The Ethernet Fieldbus.

© EtherCAT Technology Group

Ethernet for Real-Time Communication

Oct 2014

Main Performance Problems:

1. Bandwidth Utilization

2. Stack Delays

3. Switch Delays

EtherCAT Introduction and Overview


Ethernet Frame Payload: min. 46 Bytes

1. Industrial Ethernet Bandwidth Utilization

Oct 2014

Minimum Ethernet Frame: 84 BytesExample: with 4 Bytes Process Data (32 I/O): 4/84 =

4,75% Application Data Ratio

Ethernet HDR

14 Bytes

Process

Data

Process Data, e.g. 1..4 Bytes

FCS CRC

4 B.

Interpacket Gap

14 Bytes

≥ 84 Bytes, regardless which Protocol

Ethernet HDR UDPHDR

Ethernet/IPCIP HDR

14 Bytes 20 Bytes 8 Bytes 20 Bytes

Process

Data

Payload e.g.4 Bytes

FCS CRC

4 B.

IP HDR Interpacket Gap

14 Bytes

≥ 84 Bytes, e.g. with



Industrial Ethernet Bandwidth Utilization

Oct 2014 EtherCAT Introduction and Overview


IP

2. Industrial Ethernet Stack Delays

Oct 2014

Industrial Ethernet

Protocol Stacks are

BIG

IP

TCP UDPEncapsulation

CIP Message Encapsulation

Implicit Msg

Explicit Msg

CIP Network & Transport

Device Profile Application Objects

(e.g. I/O)

Ethernet MAC

I/O Ports

Processing then

needs

TIMEEtherCAT Introduction and Overview


Stack Performance Comparison (I)

• Stack performances of the Ethernet technologies differ substantially, due to the different complexity of the stacks

• Softing, a German specialist for field bus technology published* the following comparison of the stack delay times:

• All three protocols were implemented on the same hardware (interface board with FPGA + Softcore CPU) and by the same team, so they are indeed comparable

Stack Time Profinet IO Ethernet/IP EtherCATAverage 0.58 ms 1.89 ms 0.11 msMax: 0.74 ms 2.96 ms 0.18 msMin: 0.54 ms 1.23 ms 0.05 ms

* Source: „Einer für alle; Flexible Real-Time-Ethernet Anschaltung mit FPGA“, messtec drives Automation Real-Time Ethernet Sonderheft 2010, by Frank Iwanitz,

Business Development Manager Real-Time Ethernet at Softing GmbH, Munich, GermanyOct 2014 EtherCAT Introduction and Overview


0 0,5 1 1,5 2 2,5 3

Profinet IO

Ethernet/IP

EtherCAT

EtherCAT (SSC)

Min

Max

Average

Stack Performance Comparison (II)

• Softing stack performance data shown in a diagram, + Beckhoff EtherCAT Slave Stack Code (SSC*)

* SSC Stack Delay time measured on EL9800 EtherCAT Evaluation Kitusing the 10 Mhz Serial Process Data Interface and a 40 MHz

16 Bit PIC CPU; 2 Byte Output Data, min 15µs, max 20µsOct 2014 EtherCAT Introduction and Overview


3. Industrial Ethernet Switch Delays

Oct 2014

Switch Buffer Delay: Unpredicable „by Nature“

Buffer delay depends on buffer load @ frame arrival. QoS (Quality of Service) eases the pain byintroducing multiple priorities (and buffers), but does not resolve the issue.



3. Industrial Ethernet Switch Delays

Oct 2014

Almost all Switches use „Store & Forward“ Line Topology means cascaded Switches

Substantial accumulated delay and jitter evenwithout buffer delay (if switches are idle).

Typical Store & Forward Delay per switch: Frame length (7…122µs) + 3µs.Example: Full frame, 20 nodes in line topology: 2,5 ms

Internal SwitchesInternalSwitchSwitchSwitch

InternalSwitch



Ethernet for Real-Time Communication?

Oct 2014

Quote: „RT in Profinet provides similarReal-Time properties like Profibus“

Source: Profibus Internationalhttp://www.profibus.org.pl/index.php?option=com_docman&task=doc_view&gid=28

Quote: „When tested up to 80 percent network bandwidth utilization, using both managed and unmanaged switches, the system managed 16 position configured axes with an 8 ms coarse update rate. “

Source: Rockwell Automation, White Paper: “Scalability-The Best Approach to Change”, Aug 2012

http://literature.rockwellautomation.com/idc/groups/literature/documents/wp/ia-wp002_-en-p.pdf

20ms

8ms



EtherCAT is:

- Faster

- Industrial Ethernet

- Flexible Topology

- Easier to configure

- Cost effective

- Easier to implement

- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile

EtherCAT: Performance Breakthrough

Oct 2014

© h

arve

pino

-Fot

olia

.com



EtherCAT is:

- Faster


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile

EtherCAT: highest Performance

The fastest Industrial Ethernet Technology

• 1000 distributed digital I/O in 30µs

• 100 Servo-Axis every 100 µs

• EtherCAT directly to the I/O Slice, no Sub-Bus

• Optimal Usage of the Standard Ethernet Port in the Controls, no extra hardware

• Reason for this unique performance:The EtherCAT Functional Principle (Ethernet on the Fly)


EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Functional Principle: Ethernet „on the fly“

• 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

Car27

Oct 2014


Functional Principle: Ethernet “on the Fly“


• Efficient: Typically only one Ethernet Frame per Cycle• Ideal Bandwidth Utilization for maximum Performance

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile



Slave Device

EtherCAT Slave Controller

Slave Device


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

(1 Bit…60 Kbyte, if needed using several frames)– Compilation of process data can change in each cycle, e.g.

ultra short cycle time for axis, and longer cycles for I/O update possible

– in addition asynchronous, event triggered communication

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile



• 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

Master

Ethernet Header ECAT HDR CRCPLC Data 1

HD

R1

NC Data

HD

R2

PLC Data 2

HD

R 2

Oct 2014


EtherCAT resolves the Performance Problems

Oct 2014

Main Performance Problems:

1. Bandwidth Utilization

2. Stack Delays

3. Switch Delays

Resolved!

Resolved!

Resolved!


EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT - The Ethernet Fieldbus.

• EtherCAT is real time down to the I/O level• No underlying sub-systems any more

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile



• Other technologies need local I/O cycles + gateways

Fiel

dbus

C

ontro

ller

Mas

ter f

or L

ocal

E

xten

sion

Bus

CPU

RAM

Flash

Driv

er

I/O I/O I/O I/O

Fiel

dbus

C

ontro

ller

I/OCPU

RAM

Flash

Driv

er

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile



• EtherCAT: Real time down to the I/O

Eth

erC

ATC

ontro

ller

Eth

erC

ATC

ontro

ller

Driv

er

Eth

erC

ATC

ontro

ller

Eth

erC

ATC

ontro

ller

Eth

erC

ATC

ontro

ller

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile



• 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!

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


‘Slow’ Control Systems benefit, too

Reaction time with legacy fieldbus I/O:

Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus CycleBus CycleBus Cycle

Tmpd

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

PLC Task OI PLC Task OI PLC Task OI PLC Task OI PLC TaskI

Input(worst case)

Output

best case reaction time

Tmpd: Master Processing Delay

TI/O: Local I/O Update Time (local Extension Bus + Firmware)

worst case reaction time

Input(best case)

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile



System Architecture with EtherCAT:

Tmpd

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


on underlying extension bus any more

no dedicated Master Device any more

Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus CycleBus CycleBus Cycle

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile



System Architecture with EtherCAT:


TDMA = Time for Data Transfer from/to Ethernet Controller viaDirect Memory Access: neglectible

Oct 2014

TDMA (NIC)

TEtherCAT Cycle

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile



Reaction Time with EtherCAT:

• 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


Input(worst case)

Output

worst case

Input(best case)

best case

EtherCAT Bus Cycle

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Control System, e.g. IPC

Fieldbus: requires Mapping in Control System

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

Feldbus Scanner/Master

logi

cal p

roce

ss im

ages

PLC Data

Data n

NC Data

DPRAMnode 1

node 2

node 3

node 4

node 1

node 2

node 3

node 4

Mapping

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Fieldbus: requires Mapping in Control System

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

Control System, e.g. PLCFeldbus Scanner/

Master

logi

cal p

roce

ss im

age

DPRAMnode 1

node 2

node 3

node 4

node 1

node 2

node 3

node 4

Mapping

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT: Mapping moved into Slave Devices

• Control System is unburdened, master becomes very simple

• Data is transmitted according to the application requirements: extremely fast, flexibly and efficiently

PLC Data NC Data Data n Ethernet

logi

cal p

roce

ss im

ages

up

to 4

GB

yte

HD

R 1

HD

R 2

HD

R 3

Datagram 1 Datagram 2 Datagram n

PLC Data

Data n

NC Data

Master

Ethernet Header ECATHDR

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile

Synchronization


Synchronization

Synchronization

Sou

rce:

kon

flikt

y.pl

Timing – Synchronous with Frame


PositionSignal

= x

SamplePoint

Master Jitter

108 µs 94 µs 101 µs 104 µs

Velocity= x‘

100 µs Cycle Time

Sampling error because of jitter

~4 µs

equidistant

EtherCATIn Calc. Out

A/D

D/AIn

D/A

Calc. Out In Calc. Out InIn

A/D A/D

Calc. Out

D/A D/A

A/D

D/A

Out

Gradiant = velocity

Not in sync with IN

A/D

Error due to sample deviation

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile

Timing – Synchronous with Frame

Problems of this approach• I/O signal timing depends on Master• Modern (multicore) CPU systems

will always jitter in the range of 1.. 5 µs

Measuring error due to sample deviation:May need special Hardware in the Master

Solution• Timing with Distributed Clock (DC) System


EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT Propagation Delay Measurement (1)

• EtherCAT Node measures time difference between leaving and returning frame

EtherCAT FrameProcessing Direction

EtherCAT FrameForwarding Direction

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


IPC

EtherCAT Propagation Delay Measurement (2)

• EtherCAT Node measures time difference between leaving and returning frame

Master

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Distributed Clocks

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

M∆tIPC

SMaster

S

S S S S

S

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Distributed Clocks

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

Jitter: ~ +/-20ns

Simultaneousness: ~15 ns

Interrupt Node 1

Interrupt Node 300

Oct 2014

Synchronous with Distributed Clocks


SamplePoint

100 µs Cycle Time

100 µs 100 µs 100 µs 100 µs

Velocity= x‘

DC Sync

PositionSignal

= x

EtherCATIn Calc. Out

Sync In

In

A/DA/D

D/A

Calc. Out In

A/D

D/A

Calc. Out In

A/D

D/A

Sync Out

Calc. Out

D/A

equidistant

No sampling

Error

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


• EtherCAT networks can be coupled via EtherCAT Bridge• Bridge provides hardware synchronization of several networks

Synchronization of multiple Networks

Oct 2014

SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE


SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE

SLAVE SLAVE SLAVE

SLAVE

SLAVE

SLAVE

MASTER1

MASTER2

MASTER3

1

2

3

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


• EtherCAT networks can be coupled via EtherCAT Bridge• Bridge provides hardware synchronization of several networks

Synchronization of multiple Networks

Oct 2014

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE



SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE

SLAVE SLAVE SLAVE

1

MASTER1

MASTER2

MASTER3

1

2

3

1

SYNCHRONOUS

SYNCHRONOUS

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


External Clock Synchronization: IEEE 1588

• Switchport with integrated IEEE 1588 Boundary Clock

MS

S

S S S S

Boundary Clock

S

Master

IEEE 1588

Grandmaster

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT is Industrial Ethernet!

• fully transparent for TCP/IP• all Internet technologies (HTTP, FTP, Webserver,…)

available without restricting the real time capabilities!

EtherCAT Slave Device

EtherCAT MAC / DLL

TCP UDP

EthernetApplication

IP AcyclicData

Process DataMailbox

Real TimeApplication

Ethernet PHYEthernet PHY

Standard TCP/IP Stack

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT is Industrial Ethernet!

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

Virtual Ethernet Switch

FunctionalitySwitchport

Master

Webserver

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT Switchport

Ethernet MAC PHY

Switchport: Any Ethernet Protocol

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

EtherCAT MAC / DLL PHYPHY

µC

Fragmentation

TX1TX2TX3

TX

TX2TX3TX1

RX RX4RX1 RX2 RX3

Process DataMailbox

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Vertical Integration (1)

…via Switchport

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

Switchport

Master

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Vertical Integration (2)

...via 2. Ethernet Port

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

2nd Ethernet Port

Master

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT wiring is more flexible

• Standard Ethernet Topology: Star

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile



• Flexible topologies – arbitrarily extendable– 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

Master

Line

Drop LineStar/Tree

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT Extra Large System Test

10.056EtherCAT Nodes

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile



• Ethernet Signal Variants of EtherCAT:– 100BASE-TX (up to 100 m between 2 nodes)– 100BASE-FX (up to 20 km between 2 nodes (single mode fibre) )– LVDS (for modular devices)

• Any number of physical layer changes allowed

Ethernet on LVDS* physical layer:for modular devices

LVDS*

20 km

100 m

Ethernet on 100BASE-FX (fibre optics)up to 20 km

Ethernet on 100BASE-TX up to 100 m

with transformer coupling

*LVDS: Low Voltage Differential Signaling according to ANSI/TIA/EIA-644,also used in IEEE 802.3ae (10 Gigabit Ethernet)

Master

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT instead of PCI

• Protection of your investment• Smooth migration path from legacy fieldbus to EtherCAT• Seamless integration of existing fieldbus devices, e.g.:– AS-Interface– BACnet MS/TP– CANopen– CC-Link– ControlNet– DeviceNet– Ethernet/IP– FIPIO– Interbus– IO-Link– Lightbus– LonWorks– Modbus Plus, RTU, TCP– PROFIBUS– PROFINET IO– …

• Maximum system expandability with low cost fieldbus gateways

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT instead of PCI

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

• Nevertheless maximum expandability

EtherCAT

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT is easier to configure

• Topology:

• Automatic Topology Expected/Actual Comparison

• Diagnosis:

• Diagnosis with exact Localization

M

Every nodeconstantlymonitors

checksum

Bit errors are detected and

localized

Even Timing Errors (e.g. Time Window for Actual Values missed) are detected and stored locally in the chip

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT is easier to configure

• Network planning:– Performance independent of:

• Slave implementation (no Stacks involved in Process Data Communication)

• Topology (no Switches/Hubs)

• Addressing– No manual address setting required– No IP- or MAC-Address Handling Required– Addresses can be assigned automatically – Addresses can be kept

• no new addressing if nodes are added

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT is lower costs (1): Engineering

• 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

• Implementation / Tools:– Standard Network Monitor Tools,

e.g. MS Network Monitor or Wireshark: free of charge– Parser Software: free of charge

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT is lower costs (2): Hardware

• Master:– 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 + lots of memory needed

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

32 BitµC

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT is easier to implement

• Slave Implementation:– 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

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile

New EtherCAT Slave Controller Chips

EtherCAT Introduction and OverviewOct 2014

ESC10/20:Altera® Cyclone™-I

IP-Core forAltera®

Cyclone™-II

Beckhoff ®

ET1100

Beckhoff ®

ET1200Hilscher

netX® 100/500

HilschernetX® 50

IP-CoreXilinx®

Spartan™-3

IP-Core forAltera®

Cyclone™-III

IP-Core forXilinx®

Spartan™-6IP-Core for

Altera®

Stratix™-IV

IP-Core forAltera®

Cyclone™-IV

IP-Core for Xilinx® Kintex™-7

IP-Core for Altera® Stratix™-V

IP-Core for FPGA ofIntel® Atom™ E6x5C

TI's Sitara™

µP family

HilschernetX® 51/52/6

IP-Core forXilinx®

Artix™-7 + Zync™

RenesasR-IN32M3-EC

AnybusNP40

InnovasicFido5000

IP-Core forAltera® Cyclone™-V

March 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT is easier to implement: Master

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

Realtime

Realtime

optional; for online functionality(e.g. scanning for devices)

.xml.xml.xml

EtherCAT Slave Information (ESI) Files

EtherCATConfiguration Tool

.xml

EtherCAT Network Information (ENI) File

Application

Process Data ImageParser Mailbox

Services

EtherCAT Master Driver

Network Driver

Standard Ethernet MAC

acycliccommands

initcyclic

commands

req. resp.

Ethernet Frames

Process Data (PD) Image description

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT is an open technology

• Protocol is disclosed completely:– 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

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT in IEC 61800-7

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

IEC 61800-7-304IEC 61800-7-301

Mapping toCANopen**

Mapping toEtherCAT

Mapping toEPL

Mapping toSERCOS I/II

Mapping toSERCOS III

Mapping toEtherCAT

IEC 61800-7-201:ProfileCiA402

IEC 61800-7-202:Profile

CIP Motion


PROFIdrive


SERCOS*

Annex A:Mapping to

CiA402

Annex B:Mapping to

CIP

Annex C:Mapping toPROFIdrive

Annex D:Mapping toSERCOS*

IEC 61800-7-1: Interface Definition

IEC 61800-7-200: Profile Specifications

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

B...

C...

*SERCOS interface™ is a trademark of SI e.V.**CANopen™ is a trademark of CAN in Automation e.V.

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT Device

DEVICE Application

EtherCAT Architecture + Device Profiles


Process DataMailbox

Ethernet Physical Layer

IP

TCP UDP

File Access

Ethernet

FoE EoE SoE CoE CoE/SoE

File System,Bootloader

HTTP, FTP,…

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

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

ATMDT

PDOMap-ping

The SERCOS* Standard

IDN

Service Channel

Process DataThe CANopen**Standard

SDO

Object Dictionary

*SERCOS interface™ is a trademark of SI e.V.**CANopen™ is a trademark of CAN in Automation e.V.

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile

EtherCAT Master OS Technology Variety

Oct 2014

• EtherCAT Masters implemented on wide range of RTOS*– eCos– FreeRTOS™– INTEGRITY®– INtime®– Linux (with RT-Preempt)– Microware® OS-9– MQXTM

– On Time RTOS-32– Oracle® Solaris (SunOS)– PikeOS– Proconos OS– QNX®– RMOS– ROS (Robot Operating System)– RTKernel– RTLinux– RTX– RTXC– RTAI-Linux– SCALE-RT– TKernel– VxWin® + CeWin®+ RTOS32Win®+LxWin– VxWorks®– Windows® CE– Windows® Embedded with IntervalZero RTX– Windows® XP/XPE with CoDeSys SP RTE– Windows® XPE/WES7/WES8 with TwinCAT RT-Extension– Windows® NT/2000/XP/Vista/7/8 with TwinCAT RT-Extension– XOberon– XENOMAI Linux– µC/OS-IITM

– µITRON*as of March 2014EtherCAT Introduction and Overview

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT is an open technology

• Foundation: November 2003• Tasks: Support, Advancement and Promotion of

EtherCAT• The worlds largest fieldbus organization • More than 2900* member companies from

58 countries in 6 continents:– Device Manufacturers– End Users– Technology Providers

• Membership is open to everybody

*as of Oct 2014

Oct 2014


ETG Team Worldwide


Dr. Guido Beckmann, GER

Andrea Bock, GER

Bin (Beryl) Fan, CHN

Oliver Fels,GER

Florian Hammel,GER

Florian Häfele,GER

Rainer Hoffmann,GER

Liliane Hügel,GER

Dr. YanQiang Liu,CHN

Prof Dr. Yong-SeonMoon, KOR

Masanori Obata,JPN

Thomas Rettig,GER

Martin Rostan,GER

Joseph P. Stubbs,USA

Key Yoo,KOR

Makiko Hori,JPN

Fengjiao (Jojo) FuCHN

Geng Cheng,CHN

Christiane Heubusch,GER

Michele Beers,USA

Burkart Lingner,GER

Dr. Karl Weber,GER

Alessandro Figini,GER

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT Technology Group Structure

Oct 2014


0

500

1000

1500

2000

2500

3000

Nov

‐03

Feb‐04

May‐04

Aug‐04

Nov

‐04

Feb‐05

May‐05

Aug‐05

Nov

‐05

Feb‐06

May‐06

Aug‐06

Nov

‐06

Feb‐07

May‐07

Aug‐07

Nov

‐07

Feb‐08

May‐08

Aug‐08

Nov

‐08

Feb‐09

May‐09

Aug‐09

Nov

‐09

Feb‐10

May‐10

Aug‐10

Nov

‐10

Feb‐10

May‐11

Aug‐11

Nov

‐11

Feb‐12

May‐12

Aug‐12

Nov

‐12

Feb‐13

May‐13

Aug‐13

Nov

‐13

Feb‐14

May‐14

Aug‐14

ETG Membership Development


Aug 2013 – Aug 2014:+ 407

Aug 2013 – Aug 2014:+ 407

As of October 2014: 2950 Members


10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Germany Europe w/o Germany America Asia ROW

ETG Membership Distribution


EtherCAT Technology Group:

a truly Global Organization

Germany

Europew/o Germany

America

Asia

33members

~ 2900members

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile

Members from 58* Countries, 6 Continents

Oct 2014 *as of Oct 2014EtherCAT Introduction and Overview

Austria

Hungary

Spain

Columbia

United Kingdom

Liechtenstein

India

Sweden

Czech Rep

USA

Netherlands

Belarus

Israel

Switzerland

Denmark

Russia

BelgiumAustralia

Korea

Ukraine

Germany

China

Slovenia

Japan

Turkey

FranceCanada

Slovakia

Italy

Taiwan

Finland

Singapore

Brazil

South AfricaSerbia

Norway

Greece

Poland

Thailand

Portugal RomaniaMexico

Bosnia andHerzegovina

Lithuania

New Zealand

Croatia

Bulgaria

Lebanon

Iran

Argentina

Ireland

Latvia

San Marino

Luxemburg Macedonia

Malta Qatar

Malaysia

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


How many members invest in the technology?

Oct 2014

• One indicator: implementation kits sold. • Until now, Beckhoff alone has sold over 1800 kits

(80% slave kits, 20%(!) master kits)• + there are slave implementation kits + master stacks from

many other vendors*, such as– Beck IPC– Deutschmann– EBV Elektronik– Hilscher– HMS anybus– IXXAT Automation– koenig-pa– port– Nagano OKI– Red one technologies– Soft Servo Systems– STMicroelectronics– Terasic Technologies– TESSERA– Xilinx – …

– acontis– esd– igH– IXXAT Automation– Kithara– Koenig-pa– MicroSys Electronics– Profimatics– Sybera– …

* Only those listed that have entered their offering in the EtherCAT Product Guide atwww.ethercat.org/products

Slav

e Mas

ter

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT: Largest Product Selection

I/O, Controller, HMI, Servo Drives, Variable Speed DrivesSensors, Slave + Master Development Kits

Control Panels, Hydraulic Valves and Pneumatic Valves,

…

Oct 2014

Official EtherCAT Product Guide:www.ethercat.org/products

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Conformance and Interoperability

• Conformance and interoperability are very important factors for the success of a communication technology– Conformity to the specification is an obligation to all users of

the EtherCAT technology– Therefore the EtherCAT Conformance Test Tool (CTT) is

used– Test Cases for the CTT are provided by the Working Group

„Conformance“ within the ETG community– The EtherCAT Conformance Test proves conformance

with issuing a certificate after passing the test at an official EtherCAT Test Center (ETC)

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Safety over EtherCAT

Oct 2014

Material feedingMuting

Two-Hand control

Protection of workspacee.g. with Laser scanner

Safety guard

Door guardingwith

Interlocking

Safely-limited Position / Speed

Setup /Maintenance

OperatorDiagnosis

Emergency stop

Modern Machine Safety Concepts


EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Safety over EtherCAT: Features

• 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 EtherCATTechnology Group (ETG).

• The protocol is developed according to IEC 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)

• Certified products with Safety over EtherCAT are available since 2005

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Safety over EtherCAT: Features (3)

• 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

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Safety over EtherCAT: Routing

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

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Safety over EtherCAT: Software Architecture

Oct 2014

EtherCAT is used as a "black channel"It contains safety and standard information

Device 1

Safety overEtherCATProtocol

Safety Application

StandardApplication

Safetyover

EtherCAT

EtherCATDLL and AL

EtherCAT Telegram

Safety data container (FSoE Frame)

Device 2

Safety overEtherCATProtocol

Safety Application

StandardApplication

EtherCAT Communication Interface

EtherCAT Communication Interface

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Safety over EtherCAT: Hardware Architecture

Oct 2014

• One channel communication system According to model A of IEC 61784-3 Annex A

Controller ASafety

Protocol

Controller BSafety

Protocol

Device

Controller ASafety

Protocol

Controller BSafety

Protocol

RJ4

5

PHY

Mag

netic

sPHY

Magnetics

RJ45 EtherCAT

Slave ControllerIn

PortOutPort

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Safety over EtherCAT: Frame Structure

Oct 2014

CMD SafeData 0 CRC_0 Safe

Data 1 CRC_1 SafeData n CRC_n Conn ID

EtherCAT FrameEthernet Header

EtherCATHeader

1. Data-gram FSC2. Data-

gram

Device 1

EtherCAT Communication interface

FSoE Protocol

Safety Application

StandardApplication

Process Data

HD

R

FSoE

FSoE Frame

FSoE Frame

The FSoE Frame is embedded 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 is changed. Every 2 Byte SafeData are checked by a 2 Byte CRCThe maximum number of SafeData is therefore not restricted by the protocol.

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Safety over EtherCAT: Safety Measures

MeasureError

Sequence Number Watchdog Connection

IDCRC

Calculation

Unintended repetition

Loss

Insertion

Incorrect sequence

Corruption

Unacceptable delay

Masquerade

Repeating memory errors in Switches

Incorrect forwarding between segments

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Safety over EtherCAT: Advantages

• Fully integrated solution:– 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

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile

Safety over EtherCAT – Open Solution

Companies with Safety over EtherCAT interface*

• FSoE Master– Baumüller, Beckhoff, Kuka, NUM, Sick, OMRON

• FSoE Drives– AMK, Baumüller, Beckhoff, Kollmorgen, Kuka, Lenze, NUM, LTi,

Stöber,

• Sensors, Safety I/Os– Beckhoff, Baumüller, BBH, NUM, OMRON, Sick, TR electronic

• Stack Provider– 3S (CodeSys), Ixxat

• Several additional machine manufacturer using Safety over EtherCAT internally in their devices:Printing machines, Tooling machines, NC Controller

Oct 2014 *available products or product announcementsEtherCAT Introduction and Overview

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Safety over EtherCAT: Implementation Example

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

Oct 2014

Standard PLC

Safety Inputs

Safety Logic

Safety Outputs

Safety Drives

Safety Sensors

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Slave N

Without Redundancy: Normal Operation

EtherCAT Master

MAC 1

RX TX

TX UnitTX

RX UnitRX

Slave 2

RX TX

RXTX

Slave 1

RX TX

RXTX

RX TX

RXTX

... ...

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Slave 2

RX TX

RXTX

Slave 1

RX TX

RXTX

EtherCAT Master

MAC 1

RX Unit TX Unit

Without Redundancy: Cable Failure

RX TX

TXRX

Slave N

RX TX

RXTX...

Slave N-1

RX TX

RXTX...

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Slave 2

RX TX

RXTX

Slave 1

RX TX

RXTX

EtherCAT Master

MAC 1

RX Unit TX Unit

Without Redundancy: Node or Cable Failure

RX TX

TXRX

Slave N

RX TX

RXTX...

Slave N-1

RX TX

RXTX...

Slave N-2

RX TX

RXTX

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Slave 2

RX TX

RXTX

Slave 1

RX TX

RXTX

Slave N

RX TX

RXTX...

EtherCAT Master

MAC 1 MAC 2

RX Unit TX Unit

With Redundancy: Normal Operation

...

RX TX RX TX

TXRX

Only 2nd Ethernet

Port required –no special

Interface Card

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Slave N

RX TX

RXTX

Slave N-1

RX TX

RXTX

Slave 2

RX TX

RXTX

Slave 1

RX TX

RXTX...

EtherCAT Master

MAC 1 MAC 2

With Redundancy: Cable Failure

RX TX RX TX

RX Unit TX UnitTXRX

...

Switchover time: < 15µsOct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


Slave N

RX TX

RXTX

Slave N-1

RX TX

RXTX

Slave 2

RX TX

RXTX

Slave 1

RX TX

RXTX...

EtherCAT Master

MAC 1 MAC 2

With Redundancy: Node or Cable Failure

RX TX RX TX

RX Unit TX UnitTXRX

...

Slave N-2

RX TX

RXTX

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT: High availability

• Cabling redundancy– 2nd Ethernet port needed on master side only

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

Master

Hot Connect Group

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT: versatile system architecture

• Master to Slave• Slave to Slave• Master to Master

Switchports

Gateways

M2M

S2S

M2S

M2S

Master

Master

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT Automation Protocol

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT and Wireless Communication

• Wireless Devices can be connected via Switchport• Wireless segment does not slow down EtherCAT

communication• Protocol: EtherCAT Automation Protocol (EAP)– Pushed and/or Polled Process Data Exchange

• Wireless Segment transparent for Master Device

Switchport

e.g. RFID Reader

Oct 2014

Master

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile


EtherCAT and Wireless Communication

• Wireless Devices can be connected via Switchport• Wireless segment does not slow down EtherCAT

communication• Protocol: EtherCAT Automation Protocol (EAP)– Pushed and/or Polled Process Data Exchange

• Wireless Segment transparent for Master Device

SwitchportMaster

e.g. Card or RFID Reader

Master with or without control

application

Master sees process data of

underlying system as local I/O data

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile



Why go for something slower, just because it is more

expensive?

Oct 2014

EtherCAT is:

- Faster

- Synchronization


- Flexible Topology


- Cost effective


- Well proven

- Open

- Conformance

- Safety

- Redundancy

- Versatile



Please visitwww.ethercat.org

for more information

EtherCAT Technology GroupETG Headquarters

Ostendstr. 19690482 Nuremberg, Germany

Phone: +49 911 54056 [email protected]

Oct 2014

The Ethernet Fieldbus. - EtherCAT Technology...

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