1. Kollmorgen EtherCat November 10, 2018
Carroll Wontrop – System Engineer

2. EtherCAT - Topics
Why Use Kollmorgen Ethercat ?
Basic Principles and Capabilities
Communication Overview
AKD Implementation
PDMM Implementation

3. Why Use Kollmorgen Ethercat ?

4. EtherCAT – Overview
What is Ethercat?
Why would I use EtherCAT?
Why would I use EtherCAT verses other networks

5. High performance Ethernet based Fieldbus Network
Ethercat – What is it ?
High performance Ethernet based Fieldbus Network
Allows transferring information quickly and deterministically
between Controller and Drive
between Controller and I/O
Uses standard Ethernet components to keep implementation cost low
Open Standard (non proprietary), Designed for the Factory

6. Why would I use EtherCAT ?
Improve Machine Performance
Higher Production Rates
Higher Quality Parts and products
Gets information quickly across the network
Accuracy - Low jitter and distributed clocks node synchronization
Fast Communication times
Now: down to 250 usec (with Kollmorgen product)
Future: ability to go to 10 usec
Supported in all Kollmorgen Servo Drive Lines

7. Why would I use EtherCAT
Real-time Information
Allows monitoring of many drive parameters
Machine Diagnostic - know when a machine problem is about to occur
Get information if the machine faults
Allows changing many drive and I/O parameters
Change parameters on the fly
Can have Remote I/O on the same network
Analog and Digital I/O, Thermocouple
Third party modules

8. Why would I use EtherCAT
Reliability
Transport information reliably, Proven in thousands of applications
Interface Flexibility
Supports many different drive opmode and interface types to fit many different customer machine control schemes and the available interfaces on other products

9. Why would I use EtherCAT
Easy Integration into the Network
Easy integration of third party products
Easy learning curve and product implementation
Special hardware chips not require as with some Networks
COE – Can Over Ethercat use COE utilizing the well known CanOpen Protocol
Less Wiring – More reliable, less wiring cost
Processing on the fly – Faster communications
Strong users group. Wide industry acceptance

10. Why would I use EtherCAT verses other networks
More Component Vendor Options
Not tied to a particular vendor
Wide I/O support
Many Vendors Support
Not a separate SW to configure - Setup is integrated right into the KAS IDE
No need for expensive Ethernet switches
Comes with Kollmorgen’ s excellent tech support (usually not needed)
Includes a distributed clock mechanism
Low jitter that meets IEEE 1588 (Precision Time Protocol standard) without additional hardware
May be the only bus needed

11. The Kollmorgen Ethercat Advantage
Combines precision transfer of information w/ Kollmorgen’ s:
Precision servo loops
High performance motors
Easy to use controllers
Tight integration between motion and machine control
Result: Industry Setting Machine Performance

12. Ethercat Basic Principles and Capabilities

13. EtherCAT – Capabilities
Processing on the fly
Deterministic for high performance motion control
Digital control – not susceptible to noise
Precise motion control between axis (Master slaving, gearing coordinated motion)
Quick sensor pickup in registration applications
Lower installation cost by eliminating both Ethernet start topology and all switches routers and hubs.

14. EtherCAT – Design Goals
Ethernet for Control Automation Technology
First developed in early 2000’s
Design Goals
Apply Ethernet to applications with quick update times
Cycle times down to 100usec
Precise Synchronization – low jitter
Low HW cost
Fast deterministic update
One cable for many signals

15. Governing Standard
IEC – Defines how Ethercat adapts the OSI seven layer communication model
Ethercat FieldBus Network
IEC (Industrial communication network spec
IEEE standards for 100Base-TX, the physical layer of Ethernet.

16. Fit in 7 Layer communication Model
Ethernet communication optimized for Precision machine control
The EtherCAT Frame replaces the Ethernet standard stack Data portion of an Ethernet Packet

17. Ethercat Protocol Overview
Physical layer is based on IEEE standards for 100Base-TX, the physical layer of Ethernet.
Data link and application layers are specifically designed for motion control applications.
The 100BASE-TX media system is based on specifications published in the ANSI TP-PMD physical media standard.
The 100BASE-TX system operates over two pairs of wires, one pair for 'receive' data signals and the other pair for 'transmit' data signals.

18. Ethercat Protocol Overview
Automatic network configuration and integrity check
Cabling over 100 Meters between each node
Electrical isolation for robust noise immunity
Motion bus - Deterministic
Data update rates down to 250 usec
Bus connection and bus Medium: 100BASE-T media system
Transmission Rate: 100 mhz,
Connector and Cables: RJ-45
Physical Media: CAT5 cable
Topology: Line

19. Network Operation - On the fly
Process data is extracted and inserted on the fly
Slave Device
AKD 1
Slave Device
EtherCAT Slave
Controller
EtherCAT Slave
Controller
A single message with data for all nodes
Each node reads its inputs and adds its outputs to the message
Without messages targeted to specific devices, maximum bandwidth is achieved
An EtherCAT network is like a railway and at each train cars are unloaded and loaded while the train moves

20. Network Operation – Distributed Clocks
Packet Routing provides precision motion command synchronization
Each receiving node uses advanced digital time-correction techniques to minimize skew and jitter to provide precise control
EtherCAT Node measures time difference between leaving and returning frame
Propagation delays between any nodes can be computed
Precise Synchronisation (<< 1 µs!) by exact adjustment of distributed clocks
EtherCAT Frame
vom Master

21. Communication Overview

22. EtherCAT Type Kollmorgen Supports
COE (CanOverEthercat)
It is the CanOpen Network run over a Ethernet foundation
Supported by Kollmorgen KAS, S700, and AKD product lines
Parameters Supported for Standards:
CiA301 - CanOpen Communication Profile for Industrial Systems
CiA402 – Drive Profile Interface

23. Ethercat COE Communication
Process Data (PDO) Communication
Deterministic, Real Time Communication - FAST
Limited parameter set
Mailbox Communication
Non-Deterministic
Service Data Objects (SDO) and ACSII Communication
Fuller parameter set
Network Startup (COE Init)
Sent once during Ethercat Network Initialization
Service Data Objects (SDO) setup by the Ethercat Master Device

24. Information Passed over EtherCAT
Setup up parameters
Diagnostics parameters
Operation parameters
Status parameters
Motion command parameters (Servo Drives)
Servo Tuning and limit parameters (Servo Drives)
Other Operational Parameters
Ethercat
Master

25. Ethercat Communication – Initialization
Steps up to full Synchronization

26. Network Operation - Ethercat Telegram
Efficient Transmission of Data
Low overhead
Ethernet Header
ECAT
EtherCAT Telegram
Ethernet DA SA
Type
Frame HDR
EtherCAT HDR
Data
Pad.
FCS
CTR
(6)
(6)
(2)
(2)
(10)
(0….1486)
(2)
(0…32)
(4)
constant Header
completely sorted (mapped) process data
Working Counter: constant
Padding Bytes and CRC generated by Ethernet Controller (MAC)

27. Network Operation - Slave Implementation
Definitions
ESC = Ethercat slave controller
Trafo = Transformer
PHY = Physical Layer (Layer 1 in OSI model)
EtherCAT Slave structure parts:
EtherCAT Master
Not part of the Slave. EtherCAT is a master-slave system. An EtherCAT master needs as only
hardware a standard NIC. It can use all information provided by the Electronic data sheet of all slaves.
Electronic Data Sheet
Every EtherCAT device shall be delivered with Electronic Data Sheet in XML format. It describes the
identity and all features of the device.
Slave Hardware
The slave hardware describes the following parts:
• Standard Ethernet Physical Layer Components
• EtherCAT Slave Controller (ESC) and EEPROM (ESC Configuration Data)
• For intelligent slaves with an application controller: Host CPU
Standard Ethernet Physical Layer Components
The physical layer is based on the standards defined by standard Ethernet according to IEEE802.3.
This means:
• Standard Ethernet plugs (RJ45 or M12)
• Magnetics
• PHYs
In order to maximize the EtherCAT performance, it is required to select the PHYs according to the
criteria listed in the ESC data sheets.
For EtherCAT devices connected to an internal backbone connection LVDS can be used as Phyical
Layer. This Physical Layer is also called “E-Bus”. Then the Magnetics and the PHYs are no longer
required, the connectors are vendor specific.
EtherCAT Slave Controller (ESC)
The ESC can either be implemented as FPGA or ASIC. This hardware handles the EtherCAT protocol
in real time. Thus, the performance of the EtherCAT communication does not depend on the
implementation of the application software in the host CPU. Neither does the communication speed
has impact on the performance of the application controller.
To connect the ESC to an application controller or just digital I/Os the following Process Data
Interfaces (PDI) are available depending on the ESC type:
• 32 Bit digital I/O
• Serial Peripheral Interface (SPI)
Used for small process data
• 8/16 bit synchronous/ asynchronous microcontroller interface
Usually used for larger process data
Process data and parameter data are exchanged via a DPRAM while the ESC behaves like a
memory. Appropriate mechanisms are provided by the ESC hardware (defined by the EtherCAT
protocol) to ensure data consistency.
ESC Configuration Data (EEPROM)
During start-up the ESC needs to load configuration data (e.g. PDI type) from an external NVRAM.
Most ESC support an I²C interface to connect an EEPROM.
Application Layer/ Host CPU
In a complex slave the application layer services are implemented on an application controller here
named as Host CPU.
The Host CPU has to support the following tasks:
- EtherCAT State Machine handling
- Process data – Exchange with the application
- Mailbox protocols (CoE, EoE etc.)
- Object Dictionary Handling
- Handling of Application Parameter (Communication Parameter are handled by ESC)
- Optional TCP/IP Stack Handling – if device supports EoE
- CC-Performance is determined by device application, not by EtherCAT Communication
In many cases an 8bit CC/ PIC is sufficient.

28. Product Configuration File

29. ESI Vendor Files
Also called Ethercat XML Device Description
Defines the communications and what objects will be passed through Cyclicly
Required by the Master to setup the ECAT Network

30. AKD Implementation

31. Network Operation - AKD Ethercat Connection

32. Velocity / Torque Control
Architecture
Typical Ethercat Configuration 1
Path Generation in Controller
PLC
PLC or
PAC
PLC or PC
PLC or PC
Machine Control
I/O
Field Bus
Motion Programming
Standalone
Multi Axis
Control
Single Axis
Controller
PDMM
Field Bus
Path Generation
Digital Drive
AKD or S700
Motion Bus
Position Control
Digital Drive
AKD or
S700
+/- 10V
Velocity / Torque Control
Analog
Drive

33. Velocity / Torque Control
Architecture
Typical Ethercat Configuration 2
Path Generation in Drive
PLC
PLC or
PAC
PLC or PC
PLC or PC
Machine Control
I/O
Field Bus
Motion Programming
Standalone
Multi Axis
Control
Single Axis
Controller
PDMM
Field Bus
Path Generation
Digital Drive
Motion Bus
Position Control
Digital Drive
+/- 10V
Velocity / Torque Control
AKD or
S700
Analog
Drive

34. Network Operation -Drive Addressing
No drive manual address setting required
Addresses assigned automatically
Addresses can be kept – no new addressing if nodes are added

35. AKD drive models that support Ethercat
AKD Drive Modes
AKD drive models that support Ethercat
AKD-P00xxx-NAEC-0000: Ethercat bus only
AKD-P00606-NACC-0000: Configurable to Ethercat or CanOpen bus

36. Network Startup (COE Init)
AKD COE Communication
Network Startup (COE Init)
Non-Deterministic – Initial Setup ( related to initial drive setup)
Sent only one time during Ethercat Network Initialization
Service Data Objects (SDO) setup by the Ethercat Master Device
Process Data (PDO) Communication
Deterministic - Operational (Realtime)
Limited parameter set
Mailbox Communication
Non-Deterministic - Operational (Non-realtime)
Service Data (SDO) and ACSII Communication
Fuller parameter set

37. AKD Opmodes supported Set by Object 0x6060
1 to 8 : ECAT Standard Opmodes
-1 to -3 : Additional Kollmorgen specific Opmodes

38. AKD Support Parameters
Most AKD Parameters are linked to Ethercat Objects
Example: Velocity Loop Proportional Gain is linked to object 0x3548

39. Control and Status Objects
Bit Wise Objects not connected to a specific AKD Parameter
Drive Control Word: 0x6040 (Master Controller to AKD)
Drive Status Word: 0x6041 (AKD to Master Controller)
Control Word
Status Word

40. Network Startup (COE Init) Communications
Sent by master to the AKD during ECAT network startup
Used to configure the drive for ECAT communications. Can in parameters to set up: opmode, high speed capture engine, network synchronization, Units scaling, Enable/Disable coordination with tthe controller, and others:
Example : Beckhodff TwinCat (Ethercat Master) ECAT Startup

41. AKD PDO Communications (Fixed)
Parameters transmitted at the ECAT update rate
The following are standard (Fixed) options
Some combination of the PDO‘s below is possible
Options: Controller to AKD
Options: AKD to Controller

42. AKD PDO Communications (Other options- Flexible PDOs)
Some other AKD parameters can be mapped into the PDO communication (Requires removing some Fixed PDOs)
Check the Appendix to the AKD Ethercat Manual to determine PDO mappable objects

43. AKD Mailbox communications
Non time critical transmission of Parameters. Example: Change Tuning gains, Limits, Scalings
Many AKD parameters can be mapped into the PDO communication (Requires removing some Fixed PDOs)
See the Appendix to the AKD Ethercat Manual for complete list

44. AKD Ethercat Notes Position Feedback Object PDO mapping
0x6064 is for interpolated position
0x6063 is for everything else.
PDO mapping
When free mapping PDO , turn off the PDOs you don’t intend to use. 
Individual PDOs limited to 8 bytes.  Some masters only will map one TX-PDO and one RX-PDO.
Ethercat Network Run-up
Often when Starting up Ethercat network via the Control Word (0x6040), will need to monitor the status word (0x6041) for the step completion before using the control Word to move on to the next step. 
Monitor the bus voltage bit in the status word, plus 300mS, for the bus voltage to be present before starting the run up.
Resetting Home
AKD firmware 1.10.x.x and up: homing will reset 0x6064 and 0x6063.  Set HOME.MODE to 13 and set FB1.OFFSET.

45. AKD Ethercat Notes Over Travel Limit Position Jump AKD XML file
May need to defeat Over travel limit setup in AKD to work with certain master
Position Jump
If position “jump” occurs in interpolated position mode, caused by the position update arriving at the drive when the drive is calculating the next set of position points set FBUS.PARAM02 and FBUS.PARAM04 = 1
AKD XML file
Use new XML file for TwinCat3 and other controllers
There are some clerical errors in the “optional” parts of the AKD’s XML files and some Ethercat masters don’t like it.  Will not allow configuration.  (Delta Tau, Omron).

46. KAS PDMM/PCMM Implementation

47. Velocity / Torque Control
Architecture
Default KAS Ethercat Configuration
PLC
PLC or
PAC
PLC or PC
PLC or PC
Machine Control
I/O
Field Bus
Motion Programming
Standalone
Multi Axis
Control
Single Axis
Controller
Field Bus
Path Generation
Digital Drive
AKD or S700
Motion Bus
Position Control
Digital Drive
AKD or S700
+/- 10V
Velocity / Torque Control
Analog
Drive

48. KAS Ethercat Configuration
Architecture
KAS Ethercat Configuration
Machine Controller
PCMM or PDMM
Servo Drive (AKD or S700)
Machine
I/O
Motor
Position Control
Velocity Control
Current Control
Application
Program
Profile
Generator
Feedback
Network
Interface
HMI
Interface
Feedback
Interface
EtherCAT
HMI

49. Network Operation - Drive Addressing
No drive manual address setting required
Addresses assigned automatically
Addresses can be kept – no new addressing if nodes are added

50. PDO Execution Time
Each Ethercat cycle
250, 500, 1000 or 2000 microsecond

51. EtherCAT System ENI file
Defines component parameters for Ethercat Network
Stored in KAS Project (for particular ones used in a project)
<?xml version="1.0" ?> -
<!-- edited with XML Spy v4.4 U ( by name (company)   -->
<EtherCATInfo xmlns:xsi=" xsi:noNamespaceSchemaLocation="EtherCATInfo.xsd"
Version="1.2">- <Vendor>  <Id>106</Id>  
<Name>Danaher Motion GmbH</Name>   <ImageData16x14>424de e c40e0000c40e c0c0c ff0000ff000000ffff00ff000000ff00ff00ffff0000ffffff00cccccccccccccccccfffffffffffffffcfcccccccccccccccfcffccfcfcfcfcccfcfcfcfcfcfcfcccfcfcfcfcfcfcfcccfcfcfcfcfcfcfcccfcfcfcfffcffccccfcfcfcfcfcfcfcccfcfcfcfcfcfcfcccfcfcfcfcfcfcfcccfcffccfcfcffccccfcccccccccccccccfcccccccccccccc</ImageData16x14>
  </Vendor>-
<Descriptions>- <Groups>- <Group SortOrder="520">  <Type>Drive</Type>   <Name LcId="1033">Drives</Name>
  <Image16x14>DRIVE</Image16x14

52. Process Data (PDO) Communication
KAS COE Communication
Process Data (PDO) Communication
Deterministic, Real Time Communication
Limited parameter set
Mailbox Communication
Non-Deterministic
Service Data (SDO) and ACSII Communication
Fuller parameter set
Network Startup (COE Init)
Sent once during Ethercat Network Initialization
Service Data Objects (SDO) setup by the Ethercat Master Device

53. Mailbox Execution time
SDO Execution Time  
ASCII Execution Time
Sending multiple commands to a single drive:
Only one command can be sent at a time.
The time to execute multiple commands is:
Number of commands    x    Execution time of a single command
Commands sent to different AKD drives at the same time
the requests do not interfere with each other.
You can be confident the function finishes execution in the same max time as to one drive
250 microsecond Update
1000 microsecond Update
Mean
9 milliseconds
Min
3 milliseconds
MAx
16 milliseconds
250 microsecond Update
1000 microsecond Update
Mean
20 milliseconds
11 milliseconds
Min
15 milliseconds
9 milliseconds
MAx
45 milliseconds
58 milliseconds

54. PDO Defaults (with AKD)
Setup in IDE

55. PDO / Link to Application Project Variables
Easy connection to Project Variable

56. PDO / Mapping Default settings – good for most applications
PDO mapping can be change to meet particular Application Needs

57. PDO – Fixed and User definable
PDO Editor tab allows changing Objects (Drive parameters) associated with each PDO
PDO mapping
When free mapping PDO , turn off the PDOs you don’t intend to use. 
Individual PDOs limited to 8 bytes.  Some masters only will map one TX-PDO and one RX-PDO.

58. PDO Mappables
To meet individual Application needs , Additional PDO mappings can be selected in the PDO Selection/Mapping tab

59. PDO / Drive parameter/ KAS FB Cross Reference
Ethercat Object
From Controller to Drive

60. PDO / Drive parameter/ KAS FB Cross Reference
From Drive to Controller

61. Network Startup (COE Init)
Sent by the PDMM/PCMM to the AKD or S700 during ECAT network startup
Used to configure the drive for ECAT communications. Can in parameters to set up: opmode, high speed capture engine, network synchronization, Units scaling, Enable/Disable coordination with tthe controller, and others
Use the Add and Edit buttons to make changes to this list

62. Communication in KAS Program
Ethercat Specific Function Blocks
Mailbox Communication
Provides access to drive parameters not included in the ML and MC motion libraries
Examples:
Tuning parameter
Limit parameter
Opmode change
Use in all IEC Languages:
ST, FFLD,FBD, and IL languages

63. Communication in KAS Program
Function Block Support for Drive/Motor Control
Enable/Disable Drive
Make Motion
Get Motion Status
Other
Contain in these sections of the Function Block Library

64. Communication in KAS Program
Mailbox Communications: DriveParamRead and DriveParamWrite FB
Enter parameter name directly : KL.KP

65. number associated with a drive Parameter
Drive Object Numbers
Determining Object
number associated with a drive Parameter
16#3480

66. MailBox Communications
ECATReadSDO and ECATReadSDO
Enter object number, size (bytes), and sub index number

67. KAS System - AKD Opmode support
Position
(Default) - Good for most applications
Object 6060 = 7 (Interpolated position mode)
Velocity
(configure through Mailbox object 6060 or Special Map PDO)
Object 6060 = 3 (Profile velocity mode)
Torque
Object 6060 = 4 (Profile torque mode)

68. Adding Non Kollmorgen Ethercat Devices
Possible Products
Safety Module
Slice IO
Gateway to other network
Invertor Drive

69. Adding Non Kollmorgen Ethercat Devices
ESI File
Also called Ethercat XML Device Description
Available from Vendor
Defines what PDO objects the Device and standard mappings
Required by the
Master to setup
ECAT Network

70. Adding Non Kollmorgen Ethercat Devices
Procedure
Locate the device’s ESI file
Add to the Project’s listing of ESI files
Determine parameters to be send through Ethercat To/from KAS controller
Set up PDO mapping
Set up COE- Init (if needed)