCOS

Open Architecture Facilitates Modular AutomationRexroth’s IndraMotion controllers take full advantage of SERCOS III

cifX – Reduced to the Maximum

Hilscher Gesellschaft für Systemautomation mbHRheinstr. 15, 65795 HattersheimPhone: +49 (0) 6190 9907-0, Web: www.hilscher.com

PC access to real time Ethernet,open architecture,

flexibility, preferably master and slave,simple integration via DPM or DMA,

PCI as you would expect, but PCI Express is on the way.

cifX - the right solution.

Currently available for PROFINET IO controllers and EtherCAT, Ethernet/IP, Powerlink, PROFINET IO and SERCOS III Slaves. Others are currently in the pipeline.

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L Since SERCOS was introduced at the begin-ning of the 90s, it has carved out a solid po-sition in the market as an open real time motion control interface for automation en-gineering applications. The fact that it is anefficient, deterministic communications pro-tocol based on optical transmission withgood noise immunity is a major reason whySERCOS has been such a big success in a variety of industries and applications. Thepopularity of SERCOS in all of the world’s large automation markets is reflected in the SERCOS organization, which looks aftermarketing, engineering development andstandardization of the technology in collab-oration with the member companies.

When we took the decision three years ago to develop anIndustrial Ethernet-based implementation of SERCOS, weset the stage for the future success of the technology. Thefamiliar, proven SERCOS mechanisms including the MotionControl Profile, telegram-based communications and hard-ware synchronization were migrated to the Ethernet stan-dard with maximum backwards compatibility. The combina-tion of SERCOS and Ethernet opens up a whole new range ofpossibilities and creates important synergies which are par-ticularly evident in the standardized cabling and end-to-endcommunications which SERCOS offers.

Besides a dramatic increase in performance,SERCOS III offers a large number of newfunctions and very easy handling while re-taining its unique real time characteristics.SERCOS now offers greater versatility for anyapplication.

Following publication of the SERCOS IIIspecification in November 2004, work hascontinued on two supplementary featureswhich open up another new range of possi-bilities. SERCOS safety is a SERCOS III com-patible protocol extension which accommo-dates safety applications up to SIL 3 withminimal cycle times and which achieved TÜVapproval last year. SERCOS IO is an enhanced

device profile for distributed I/O components, which is sup-ported by well-known terminal block manufacturers, and itwill be available by the middle of 2006.

SERCOS has now definitely made the transition from aspecific drive interface to a universal real time Ethernet so-lution.

We wish you pleasant reading

Dr. Karl Tragl, Chairman ofSERCOS International

A Blend of Tradition and Innovation

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Introduction to SERCOS IIIIn order to use Ethernet in hard real time en-vironments, SERCOS III has added a colli-sion-free real time channel which runs inparallel with an optional non real timechannel. SERCOS telegrams (Ethertype0x88CD) are transferred on the collision-free channel. This channel features excellentprotocol efficiency to ensure best possibleperformance even when a lot of nodes areattached and data volumes per device arelow. A non real time channel can be config-ured in parallel with the real time channel to

The initial SERCOS III products and ap-plications signal the start of 3rd gener-ation SERCOS and a new generation ofreal time communications. In contrastto other real time Ethernet solutions,SERCOS III is based on technologywhich has a proven track record in themarket over the past 15 years. This ap-proach simplifies migration of existingsolutions, and a whole series of newfunctions, protocols and profile exten-sions expand the range of potential ap-plications.

carry Ethernet messages and IP-based protocols including TCP/IPand UDP/IP.

Because SERCOS III uses anevolutionary approach, existingadvantages are retained, and awhole range of new features sig-nificantly extends the range ofpotential applications.

SERCOS III is based on a ringtopology. The full duplex capabil-ity of the physical Ethernet infra-structure is used to achieve re-dundant data transfer based on adouble ring topology rather thana single ring. Communicationsare not interrupted if there is acable fault anywhere in the ring. The systemcontinues to run without problem, and anintegrated diagnostic function identifies thedefective cable link or station, which canthen be repaired without affecting machineavailability. A linear topology may also beused. It does not offer the advantage of re-dundancy, but it does eliminate one cable.This can be very helpful on very large sys-tems. SERCOS III does not use the star topol-ogy of standard Ethernet, and there are nohubs or switches.

Propagation delays and jitter are reducedto a minimum, because real time data isprocessed on the fly as it passes through thenodes.

Installation of a SERCOS III network is verystraightforward and does not require specialnetwork configuration. Patch or crossovercables are used to connect all of the nodes.The device Ethernet ports are interchange-able and can even be used to connect stan-dard Ethernet devices (such as notebooks) toa SERCOS III domain. Ethernet or IP proto-cols can be used to access SERCOS III de-vices without affecting the real time behav-ior of the SERCOS III domain.

SERCOS III – 3rd Generation Hard Real TimeNew functions create new opportunities and additional potential

1·2006 3

���SERCOS interface celebrates its 20thbirthday at EMO 2005

© SERCOS International 2006

��� SERCOS safety technical data

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Dedicated real time channel forcyclic transfer of real time data

Communications settings, parameters anddiagnostic data can be exchanged betweenthe master and the slaves or between indi-vidual slaves on the SERCOS service chan-nel. To maintain compatibility, this channelis still available in SERCOS III. The new stan-dard also supports the optional non realtime channel which can be used to transferstandard internet frames (e.g. TCP/IP orUDP/IP messages). The communications cy-cles and sharing of the 100 Mbit/s band-width between real time and non real timechannels can be modified to meet the needsof the individual application.

Ideal for centralized and distrib-uted drive solutionsSERCOS III cuts the minimal achievable cycletime in half from the current 62.5 µs to 31.25µs. The higher bandwidth of the physical Ether-net infrastructure supports a sufficient numberof slaves even at these extremely short cycletimes. SERCOS III accommodates both distrib-uted drive solutions and solutions with centralsignal processing. In distributed drive applica-tions, all control loops are closed in the drivecontrol unit, and they can be implemented us-ing technology functions. With centralizeddrive architecture, only the current control loopis closed in the drive control unit. The controlloops for multiple axes are implemented in cen-tral control electronics.

Cross communication betweenslavesDue to the unidirectional nature of fiber op-tic links, it was not possible to directly ex-change data between slaves on the previoustwo generations of SERCOS. SERCOS III uses

the full duplex capability of Ethernet tosupport cross communication (CC).

Controller cross communicationbased on the C2C profileSERCOS III also supports communicationsand synchronization between several mo-tion control units. Several machine mod-ules in a network can be synchronized, andtime-critical data can be transferred be-tween controllers. The C2C (controller-to-controller) profile, which is based on thebasic SERCOS III protocol, has been de-fined to provide this functionality. Thespecification has been published at the2006 Hanover Fair.

SERCOS safety

SERCOS III reflects the increasing impor-tance of safety engineering. The safety fea-tures, called SERCOS safety, are implement-ed in a SERCOS III compatible protocolextension which makes SERCOS III suitablefor safety applications up to SIL 3 as definedin IEC 61508 even at minimum cycle times.Safety-relevant data is transferred alongwith real time data and other standard Eth-ernet protocols on a single physical medi-um.

The safety data container which is em-bedded in a SERCOS data telegram can car-ry up to 64 bits of safe user data. Using thespecific cross communication mechanism,safe data can be transferred directly be-tween slaves without first being retrievedby a master (safety controller) and redis-tributed. Because SERCOS safety is inde-pendent of the transport layer, other physi-cal transfer mechanisms can be usedbesides SERCOS III. The routing features ofthe protocol make it possible to extend asafety network to multiple lower level net-

works. The SERCOS safety concept was tested

by TÜV Rheinland in December 2005. InitialSERCOS products will become available in2006.

SERCOS III device model and theenhanced I/O profileOver the past fifteen years, the SERCOS ser-vo drive profile has developed into an es-tablished, mature device profile. It providesa rich set of functions which have a proventrack record in a wide variety of applica-tions. The device profile has undergone aprocess of expansion and generalizationduring the migration to SERCOS III. In thefuture, it will support hybrid devices whichcombine different applications in a singledevice as well as dedicated drive, I/O andcontrol devices. New device profiles for oth-er types of actuators and drive designs(closed and open loop drives, etc.) and forI/O modules, technology modules, con-trollers and monitoring devices will be de-fined and standardized. An enhanced deviceprofile for distributed I/O units is currentlyunder development. The profile is suitablefor modular I/O units with bus couplers andblock I/O devices. The specification will beavailable in the middle of 2006.

Contact:SERCOS InternationalPeter LutzManaging Director Landhausstraße 20, D-70190 StuttgartTel: +49 (0)711/2 84 57-50Fax: +49 (0)711/2 84 57-55E-Mail: info@sercos.dewww.sercos.de

Single cast connections 16384

Multi cast connections 1024

Number of safety nodes 1000 (1ms)

Number of safety multi-cast nodes 15

Min. cycle time 31,25 µs

Typical cycle time 1 .. 10 ms

SIL Level (down to min. cycle time) SIL3

User data 2..8 bytes

Overhead 11 bytes

Redundant network �SERCOS safety across multiple �SERCOS networks

Direct data exchange between �safety slaves in a SERCOS networks

Direct data exchange between �safety slaves across multiple SERCOS networks

Topology Line/Ring

Quick-Info 002 �

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��� A direct comparison of the SERCOS generations

friendly basic, or they can use the CoDeSysIEC 6-1131-3 programming tool. The con-troller has a VxWorks real time kernel withfull multi-tasking functionality. Complexautomation processes can be implementedincluding up to 256 parallel user tasks. Allmotion control, PLC and process functionsare combined on a single platform. The pow-erful, user-friendly application frameworkreflects many years of automation projectexperience.

The core element is a high-end continu-ous path control which can synchronouslyposition up to 48 servo axes (jitter <1µs). Allof the motion control functions and multi-

which have a SERCOS interface and offerplug & play functionality when they areused with aico.control. The solution featureseasy configuration and simple tuning onmulti-axis applications.

Other features:An extensive robotics technology packagesupports all standard kinematic functionsand includes all of the major motion controland robotics features. A powerful machinevision software option using the Win GUI(aico.view) simplifies setup and operation.Applications include component position

6 NEWS

A Win tool (aico.assist) helps users to quick-ly and easily configure and commission allhardware and software components. Otherfeatures include an HMI, work flow man-agement and drive components which com-municate via standardized interfaces in-cluding Ethernet, SERCOS, CAN, OPC etc.Integration into a vertical automation archi-tecture is possible at any point.

Programmers can write software in user-

The Manz aico.control is an openPC controller which can be in-stalled on any Pentium platform.Hardware scalability ranges fromthe pure Soft Motion variationand embedded systems for theOEM market to turn-key roboticcontrol including servo drive sys-tems. This solution offers excellentadaptability to application andcustomer requirements.

PC-based machine controller: aico.control

Quick-Info 003 �

axis interpolation are handled separately onthe PC controller. A wide variety of drivescan be connected via the IEC 61491compli-ant drive interface.

From the beginning of 2007, aico.controlwill support all standard RT Ethernet proto-cols in addition to fieldbus standards. Manzoffers SERCOS III as a system bus includingservo drives. The motion control portfolioincludes an extensive range of servo drives

detection, measurement, color matchingand classification.

Contact:Manz Automation AGEduard Ams Control Systems Business Unit ManagerPhone: +49 (0) 7121/90 00-25Fax: +49 (0) 7121/90 00-99E-mail: aico@manz-automation.comwww.manz-automation.com

��� Seamless control architecture is a major productivity factor

1·2006 7

Simple Migration Path to SERCOS IIPhoenix Contact’s PC WorxSoftcontrol MC PLC is ahigh-performance sequen-tial control system with in-tegrated motion control. Avariety of motion controlfunctions including elec-tronic gears, cams and fly-ing saw are implemented inthe same PLC program.

dling, assembly and packaging applications. High-performance PCs can handle up to

80 axes. Short cycle times (1 ms), high speedand excellent precision can be achieved bycombining INTERBUS and SERCOS. The sys-tem will also accommodate a variety ofdrives.

Contact:Phoenix ContactPress and Public RelationsA. Josephs-Olesch M.A.Phone: +49 (0) 52 35/3-41512Fax: +49 (0) 52 35/3-418 25E-mail: a.josephs-olesch@phoenixcontact.comwww.phoenixcontact.com

A library of standardized IEC 61131 functionmodules complying with PLCopen FBS forMotion Control is provided. The entire engi-neering framework for a machine is handledin a single tool, eliminating the need forcumbersome interfaces. Powerful PC Worxfunctions simplify commissioning and pro-vide comprehensive diagnostic support. Thesolution reduces engineering effort and in-creases the clarity of PLC programs in han-

��� Motioncontrol modulesenhance enginee-ring efficiency

Quick-Info 004 �

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Intensive testing has shown that a blockcycle time of less than 250 µs can beachieved on the andronic 2060 during execution of G&M code programs. Becauseposition data can be transferred to thedrive controller 4000 times per second onthe andronid 1000 (250µs SERCOS cycle), itis possible to produce audible music withthe motor following conversion to an G&Mcode program. A one-half degree rotationof the motor shaft corresponds to the trav-el of a loudspeaker membrane.

Despite the fact that precision, high-speed position commands ought to be suf-ficient to produce music of reasonablequality (position information can be trans-ferred 4000 times per second), you actuallyneed 100% speed and acceleration pre-

A number of visitors to the andron GmbHstand at the GrindTec show in Augsburg,Germany were taken aback when theysaw someone holding a watering can nextto the servo motors which were on dis-play. Music that sounded like a gramo-phone was coming out of the wateringcan. However, the message that the teamat the show wanted to convey had noth-ing to do with old recording technology.Using the watering can to amplify thesound was intended to demonstrate theoutstanding performance of a new mo-tion control system family, the CNC andronic 2060, in combination with the andronid 1000 digital servo controller.

control to achieve good audio quality (dueto a small servo lag error). The look-aheadfeature of the andronic 2060 CNC con-troller (min. 2000 G&M codes look-aheadwith no speed limitations) provides a solidbasis for pre-control, and it ensures thatpath commands to the drive amplifier re-main within the desired position, speed,acceleration and jerk rate limits. Pre-con-

trol up to the third-derivative is certainlybetter than having to make continuouscorrections.

This is all very interesting, but what arethe applications for a system in this speedcategory? There is increasing demand forcomplex multi-axis continuous path con-trol which must meet stringent contour ac-curacy or finish quality requirements. Therange of applications ranges from toolgrinding and HSC milling in mold makingto special applications such as high-preci-sion eccentric grinding or production ofprogressive lenses for eyeglasses.

With the SERCOS interface, positioncommands can be sent synchronously to allof the servo drives which are on on the linkbetween the NC and the servo drives. Dueto high clock consistency, every drive canuse fine internal interpolation to perform100% speed and acceleration pre-control.It makes no difference whether data is sup-plied to one drive or sixteen.

The system also offers total noise im-munity, because the data is sent via a fiberoptic link. Experience shows that no faster,more reliable and better synchronized in-terface between controllers and the drivesis available on the market today.

Contact:andron GmbH, WasserburgBernd DeißCNC Development ManagerPhone: +49 (0) 8382/98 55-0Fax: +49 (0) 8382/98 55-50E-mail: info@andron.dewww.andron.de

Send Position Data 4000 Times Per Secondwith SERCOS and “make music” with your servo motor

��� A watering can brings out the “mu-sical talent” of a servo motor which canprocess position information 4000 timesper second using the SERCOS interface. Quick-Info 005 �

Simple Migration to SERCOS IIIWhen the SERCOS standard was intro-duced at the end of 1980s, it set thestandard for real time communicationsin automation applications. SERCOS IIImakes this proven standard available onEthernet.

ta is responsible for the FPGA implementa-tion of the standard, which means that thecompany will be able to provide cus-tomized SERCOS III for use in customer-specific products in addition to the stan-dard FPGA implementation. Master andslave functionality can be combined in anFPGA with additional functions (e.g. µCon-trollers) or application-specific functionsto reduce interface costs.

Automata also supplies master andslave driver software for SERCOS III. The

software is available as “C” code. It is verycompact and has no operating system orplatform dependencies. The basic versionsof the master and slave drivers have all ofthe familiar SERCOS I/II functions. An IPchannel, cross communications and hot-plugging are available as optional modules.Users can also use license-free master driv-ers for Windows XP® and CE.net®.

API compatibility with previous versionswas a major design goal during develop-ment of the driver software. Migration

Automata now offers hardware modulesand driver software for the next generationSERCOS as well. On behalf of IGS, Automa-

Manz Automation AGSteigäckerstraße 5

D-72768 Reutlingenaico@manz-automation.com

robotics

handling

multi axismotion control

nc control

logic control

vision

www.machine-control.com

machine control without limits

I M P R E S S U M

Publishing, concept and design:STROBL GmbH, Ilsfeld-Auenstein, Phone +49 (0)70 26 /9 60 17E-Mail: info@stroblgmbh.de

Responsible for content:Peter Lutz, SERCOS International

Publication does not imply that the solutions described or the designations used are not protected by trademark, patent orintellectual property rights.

from SERCOS I/II to SERCOS III requires minimal effort. The APIis identical, and all of the familiar functions remain un-changed. A PCI card with one or two SERCOS III interfaces isavailable for PC-based platforms. The two interfaces can beoperated independently as master or slave.

The Automata A1 is a control system on a PC platform withintegrated SERCOS III interface and a bus coupler for the WAGO 750 I/O system. The products provide a fast, simple,cost-effective migration path to SERCOS III. They can be usedby OEMs as hardware and software components and by ma-chine manufacturers who create their applications with anIEC-61131 tool for use on a finished controller solution.

Contact:Automata GmbH & Co. KGMr. Christoph MelzerGewerbering 5, D-86510 RiedPhone: +49 (0) 8233 /7916 0Fax: +49 (0) 8233 /7916 99E-mail: info@automata.dewww.automataweb.com

��� Diagram of the A1 control system and the SERCOS III PCI card

Quick-Info 006 �

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Rexroth offers two crucial elements forsuccessful implementation of a distributedsolution: excellent control solutions andopen seamless programming.

This combination gives machine manu-facturers what they need to design fullymodular solutions and meet a wide rangeof customer requirements including fieldbus and process control.

Distributed modules perform high-qual-ity motion control operations indepen-dently of cycle times in the higher-levelcontroller, thus increasing overall systemperformance.

��� High data rates up to 100Mbit/s will support an IP channel for standard Ethernet proto-cols which share the communications medium with cyclic real time data.

SERCOS III: Ethernet-based hard real timeDecentralized solutions require open, high-performance command communications.This is exactly what the non-proprietarySERCOS III real time interface on Rexroth’smotion logic systems provides. The thirdgeneration of the world’s only standardizeddrive interface combines proven real timemechanisms with the physical infrastruc-ture of Ethernet. Obsolescence is not an is-sue for users of existing applications andthe 1.5 million SERCOS nodes which are in-stalled world wide. Machine manufacturerscan exploit additional functionality includ-ing hardware-based synchronization, low-cost CAT5e cabling and enhanced safety.SERCOS III guarantees media redundancywithout controller dependency in synchro-nous operation. A cable fault does not im-pair system availability, and all slave nodesin the ring topology continue to receive thesynchronous clock. Logical addresses areused to access devices in a ring or linetopology regardless of the network config-uration. Hot-plug functionality enablesSERCOS III users to attach additional nodesduring ongoing operation. I/O peripheralsas well as drives can be attached to thenetwork, making SERCOS III a universal bussystem which is suitable for all applica-tions.

The C2C communications profile speci-fies standardized peer-to-peer communi-cations between SERCOS III nodes. Au-tonomous machine segments, which havebeen automated using IndraMotion tech-nology, can be linked and synchronizedacross segments while delivering hard real

time performance. SERCOS III with C2Cfunctionality incorporates two crucial ele-ments of distributed, synchronous real timeoperation:

� distributed peer-to-peer communica-tions at the master level: controllers canexchange data in a distributed environ-ment across machine segment bounda-ries

� peer-to-peer communications at theslave level: I/O and slave nodes can es-tablish a direct bi-directional communi-cations relationship with each other(cross communication). This significant-ly enhances system performance, be-cause the SERCOS master does not haveto fetch and distribute the data. The lo-ad on the controller is reduced.

High data rates up to 100Mbit/s will sup-port an IP channel for standard Ethernetprotocols on the same medium as the cyclicreal time data. Users of this high-perform-ance, future-proof bus enjoy the benefitsof an open communications system whichsupports controllers, drives and peripheralsfrom a wide range of manufacturers. Theversatile SERCOS III IP channel is anothergreat feature for manufacturers and users.No SERCOS master is needed for IP com-munications. Installation, parameterizationand diagnosis of SERCOS III nodes can takeplace without a controller.

In addition, SERCOS safety, which ful-fills requirements up to SIL3 as defined inIEC61508 and which was recently approvedand certified by TÜV Rheinland, has beenavailable since the end of 2005. When it isused as a safety network, SERCOS supportshierarchical and distributed controller ar-chitectures as well as routing. Safety nodeson multiple SERCOS networks can ex-change information in a distributed envi-ronment.

Turnkey technology functions cutdown the engineering effortRexroth currently implements the SERCOSIIII real time solution in its controllers andintelligent drives. The multi-axis IndraMo-tion MLD motion logic solution which isbased on the IndraDrive family of productscombines sophisticated drive functions withflexible IEC 61131-3 compliant sequentialcontrol and process-oriented PLCopen tech-nology modules including cam groups, printmark control, winders and on-the-fly ma-

An Open Door to Modular AutomationRexroth’s IndraMotion controllers join the SERCOS III platform

The idea is simple and compelling. Dis-tributed automated modules replacehighly complex automation solutionswhich are based on a central controller.The new approach reduces engineering,programming and installation complexi-ty. More importantly, machine manu-facturers can reduce manufacturingcosts, and exploiting the advantages ofmodular design. This provides producersthe flexibility to adapt the machine tosuit customer preferences. This is ex-actly the approach Rexroth has takenwith the new motion logic systemswhich are part of its IndraMotion fami-ly. The powerful IndraMotion MLD con-trollers at the drive level and the con-troller-based IndraMotion MLC arebased on the non-proprietary SERCOS IIIstandard, which is the Ethernet-basedversion of the SERCOS interface.

1·2006 11

chining. Customer response to on-boardsafety technology in the drives has beenvery positive. 50% of the IndraDrive unitswhich Rexroth ships are now equipped withthis technology. The safety functions in-cluding safe hold and safe motion havebeen certified for compliance to EN 954-1,Category 3, and the Rexroth “Safety onboard“ solution offers a special feature.With other designs, the machine has to beshut down at least every 8 hours for forceddynamics to detect “sleeping” faults. OnRexroth systems, the tests run automatical-ly online in the background during normaloperation without manual intervention.

The IndraMotion MLD synchronizes upto 8 axes using integrated SERCOS III com-munications in hard real time. Settlingtimes are less than or equal to 50 ms. Onedrive acting as the master configures thedrive ring and uses enhanced SERCOS pa-rameters to communicate with the otherdrives. In CCD (cross communication drive)mode, the master drive acts as a communi-cations gateway for process data which ison route to the slave drives.

Runtime system not dependentof the hardwareThe controller-based IndraMotion MLC version,

which can handle up to 16 intelligent In-draDrives, is the solution of choice when a largenumber of axes are involved. A hardware func-tion module adds SERCOS III functionality to

the rack-size controller. In addition to a largenumber of single and multiple axis functions, thebasic version of the MLC controller offers a com-prehensive library including technology func-

Our motivation: Your drive!

��� The “C2C” communications profile defines standardized peer-to-peer communicationbetween SERCOS III nodes.

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tions for a variety of sub-processes in applica-tions such as packaging machines. On applica-tions with an even higher number of axes, mul-tiple MLC controllers can be linked via SERCOSIII to create a controller cluster.

An IEC 61131-3 compliant IndraLogic PLC isused on some hardware versions. This signifi-cantly streamlines the programming effort, be-cause programs and program segments can bere-used at various automation levels. This

makes it easier to scale the modules to addressa wide range of axis numbers and complexitylevels. The Rexroth IndraWorks engineeringframework makes things even easier for theuser. It includes all of the key software toolsand acts as a single point of engineering. Theplatform which is based on Microsoft’s .NETtechnology provides all of the tools which engi-neers need.

All of the engineering, programming

��� The Rexroth IndraWorks engineering environment includes all of the tools which engi-neers need in a single point of engineering.

and parameterization tools are consolidat-ed in a standardized, intuitive software ar-chitecture. The entry-level version offersdialogue-based parameterization tools fordrive systems. The top of the range versioncovers the complete engineering spec-trum. Engineers are only presented withthe functions which they need for the par-ticular system and the required softwarecomponents such as application-specificwizards or the new cam editor.

Bosch Rexroth AG, part of the BoschGroup, achieved sales of approximately 4.6billion euros in 2005 with over 28,200 em-ployees. Under the brand name of Rexroththe company offers all drive and controltechnologies, from mechanics, hydraulicsand pneumatics through to electronics.Over 500,000 customers worldwide utilizeRexroth’s unique technological know-howto implement their innovative and future-oriented systems and machine concepts.The global player, represented in over 80countries, is an extensive supplier of com-ponents and systems for industrial andfactory automation and mobile applica-tions.

Contact:Bosch Rexroth AGElectric Drives and Controls Business UnitErik DildeyProduct Management+49 (0) 9352/40-5343+49 (0) 9352/403-5343erik.dildey@boschrexroth.de

Reader queries:Phone: +49 (0) 93 52/40-45 52Fax: +49 (0) 93 52/403-45 52E-Mail: susanne.herzlieb@boschrexroth.de

W O R K S H O P S · F A I R S · C O N F E R E N C E S

Presence at trade shows■ Hannover Fair, April 24th -28th 2006, Hall 9, Stand A43,

Hannover/Germany■ Industrial Networks Forum, June 20th – 22nd 2006,

Hall5 5, Stand A14, Zürich Exhibition Center/Switzerland■ PackExpo, October 29th – November 2nd 2006,

McCormick Place, Chicago /USA■ SPS / IPC/ DRIVES, November 28th – 30th 2006, Hall 6,

Stand 110, Nuremberg Exhibition Center/ Germany

Workshops SERCOS goes Ethernet■ Stuttgart, June 28th 2006 and

Hannover, September 14th 2006More information is available at www.sercos.de/workshops

Discussions/Conferences ■ 1st ICOA Open Automation Conference, May 12th 2006,

Shanghai /China■ Automation and Networking Conference, May 17th 2006,

Birmingham/GB■ Industrial Networks Forum, 22.6.2006, Zürich Exhibition

Center/Switzerland■ 4th Industrial Ethernet Congress July 4th – 5th 2006,

Stuttgart /Germany

Quick-Info 007 �

For further information please contact:

SERCOS InternationalPeter LutzPhone +49 (0) 711/ 2 84 57 50E-mail: info@sercos.de

1·2006 13

Keeping in StepStandard WAGO technology links to the WAGO I/O SYSTEM

Most drive systems manufacturersuse the SERCOS fieldbus. At the Han-nover Fair, WAGO will present a cou-pler for the WAGO I/O System, whichfully supports the Sercos III V. 1.20protocol and is compatible with thenew Sercos III I/O profile.

Safety applications can also be deployedas safety functions are an integral part ofthe system. An additional standard Ether-net channel, for PC applications for exam-ple, is also included. With its new SERCOS

III couplers, which will be available towardsthe end of the year, WAGO will once againbe playing a pioneering role. It would behard to find similarly equipped peripheralson the market.

WHY WAGO� Sercos III V. 1.20 protocol� Sercos III I/O profile� extremely compact I/O system� very large selection of I/O terminal blocks

Contact:WAGO Kontakttechnik GmbH & Co. KGHansastraße 27, D-32423 MindenPhone: +49 (0) 571/887-0Fax: +49 (0) 571/887-169E-mail: info@wago.comwww.wago.com

The solution offers very good performanceand excellent connectivity. There is no needfor routing through another fieldbus. A 100Mbit/s transfer rate, full synchronizationwith the motion clock and peer-to-peercommunications give users what they needfor time-critical applications, and the ringtopology provides extra security (redun-dancy). Quick-Info 008 �

��� The WAGO 750 I/O SYSTEM, the compactuniversal fieldbus for industrial applications

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Finding an answer to this question couldapparently save machine producers a sig-nificant amount of money, and ISG, whichis known for its popular and versatile NCand motion kernel, has developed a real-time engineering simulation environmentcalled virtuos which solves the problem.Engineers can use virtuos to install, testand optimize actual CNC or PLC hardwareand software on a virtual machine.

How can you operate a CNC or PLC witha new machine or production systembefore the machine or system is finished?

The virtual machine is created by simu-lating the behavior of an actual machine ona standard PC. Virtuos provides a graphicalmodeling tool which can be used to de-scribe functional, kinematic and dynamicbehavior in a form that is meaningful toengineers, namely as a block or detailedwiring diagram with physical Parameters.Simulation is based on a module librarywhich can be enhanced by C programmersas needed. Linear MATLAB modules can al-so be imported and executed in real timewithout MATLAB. Modules for field anddrive bus nodes, logic, control and drive de-vices, mechanical components, etc. can becombined to simulate the entire machine.The behavior model is linked to an underly-

ing real-time operating system and execut-ed in a cyclic/deterministic environment.Oscilloscope functions in the modeling toolallow users to monitor physical variables inthe model. The cycle time depends on thebus which is used. It can be 0.5 ms for aSERCOS bus for example. The dynamic vari-ables in the model can be calculated usingan faster underlying clock rate.

Within the capability limits of the mod-el, the simulation PC acts just like a realmachine (hardware in the loop simulation)on SERCOS bus or Profibus. 3D visualiza-tion of the total machine, production sys-tem or entire plant is based on existingCAD models from the machine designphase in VRML format. The files are import-

Simulated Real-Time Production Environment

��� Simulation work station: actual control (CNC or PLC), actual drive bus / fieldbus and simulation PC

ed and converted to moveable machine objects using virtuostools. Virtuos is a tool for creating a holistic simulation of ma-chines and production systems. It reduces commissioning timeand supports the machine or system throughout the life cycleincluding sales, product development, commissioning, training,maintenance and service. Because virtuos can be integratedinto PC-based controls (CNC or PLC), uses do not need any ad-ditional equipment to take advantage of its impressive benefits(software in the loop simulation). Real-time capability, holisticengineering modeling and integration in the Real control arethe outstanding features of virtuos.

Contact:ISG - Industrielle Steuerungstechnik GmbHUlrich EgerRosenbergstraße 28, D-70174 StuttgartPhone: +49 (0) 711/2 29 92-31Fax: +49 (0) 711/2 29 92-25E-mail: ulrich.eger@isg-stuttgart.dewww.isg-stuttgart.de

SERCOS III on netXSERCOS III combines the advantages of proven real time mecha-nisms with the benefits of Ethernet communications. Hilscheroffers three slave platforms which are based on netX technology:� CIFX 50-RES PCI card� COMX-CA-RES communications module� netX 100, netX 500 communications controller

The ARM 926 CPU executes the communications portion of theSERCOS III protocol in the netX. The host system has access tothe data and the configuration via a dual port memory.

SERCOS III Features: � real time data� service channel: read, write, standard commands� synchronization� initialization (phase acceleration)� redundancy� topology recognition: ring and line� 2 RJ45 jacks� simple LED-based diagnostics� 3.3 V technology� 100 MBit/s � crossover function

With the netX 100 and netX 500, the application program and the communications can be implemented in a chip, and Hilscher can supply tools and evaluation boards for this pur-pose. netX includes four A/D converters, two encoders and athree-phase PWM for drive applications.

One of the big advantages of netX technology is the factthat the CIFX 50-RES, COMX-CA-RES and netX can be used forPROFINET IO, PowerLink, EtherCAT and EtherNet/IP.

Hilscher will be presenting products for SERCOS III at thejoint stand (A43) in Hall 9 at this year’s Hanover Fair. Productsfor SERCOS III master are in the pipeline.

Contact:Hilscher Gesellschaft für Systemautomation mbHUwe ZeierRheinstraße 15, D-65795 HattersheimPhone: +49 (0) 6190/99 07-0Fax: +49 (0) 6190/99 07-50E-Mail: info@hilscher.comwww.hilscher.com

Quick-Info 009 �

Quick-Info 010 �

16 NEWS

Members of the SERCOS interface e.V. ������� � � � �

Company: Dept:

First Name: Last Name:

Street:

Post/ZIP Code: City:

Phone: Fax:

E-Mail: Internet:

SERCOS InternationalPhone: +49 (0)711/284 57-50 · Fax: +49 (0)711/284 57-55

email: info@sercos.de · Internet: www.sercos.de

Fax: +49 (0) 711-2845755Yes,

I am interested in SERCOS and

SERCOS III. Please send me m

ore information.

FAX RESPONSE CARD■■ Quick-Info 001 · Fax: +49 (0)711/2 84 57-55■■ Quick-Info 002 · Fax: +49 (0)711/2 84 57-55■■ Quick-Info 003 · Fax: +49 (0) 7121/90 00-99■■ Quick-Info 004 · Fax: +49 (0) 52 35/ 3-418 25■■ Quick-Info 005 · Fax: +49 (0) 8382/98 55-50

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■■ Information ■■ Contact

■ ABB Automation Systemswww.abb.comACD Antriebstechnik www.acd-elektronik.deAndronwww.andron.deAutomata www.automata.de

■ G. Bachmann Electronic www.bachmann.atBaumüller Nürnberg www.baumueller.deBeckhoff Industrie Elektronik www.beckhoff.comBerger Lahrwww.berger-lahr.deBosch Rexrothwww.boschrexroth.de

■ Consysta Automation www.contraves-drives.comControl Techniques www.controltechniques.com

■ Danaher Motion www.danaher-motion.de

■ EIVD www.eivd.chELAUwww.elau.deESR Pollmeier www.esr-pollmeier.de

■ Fagor Automation www.fagorautomation.mcc.esFöhrenbach Servodrives www.foehrenbach.com

■ G.D.www.gidi.it

■ Hilscherwww.hilscher.com

■ IBH Automation www.ibh-cnc.comISG Industrielle Steuerungstechnikwww.isg-stuttgart.deISW, Universität Stuttgartwww.isw.uni-stuttgart.de

■ Lust DriveTronics www-lust-drivetronics.de

■ Manz Automation www.manz-automation.com

■ Parker Hannifinwww.parker.comPhoenix Contactwww.phoenixcontact.dePromicon Elektronikwww.promicon.de

■ Rockwell Automationwww.rockwell.com

■ Schleicherwww.schleicher-electronic.comSchneider Automationwww.modicon.deSEW-Eurodrivewww.sew-eurodrive.deSieb & Meyerwww.sieb-meyer.deSMITECwww.smigroup.it

■ Trio Motion Technologywww.triomotion.com

■ Universidad de Zaragozawww.unizar.es

■ Xilinxwww.xilinx.com

SERCOS North AmericaAutomation Intelligencewww.motiononline.comBeckhoff Automation www.beckhoff.comBosch Rexroth Group www.boschrexroth-us.comCAMC, www.camc-online.orgCincinnati Lambwww.cincinnatilamb.comDanaher Motionwww.danahermotion.comIndustrial Indexing Systemswww.iis-servo.comMDSIwww.mdsi2.com

National Instrumentswww.ni.comRobotic Systems Integrationwww.roboticsys.comRockwell Automationwww.allen-bradley.comSamsungwww.samsungelectronics.comUniversity of Akron www.uakron.eduYaskawawww.yaskawa.com

SERCOS JapanAmadawww.amada.comBosch Rexroth Automationwww.boschrexroth.co.jpDigital Electronicswww.digitalelectronics.comHiratawww.hirata.comHonda Engineeringwww.honda.comMori Seikiwww.moriseiki.co.jpNippon Pulse Motorwww.nipponpulse.comNissan Motorwww.nissan.co.jp

Okumawww.okuma.comOptonwww.opton.co.jpSanyo Denkiwww.sanyodenki.jpShiga Yamashitawww.shigayamashita.co.jpToshiba Machinewww.toshiba-machine.co.jpToyoda Machine Workswww.jtekt.co.jpYaskawa Electricwww.yaskawa.co.jp