21.04.23 1
ITW: EtherCAT
21.04.23 2
ITW: EtherCAT
Basics → Michael, Martin
Diagnostics → Josef
Hands on → Martin, Itzko
ITW 2009 - EtherCAT
EtherCAT is faster!
Bandwidth Usage of Ethernet for I/O and Drives:
Ethernet Header Data: ≥46 Bytes CRC I/O
Request with output data
User data:e.g. 2Bit…6Byte
4 Bytes22 Bytes
IPG
12 Bytes
I/OResponse with input data
Ethernet Header Data: ≥46 Bytes CRC IPG
node reaction
time
Ethernet Frame: ≥ 84 Bytes (incl. Preamble + IPG Inter-Packet Gap)
- with 4 Byte input + 4 Byte output per node:
- 4,75% application data ratio at 0µs reaction time/node
- 1,9% application data ratio at 10µs reaction time/node
ITW 2009 - EtherCAT
Difference EtherCAT – Real Time Ethernet
TCP/IP(original Windows Stack)
I/O System
NDIS Protocol Process Images
NDIS MiniportNDIS Miniport TwinCAT I/O TwinCAT I/O
EthernetController
EthernetController
e.g. Profibus Master
TwinCAT I/O with Y-Driver
similar core technology on the Master
Windows TwinCAT
ITW 2009 - EtherCAT
Difference EtherCAT – Real Time Ethernet
Real Time Ethernet EtherCAT
Switch Delay:10..300 µs depends on Switch and data size
Different Technology on the Slave site –> no switch
Topic Today
ITW 2009 - EtherCAT
Slave Device
EtherCAT Slave Controller
Slave Device
EtherCAT Slave Controller
Functional Principle: Ethernet „on the Fly“
Process data is extracted and inserted on the fly
Process data size per slave 1 Bit…60 Kbyte
In addition asynchronous event triggered communication
ITW 2009 - EtherCAT
Functional Principle: Ethernet „on the Fly“
Minimal protocol overhead via implicit addressing
Advantages:
Optimized telegram structure for decentralized I/O
Communication completely in hardware: maximum performance
no switches needed if only EtherCAT devices in the network
Outstanding diagnostic features
Ethernet-Compatibility maintained
DVI
IPC
....
Ethernet HDR EH Data CRCFH WKC
ITW 2009 - EtherCAT
Demo: Working Counter
Demo
WC Konfiguration
Example: EL2008 disconnected WC Alarm
ITW 2009 - EtherCAT
Demo: Working Counter
Demo
WC Konfiguration
WC=0 because of expected WC Value
ITW 2009 - EtherCAT
Demo: Working Counter
Demo
WC Konfiguration
WC=1 because of msising Slave
ITW 2009 - EtherCAT
Functional Principle: Ethernet „on the Fly“
Minimal protocol overhead via implicit addressing
DVI
IPC
....
Ethernet HDR EH Data CRCFH
WK
C
EH Data WK
C
EH Data WK
C
Diagnostic areas on one cable with Sync Units
ITW 2009 - EtherCAT
Demo: Sync Unit
Demo
Sync Unit Konfiguration
Example: disconnected EL3102 influences EL1008
ITW 2009 - EtherCAT
Demo: Sync Unit
Demo
Sync Unit Konfiguration
Group with EL3102 disconnected no valid data from EL1008!
ITW 2009 - EtherCAT
Demo: Sync Unit
Demo
Sync Unit Konfiguration
give own SyncUnit for EL1008 and EL3102
ITW 2009 - EtherCAT
Demo: Framesize & MTU
Demo
ITW 2009 - EtherCAT
EtherCAT Performance
* Source: Ethernet Powerlink Spec V 2.0, App.3
40 Axis (each 20 Byte Input- and Output-Data)
50 I/O Station with a total of 560 EtherCAT Bus Terminals
2000 Digital + 200 Analog I/O, Bus Length 500 m
Performance EtherCAT: Update-Time 276µs at 44% Bus Load, Telegram Length 122µs
56% bandwidth remaining,
e.g. for TP/IP
ITW 2009 - EtherCAT
Topology – Line Topology
DVI
IPC
....
Arbitrary number of devices in a line
Up to 65.535 devices
EK1100EtherCAT Coupler
EK1110EtherCAT Extension
ITW 2009 - EtherCAT
Topology – Bus
DVI
IPC
....
ITW 2009 - EtherCAT
21.04.23 19
EtherCAT Cables: ZB9010/20, ZK1090-9191-00xx
ZB9010/ZB9020 ZB9010 Industrial EtherCAT / Ethernet cable, standard cable, CAT 5e, 4 wires
ZB9020 Industrial EtherCAT / Ethernet cable, trailing cable, CAT 5e, 4 wires
ZK1090-9191-0xxx pre-assembled Ethernet / EtherCAT cables with
RJ 45 plug enables fast, easy wiring inside the control cabinet for short distances on the machine PUR cables in robust industrial quality distinguish themselves from office cables by both their
mechanical and their EMC characteristics 0.5m to 10 m
ITW 2009 - EtherCAT
21.04.23 20
EtherCAT Connector: ZS1090-0003 & ZS1090-0005
ZS1090-0003
EtherCAT / Ethernet connector, RJ45, four-pole, IP20, for field assembly
ZS1090-0005 CAT6 EtherCAT / Ethernet plug suitable for gigabit due to 8-pole implementation robust IP 20 die-cast zinc housing is made of only two parts and can be assembled in the field
without special tools Cables from AWG 22-26 can be connected fits the cables
ITW 2009 - EtherCAT
Topology – Bus with drop lines
DVI
IPC
....
Diagnostic
ITW 2009 - EtherCAT
Topology – Tree structure
DVI
IPC
....
ITW 2009 - EtherCAT
Topology – Star Topology with real time
DVI
IPC
....
EK1122EtherCAT junction
EK1101EtherCAT coupler with ID-Switch
ITW 2009 - EtherCAT
Identification for a group of Hot Connect“ devices:
EEprom -> Secondary Slave Address
Process Image (Hardware ID Switch, EK1101)
EtherCAT Hot Connect
Demo
ITW 2009 - EtherCAT
Demo: Hot Connect
Demo
Define Hot Connect Group
Right Klick on Coupler - Bottom Up, own SyncUnits are defined
ITW 2009 - EtherCAT
Hot Connect Application: FERAG
Flexible and modular bundling of magazines
ITW 2009 - EtherCAT
Topology – Star Topology with LWL
DVI
IPC
....
EK15211-Port EtherCATmultimode LWL junction
LWL
EK1501EtherCAT coupler with ID-Switchmultimode LWL connection
ITW 2009 - EtherCAT
Topology - EtherCAT over multimode LWLITW 2009 - EtherCAT
Cable redundancy
Only a second Ethernet Port is required on the master – possible with all EtherCAT slave devices
DVI
IPC
....
Redundancy with EK1122 ?-> NO
Demo
ITW 2009 - EtherCAT
Demo: Cable Redundancy
Demo
Configure Redundancy Adapter
Licence needed! Select Redundancy Port if possible!
ITW 2009 - EtherCAT
Demo: Cable Redundancy
New diagnosis variables
- Detect location of error
- Detect missing link
Only ONE failure at time!
Demo
ITW 2009 - EtherCAT
Redundant optical ring with EK1501 and EK1521
≤ 2 km
≤ 2 km
≤ 2 km
≤ 2 km
ITW 2009 - EtherCAT
Redundant optical ring with EK1501 and EK1521
Example: Snow Blower Control
Berchtold, Austria:
System with up to 1000 snow makers
ITW 2009 - EtherCAT
Interfaces of / to all important Bus Systems
InterbusEthernet(netzwork variables)
+ any CAN protocols
+ further PB protocols
(MC)
Demolater
ITW 2009 - EtherCAT
Topology – EtherCAT Bridge
DVI
IPC
....
DVI
IPC
....
DVI
IPC
....
Power Supply
EL6692EtherCAT Bridge Terminal
M1
M2
M3
• 480 Byte each direction• DC-Sync• EtherCAT Slave
SnapIn/PlugIn
Demo
ITW 2009 - EtherCAT
Demo: EL6692 Bridge
Demo
Check documentation for features!
- transport time
- DC synchronisation not supported in TwinCAT 2.10
ITW 2009 - EtherCAT
Port Multiplier and Star Topology
DVI
IPC
....
No MAC address will be used
Several (real time) Ethernet protocols are possible on one master port
Star Topology with real time support
CU2508Echtzeit Ethernet Port multiplier
ITW 2009 - EtherCAT
EtherCAT Memory Terminal for flexible Machine Concepts
EL6080
128kByte NOVRAM
Parameter & Recipes
cyclic data like: production counters hours of operation counter
Applications: modular machine counter
Basis for„Dongle-Terminal“ ?
ITW 2009 - EtherCAT
EtherCAT Switchport
Switchport Terminal – EL6601 + EL6614
• Interface to each Ethernet device in the network
• Ethernet Frames will be included in the EtherCAT protocol
• „Ethernet over EtherCAT“
Ethernet PHY
EtherCAT MAC / DLL
Process DataMailbox
Ethernet PHY
µC
Ethernet MAC PHY
Fragementation
ITW 2009 - EtherCAT
Switchport Terminal – EL6601 + EL6614
EtherCAT Switchport
EtherCAT MAC / DLL PHYPHYProcess DataMailbox
µC
Ethernet MAC PHY
Fragmentation
TX1TX2TX3
TX
TX2TX3TX1
RX RX4RX1 RX2 RX3
Interface to each Ethernet device in the network
Ethernet Frames will be included in the EtherCAT protocol
„Ethernet over EtherCAT“
ITW 2009 - EtherCAT
EtherCAT is Industrial Ethernet!
• Any Ethernet Device can be connected to the Switchport
• Access to web server with standard browser
DVI
IPC
....
virtual Ethernet Switch
Functionality Switchport
ITW 2009 - EtherCAT
EtherCAT and Wireless Communication
DVI
IPC
....
Switchport
Networ
k Var
iable
Proto
col
• Wireless Devices can be connected to Switchport • Wireless does not reduce the performance
in the EtherCAT segment • Protocol:
EtherCAT network variables• Wireless segment transparent
for the master
ITW 2009 - EtherCAT
Keep your ESI & Systemmanager Extensions up to date !ITW 2009 - EtherCAT
Version Identification – Software
ESC(ASIC
orFPGA)
µC
E²PROM
Device identification,Description, Process Image
Communicationand Diagnosis Functionality
Terminal specific functionse.g. Analog Input, SSI etc.(only at complex terminals)
FPGA Terminal specific functione.g. Encoder
ITW 2009 - EtherCAT
E²PROMITW 2009 - EtherCAT
FPGAITW 2009 - EtherCAT
µC
Attention!
ITW 2009 - EtherCAT
Increase of the Machine Efficiency through XFC XFC – eXtreme Fast Control Technology
XFC Basics
Fast IO, Time Stamp, Oversampling,Micro Increments
Application Examples: Control Engineering Machine with two transitions Demonstration Examples
EtherCAT & TwinCAT: AgendaXFC – eXtreme Fast Control Technology
Increase of the Machine Efficiency through XFC XFC – eXtreme Fast Control Technology
XFC-ComponentsXFC – eXtreme Fast Control Technology
XFC-Technology
Distributed-Clocks
Time-Stamp
Oversampling
Fast I/Os
XFC – eXtreme Fast Control Technology
Micro Increments
Fast I/O-Terminals 1µs TON/TOFF
Signal
Minimum reaction time
Time
Input: EL1202
Output: EL2202
85 µs 185 µs
XFC – eXtreme Fast Control Technology
Demo
Demo: Distributed Clocks
See special documentation for DC basics
XFC – eXtreme Fast Control Technology
Demo: Distributed Clocks
New Datagrams appear if DC is used – see documentation for settings
XFC – eXtreme Fast Control Technology
Demo: Distributed Clocks
Special dialog if Slave supports DC
See online diagnosis for quality reasons
XFC – eXtreme Fast Control Technology
Time-Stamp Terminal
Exact Reaction Time
Input: EL1252
Output: EL2252
Signal
Time
Exact Time Resolution
Time equidistant reactions
XFC – eXtreme Fast Control Technology
Demo
Oversampling-Terminals
Oversampling – extreme measurements
SPS-cycle SPS-cycle
Measuring cycle
Fast signal scanning
Analog value collection
XFC – eXtreme Fast Control Technology
Oversampling-Terminals
Exact output pulse
Output: EL2262
Signal
Time
XFC – eXtreme Fast Control Technology
Fast signal scanning
Output short impulses
Demo
Micro Increments (MI)
Encoder Signal
PLC / Bus Cycle
XFC – eXtreme Fast Control Technology
1 2 3 4 5 6 7
3 4 5 6 7
3,05 4,6 5,8 6,8 7,6
internal counter
Value without MIValue with MI
Time of rising and falling edge is used to calculate the micro increments (256 bit).
Micro Increments (MI) XFC – eXtreme Fast Control Technology
without Micro Increments:
Cycle Time Position t Position t+1 ∆ Position Speed
1 0 3 3 3
1 3 4 1 1
1 4 5 1 1
1 5 6 1 1
1 6 7 1 1
with Micro increments:
Cycle Time Position t Position t+1 ∆ Position Speed
1 0 3,05 3,05 3,05
1 3,05 4,6 1,55 1,55
1 4,6 5,8 1,2 1,2
1 5,8 6,8 1 1
1 6,8 7,6 0,8 0,8
Micro Increments (MI)
Micro Increments:
Better position resolution at low speeds with standard encoder
More accurate speed calculation
No filter needed (NC)
filter causes delay in the reaction time
Result:
machine runs more smoothly
coupled axes: better synchronization (by less delay)
Will be implemented in: EL5101 and EL5151
XFC – eXtreme Fast Control Technology
Micro Increments (MI)XFC – eXtreme Fast Control Technology
Micro Increments (MI)XFC – eXtreme Fast Control Technology
Microincrements in EL51xx: Enabled by CoE
Demo
I/O Response Timing: Control Cycle Usage
Tresp (average) = 2.5-3 cycle
CPU Time
Tresp (average) = 1.5 cycle
Tresp, PROFIBUS
PLC
.
t
Input
Output
PROFIBUS
K-Bus
EtherCAT-In
PLC
t
Input
Output
EtherCAT-Out
Tresp, EtherCAT
PROFIBUS-Timing
XFC-Timing
Demo
XFC – eXtreme Fast Control Technology
Demo: Separate Input UpdateXFC – eXtreme Fast Control Technology
Default: 1 (or more) Ethernet frames, sent when Task finished
Demo: Separate Input UpdateXFC – eXtreme Fast Control Technology
Additional Input frame(s):
- at “CPU Limit” when BaseTime = TaskTime
- at “PreTicks” when BaseTime < TaskTime