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