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ITW: EtherCAT 17.04.2017 1.

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Presentation on theme: "ITW: EtherCAT 17.04.2017 1."— Presentation transcript:

1 ITW: EtherCAT

2 Basics → Michael, Martin Diagnostics → Josef
ITW EtherCAT ITW: EtherCAT Basics → Michael, Martin Diagnostics → Josef Hands on → Martin, Itzko 2

3 EtherCAT is faster! ITW 2009 - EtherCAT
Bandwidth Usage of Ethernet for I/O and Drives: Ethernet Frame: ≥ 84 Bytes (incl. Preamble + IPG Inter-Packet Gap) User data: e.g. 2Bit…6Byte 22 Bytes 4 Bytes 12 Bytes Ethernet Header Data: ≥46 Bytes CRC IPG I/O Request with output data node reaction time I/O Response with input data Ethernet Header Data: ≥46 Bytes CRC IPG 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

4 Difference EtherCAT – Real Time Ethernet
ITW EtherCAT Difference EtherCAT – Real Time Ethernet TwinCAT I/O with Y-Driver similar core technology on the Master Windows TwinCAT TCP/IP (original Windows Stack) I/O System NDIS Protocol Process Images NDIS Miniport TwinCAT I/O Ethernet Controller e.g. Profibus Master

5 Difference EtherCAT – Real Time Ethernet
ITW EtherCAT Difference EtherCAT – Real Time Ethernet Different Technology on the Slave site –> no switch Real Time Ethernet EtherCAT Topic Today Switch Delay: µs depends on Switch and data size

6 Functional Principle: Ethernet „on the Fly“
ITW EtherCAT Functional Principle: Ethernet „on the Fly“ Slave Device Slave Device EtherCAT Slave Controller EtherCAT Slave Controller Process data is extracted and inserted on the fly Process data size per slave 1 Bit…60 Kbyte In addition asynchronous event triggered communication EtherCAT can address data in several ways: process data is typically addressed logically; each slave device knows the address areas within the logical 4 Gbyte address space that are relevant to him. In this mode the “car label” (datagram header) contains the logical 32 bit address. In addition one can communicate with each slave also by device addressing – e.g. for configuration, for TCP/IP or other Ethernet protocols, or for directly accessing diagnosis data. In order to do so, the address inside the datagram header is split into a 16 bit device address (the assigned address or the position address within the network segment) and into a 16 bit data address within the slave device. Thus up to 64 kbyte of memory can be addressed directly within the device (of course more data can be addressed indirectly, e.g. via TCP/IP).

7 Functional Principle: Ethernet „on the Fly“
ITW EtherCAT Functional Principle: Ethernet „on the Fly“ Minimal protocol overhead via implicit addressing DVI IPC .. Ethernet HDR EH Data CRC FH WKC 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

8 Demo: Working Counter ITW 2009 - EtherCAT Demo WC Konfiguration
Example: EL2008 disconnected WC Alarm

9 Demo: Working Counter ITW 2009 - EtherCAT Demo WC Konfiguration
WC=0 because of expected WC Value

10 Demo: Working Counter ITW 2009 - EtherCAT Demo WC Konfiguration
WC=1 because of msising Slave

11 Functional Principle: Ethernet „on the Fly“
ITW EtherCAT Functional Principle: Ethernet „on the Fly“ Minimal protocol overhead via implicit addressing DVI IPC .. Ethernet HDR FH Data Data Data CRC EH WKC EH WKC EH WKC Diagnostic areas on one cable with Sync Units

12 Demo: Sync Unit ITW 2009 - EtherCAT Demo Sync Unit Konfiguration
Example: disconnected EL3102 influences EL1008

13 Demo: Sync Unit ITW 2009 - EtherCAT Demo Sync Unit Konfiguration
Group with EL3102 disconnected  no valid data from EL1008!

14 Demo: Sync Unit ITW 2009 - EtherCAT Demo Sync Unit Konfiguration
 give own SyncUnit for EL1008 and EL3102

15 ITW EtherCAT Demo: Framesize & MTU Demo

16 56% bandwidth remaining, e.g. for TP/IP
ITW EtherCAT EtherCAT Performance 40 Axis (each 20 Byte Input- and Output-Data) 50 I/O Station with a total of 560 EtherCAT Bus Terminals 2000 Digital 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 * Source: Ethernet Powerlink Spec V 2.0, App.3

17 Topology – Line Topology
ITW EtherCAT Topology – Line Topology Arbitrary number of devices in a line Up to devices EK1100 EtherCAT Coupler EK1110 EtherCAT Extension DVI IPC ..

18 ITW EtherCAT Topology – Bus DVI IPC ..

19 EtherCAT Cables: ZB9010/20, ZK1090-9191-00xx
ITW EtherCAT EtherCAT Cables: ZB9010/20, ZK xx ZB9010/ZB9020 ZB9010 Industrial EtherCAT / Ethernet cable, standard cable, CAT 5e, 4 wires ZB9020 Industrial EtherCAT / Ethernet cable, trailing cable, CAT 5e, 4 wires ZK xxx 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 19

20 EtherCAT Connector: ZS1090-0003 & ZS1090-0005
ITW EtherCAT EtherCAT Connector: ZS & ZS ZS EtherCAT / Ethernet connector, RJ45, four-pole, IP20, for field assembly ZS 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 can be connected fits the cables 20

21 Topology – Bus with drop lines
ITW EtherCAT Topology – Bus with drop lines DVI IPC .. Diagnostic

22 Topology – Tree structure
ITW EtherCAT Topology – Tree structure IPC .. .. DVI

23 Topology – Star Topology with real time
ITW EtherCAT Topology – Star Topology with real time EK1101 EtherCAT coupler with ID-Switch EK1122 EtherCAT junction DVI IPC ..

24 ITW EtherCAT EtherCAT Hot Connect Identification for a group of Hot Connect“ devices: EEprom -> Secondary Slave Address Process Image (Hardware ID Switch, EK1101) Demo 24

25 Demo: Hot Connect ITW 2009 - EtherCAT Demo Define Hot Connect Group
Right Klick on Coupler - Bottom Up, own SyncUnits are defined

26 Hot Connect Application: FERAG
ITW EtherCAT Hot Connect Application: FERAG Flexible and modular bundling of magazines

27 Topology – Star Topology with LWL
ITW EtherCAT Topology – Star Topology with LWL EK1501 EtherCAT coupler with ID-Switch multimode LWL connection LWL DVI IPC .. EK1521 1-Port EtherCAT multimode LWL junction

28 Topology - EtherCAT over multimode LWL
ITW EtherCAT Topology - EtherCAT over multimode LWL

29 Cable redundancy ITW 2009 - EtherCAT Demo Redundancy with EK1122 ?
DVI IPC .. Redundancy with EK1122 ? -> NO Only a second Ethernet Port is required on the master – possible with all EtherCAT slave devices

30 Demo: Cable Redundancy
ITW EtherCAT Demo: Cable Redundancy Demo Configure Redundancy Adapter Licence needed! Select Redundancy Port if possible!

31 Demo: Cable Redundancy
ITW EtherCAT Demo: Cable Redundancy Only ONE failure at time! Demo New diagnosis variables Detect location of error Detect missing link

32 Redundant optical ring with EK1501 and EK1521
ITW EtherCAT Redundant optical ring with EK1501 and EK1521 ≤ 2 km ≤ 2 km ≤ 2 km ≤ 2 km

33 Redundant optical ring with EK1501 and EK1521
ITW EtherCAT Redundant optical ring with EK1501 and EK1521 Example: Snow Blower Control Berchtold, Austria: System with up to 1000 snow makers

34 Interfaces of / to all important Bus Systems
ITW EtherCAT Interfaces of / to all important Bus Systems Demo later + any CAN protocols Interbus Ethernet (netzwork variables) + further PB protocols (MC)

35 Topology – EtherCAT Bridge
ITW EtherCAT Topology – EtherCAT Bridge Demo DVI IPC .. Power Supply EL6692 EtherCAT Bridge Terminal M1 M2 M3 SnapIn/ PlugIn 480 Byte each direction DC-Sync EtherCAT Slave

36 Demo: EL6692 Bridge ITW 2009 - EtherCAT Demo
Check documentation for features! transport time DC synchronisation not supported in TwinCAT 2.10

37 Port Multiplier and Star Topology
ITW EtherCAT Port Multiplier and Star Topology No MAC address will be used DVI IPC .. CU2508 Echtzeit Ethernet Port multiplier Star Topology with real time support Several (real time) Ethernet protocols are possible on one master port

38 EtherCAT Memory Terminal for flexible Machine Concepts
ITW 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“ ?

39 Switchport Terminal – EL6601 + EL6614
ITW EtherCAT Switchport Terminal – EL EL6614 Interface to each Ethernet device in the network Ethernet Frames will be included in the EtherCAT protocol „Ethernet over EtherCAT“ EtherCAT Switchport Ethernet MAC PHY µC Fragementation EtherCAT MAC / DLL Mailbox Process Data Ethernet PHY Ethernet PHY

40 Switchport Terminal – EL6601 + EL6614
ITW EtherCAT Switchport Terminal – EL EL6614 RX Interface to each Ethernet device in the network Ethernet Frames will be included in the EtherCAT protocol „Ethernet over EtherCAT“ EtherCAT Switchport Ethernet MAC PHY µC RX1 RX TX RX2 RX3 RX4 Fragmentation EtherCAT MAC / DLL Mailbox Process Data PHY PHY TX2 TX3 TX1 TX2 TX3 TX1

41 EtherCAT is Industrial Ethernet!
ITW EtherCAT EtherCAT is Industrial Ethernet! Any Ethernet Device can be connected to the Switchport Access to web server with standard browser virtual Ethernet Switch Functionality Switchport DVI IPC ..

42 EtherCAT and Wireless Communication
ITW EtherCAT EtherCAT and Wireless Communication 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 Network Variable Protocol DVI IPC .. Switchport

43 Version Identification – Hardware
ITW EtherCAT Version Identification – Hardware Week of production Year of production Software version Hardware version

44 Keep your ESI & Systemmanager Extensions up to date !
ITW EtherCAT Keep your ESI & Systemmanager Extensions up to date !

45 Version Identification – Software
ITW EtherCAT Version Identification – Software Device identification, Description, Process Image E²PROM ESC (ASIC or FPGA) Communication and Diagnosis Functionality µC Terminal specific functions e.g. Analog Input, SSI etc. (only at complex terminals) FPGA Terminal specific function e.g. Encoder

46 ITW EtherCAT E²PROM

47 ITW EtherCAT FPGA

48 ITW EtherCAT µC Attention!

49 Increase of the Machine Efficiency through XFC
XFC – eXtreme Fast Control Technology Increase of the Machine Efficiency through XFC

50 EtherCAT & TwinCAT: Agenda
XFC – eXtreme Fast Control Technology EtherCAT & TwinCAT: Agenda XFC Basics Fast IO, Time Stamp, Oversampling, Micro Increments Application Examples: Control Engineering Machine with two transitions Demonstration Examples

51 Increase of the Machine Efficiency through XFC
XFC – eXtreme Fast Control Technology Increase of the Machine Efficiency through XFC

52 XFC – eXtreme Fast Control Technology
XFC-Components

53 XFC-Technology XFC – eXtreme Fast Control Technology Time-Stamp
Micro Increments Fast I/Os Oversampling Distributed-Clocks

54 Fast I/O-Terminals 1µs TON/TOFF
XFC – eXtreme Fast Control Technology Fast I/O-Terminals 1µs TON/TOFF Demo Signal Minimum reaction time Time Input: EL1202 Output: EL2202 85 µs 185 µs

55 Demo: Distributed Clocks
XFC – eXtreme Fast Control Technology Demo: Distributed Clocks See special documentation for DC basics

56 Demo: Distributed Clocks
XFC – eXtreme Fast Control Technology Demo: Distributed Clocks New Datagrams appear if DC is used – see documentation for settings

57 Demo: Distributed Clocks
XFC – eXtreme Fast Control Technology Demo: Distributed Clocks Special dialog if Slave supports DC See online diagnosis for quality reasons

58 Time-Stamp Terminal XFC – eXtreme Fast Control Technology
Exact Time Resolution Time equidistant reactions Demo Exact Reaction Time Input: EL1252 Output: EL2252 Signal Time

59 Oversampling-Terminals
XFC – eXtreme Fast Control Technology Oversampling-Terminals Fast signal scanning Analog value collection Oversampling – extreme measurements Measuring cycle SPS-cycle SPS-cycle

60 Oversampling-Terminals
XFC – eXtreme Fast Control Technology Oversampling-Terminals Fast signal scanning Output short impulses Demo Signal Output: EL2262 Time Exact output pulse

61 Micro Increments (MI) XFC – eXtreme Fast Control Technology
Encoder Signal internal counter Value without MI 3, , , , ,6 Value with MI PLC / Bus Cycle Time of rising and falling edge is used to calculate the micro increments (256 bit).

62 Micro Increments (MI) XFC – eXtreme Fast Control Technology
without Micro Increments: Cycle Time Position t Position t+1 ∆ Position Speed 1 3 4 5 6 7 with Micro increments: 3,05 4,6 1,55 5,8 1,2 6,8 7,6 0,8

63 Micro Increments (MI) XFC – eXtreme Fast Control Technology
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

64 XFC – eXtreme Fast Control Technology
Micro Increments (MI)

65 Microincrements in EL51xx: Enabled by CoE
XFC – eXtreme Fast Control Technology Micro Increments (MI) Demo Microincrements in EL51xx: Enabled by CoE

66 I/O Response Timing: Control Cycle Usage
XFC – eXtreme Fast Control Technology I/O Response Timing: Control Cycle Usage PROFIBUS-Timing Tresp, PROFIBUS Tresp (average) = cycle PLC PROFIBUS K-Bus . Input Output t XFC-Timing Tresp (average) = 1.5 cycle PLC Demo EtherCAT-In EtherCAT-Out Input Output t CPU Time Tresp, EtherCAT

67 Demo: Separate Input Update
XFC – eXtreme Fast Control Technology Demo: Separate Input Update Default: 1 (or more) Ethernet frames, sent when Task finished

68 Demo: Separate Input Update
XFC – eXtreme Fast Control Technology Demo: Separate Input Update Additional Input frame(s): - at “CPU Limit” when BaseTime = TaskTime - at “PreTicks” when BaseTime < TaskTime


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