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EtherCAT Training
Content
15.03.2012
Hardware
Function principle
Topology
Advantages and efficiency
In praxis: Driver installation in System
Manager
EtherCAT data exchange
Protocol
Performance
The Fieldbus EtherCAT
Configuration in System Manager
In praxis: Parameterization and
commissioning in System Manager
Sync Units
In praxis: Hot Connect
Diagnosis
In praxis: Cable redundancy
XFC eXtreme Fast Control Technology
In praxis: Timestamp terminal
In praxis: Oversampling terminal
EtherCAT Training
Hardware
EtherCAT Fieldbus master
IPC / Control Panel
Intel chipset based network card
with special TwinCAT real-time
Ethernet driver:
FC9001/9002/9004/9011
Supported network adapter in
Information System
(online:http://infosys.beckhoff.com/c
ontent/1033/tcsystemmanager/refer
ence/ethercat/html/ethercat_supnet
workcontroller.htm?id=10257)
Embedded PC / Control Panel
CX90xx
CX10xx
CX50xx
etc.
15.03.2012
EtherCAT Training
Hardware
Overview standard components EL (IP20)
Bus Coupler
/ EK1101
EK1100
EtherCAT Training
Hardware
Overview standard components KL (IP20)
Bus Coupler
End terminal:KL9010
BK1120
EtherCAT Training
Hardware
Overview standard components EP (IP67)
EP1111 EtherCAT Box
EP1122 EtherCAT 2-port junction
EtherCAT Training
Hardware
Further EtherCAT components
EK1501
EK1521
EK1122
EK1110
15.03.2012
EK 1132
EL6692
EtherCAT Training
Functional principle
EtherCAT Ultra high-speed for Automation
15.03.2012
EtherCAT Training
Functional principle
Highlights
Ethernet up to the terminal complete continuity
Ethernet process interface scalable from 1 bit to 64 kbyte
First true Ethernet solution for the field level
exact timing and adapted to synchronisation
Different approaches that try to provid real-time capability for classical
Ethernet:
Suspend collision detection (CSMA/CD)
Special switches that distribute Ethernet telegrams in a precisely
controlled timely manner
Problem
Even for very small data quantities a complete Ethernet frame has to
be sent
An underlying bus system adds small delays (e.g. K-bus)
15.03.2012
EtherCAT Training
EtherCAT
Ethernet down to the I/O terminals!
Direct access of EtherCAT slave controller (ESC) to process data in
EtherCAT frame
ESC differs by command header between process data and other
commands
Ring bus system with software based ending
Ethernet view: EtherCAT bus is one Ethernet node
Process data e.g. from the PLC are no longer received and
interpreted in devices. Process data is taken from the telegram by
the EtherCAT Slave Controller (ESC) or copied into it.
The EtherCAT frame is delayed [ns] by passing through the
EtherCAT slaves.
The last node in the segment returns the frame to EtherCAT-master.
15.03.2012
EtherCAT Training
10
EtherCAT
ESC
EtherCAT Slave Controller (ESC) handles the EtherCAT
communication in an EtherCAT slave.
Each EtherCAT slave has such an ESC to ensure that cyclical and
acyclical process data can be exchanged between mater and slave
via the EtherCAT fieldbus.
This ESC can handle simple functions such as digital inputs and
outputs directly, or it can be connected to a further processor in the
EtherCAT slave via serial/parallel interfaces for handling more
complex tasks such as drive control.
15.03.2012
EtherCAT Training
11
EtherCAT
Scheme of EtherCAT slave
15.03.2012
EtherCAT Training
12
EtherCAT
typical embedding of ESC
From the RJ45 socket electrical signals are transferred to the PHY
(PHYsical interface) via the transformer.
It extracts the user data from the coded Ethernet signal and
transfers them to the ESC for processing.
The EtherCAT telegram is then relayed with minimum delay (due to
dynamic processing) to the next EtherCAT slave via the PHY and
the socket.
The ESC automatically parameterises itself with configuration data
from an EEPROM.when the salve starts up. If a further CPU exists
in the slave, the slave can communicate with it via interfaces.
15.03.2012
EtherCAT Training
13
Topology
EtherCAT Ultra high-speed for Automation
15.03.2012
EtherCAT Training
14
Topology
EtherCAT Training
15
Topology variant
line: any number of nodes lined up
IPC
..
..
DVI
up
65,535
nodes
Cable: standard CAT5 cable
without crossover
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EtherCAT Training
16
Topology variant
Daisy Chain
IPC
..
..
DVI
Up to
65,535
nodes
Cable: standard CAT5 cable
without crossover
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EtherCAT Training
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Topology variant
Daisy Chain + drop lines
IPC
..
..
DVI
Up to
65,535
nodes
Cable: standard CAT5 cable,
without crossover
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EtherCAT Training
18
Topology variant
mixed structures
IPC
..
..
DVI
Up to
65,535
nodes
Cable: standard CAT5 cable
without crossover
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EtherCAT Training
19
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EtherCAT Training
20
EtherCAT Training
21
Seamless integration
of exisiting fieldbus devices
Process image update-time
via EtherCAT (1500
bytes input and output data):
150s
Until now:
Process image update-time
via PCI ( 500 byte input and
output data): 400s
15.03.2012
EtherCAT Training
22
EoE
Switchport
IPC
..
..
DVI
e.g.
connection of
Label
printer/Scann
er
15.03.2012
Programming/
Parameterization
directly in I/O
range
EtherCAT Training
23
IPC
..
..
DVI
24
In practise
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EtherCAT Training
25
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EtherCAT Training
26
1
Network card operating system
15.03.2012
EtherCAT Training
2
Other
fieldbus
27
In praxis
Real-time Ethernet driver
The installation of the real-time Ethernet driver can be done easily
via the TwinCAT System Manager
To use the cable redundancy, the driver has to be istalled on two
network cards
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EtherCAT Training
28
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EtherCAT Training
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EtherCAT Training
30
Publisher/
Subscriber
EL6601
FC1100
Maximum
synchronous
Data quantity
480 bytes,
bidirectional
variable
1024 bytes,
bidirectional
(publisher/
subscriber
method)
1024 bytes,
bidirectional
Maximum
asynchronous
data quantity
Optional
AoE support
Yes
Yes
Yes
Yes
DC support
Yes
notice
- recommended for
synchronization of
EtherCAT systems
- TwinCAT 2.11
required
- use of an
Ethernet port in
both systems as
real-time device
- recommended
for synchronous
data exchange
- transfer of RT
devices into
EtherCAT
terminal
- recommended
for synchronous
data exchange
- Requires free
PCI slot in the
IPC
- TwinCAT 2.11
R2 required
- CX5000 as
subordinate
autonomous
controller with its
own IO is
integrated in the
higher level
system as an
EtherCAT slave
- option B110
required
- TwinCAT 2.11
R2 required
15.03.2012
EtherCAT Training
CX50x0B110
31
TwinCAT
Ec Master
15.03.2012
TwinCAT
Ec Master
EtherCAT Training
TwinCAT
Ec Master
Ec Slave
(CX/IPC)
32
Protocol
EtherCAT Ultra high-speed for Automation
15.03.2012
EtherCAT Training
33
Protocol
optimised protocol directy within the Ethernet frame
fully hardware-implemented
for routing and socket interface: UDP datagram
processing while passing
distributed clock for accurate synchronisation
Time stamp data types for resolution in nanosecond range
Oversampling data types for hight-resolution measurements
15.03.2012
EtherCAT Training
34
Protocol in detail
description
The EtherCAT protocol is an Ethernet protocol optimized for process
data. It is sent consistently in one (ore further) Ehternet frames or
via UDP/IP.
The Ethernet frame has a size of 1514 byte. EtherCAT datagramms
(process data, etc.) with a user size of 1486 byte can be sent.
Larger process images are distributed over several Ethernet frames.
With the EtherCAT process data in the Ethernet frame a process
image up to 4 gigabytes can be served.
The data sequence is independent of the physical order of the
EtherCAT slaves in the network, addressing can be in any order.
Device profile according to CANopen (CoE) or Sercos (SoE)
15.03.2012
EtherCAT Training
35
Protocol in detail
Structure of frames
EtherCAT uses standard frames according to IEEE 802.3
no shortened frames
alternatively via UDP/IP (if IP routing is needed)
MTU=Maximum
Transmission Unit,
in computer
network the
maximum non
fragmented
transferable data
volume.
48 Bit
48 Bit
16 Bit
16 Bit
Destination
Source
EtherType
Header
Ethernet H.
IP Header
32 Bit
CRC
TCP /IP
CRC
UDP /IP
1..n EtherCAT
telegrams
64 Bit
UDP H.
Header
Length
0
15.03.2012
EtherCAT Training
1 Bit
4 Bit
Res.
11
Type
12
15
36
Protocol in detail
Continuity for technologies
fully transparent for TCP/IP
all internet technologies available: HTTP, FTP,
Without restricing the real-time capabilities of the bussystem!
EtherCAT Device
Ethernet
Application
Standard
TCP/IP
Stack
TCP
Real Time
Application
UDP
Acyclic
Data
IP
Mailbox
Process Data
15.03.2012
EtherCAT Training
Ethernet PHY
37
Performance
EtherCAT Ultra high-speed for Automation
15.03.2012
EtherCAT Training
38
Performance
256 digital I/Os in 12 s
1,000 digital I/Os in 30 s
200 analog I/Os (16 Bit) in 50 s, that is equivalent to 20 kHz
sampling rate
100 servo axis each 100 s
12,000 digital I/Os in 350 s
The EtherCAT bus system is so fast that between two (PLC) control
cycles internal EhterCAT eradication can be done (compare XFC)
EtherCAT is not limited to 100MBaud
The bus system is no longer the bottle neck of the control!
15.03.2012
EtherCAT Training
39
Performance
Function principle Ethernet on the Fly
Wagen
27
Example ICE:
Train (Ethernet Frame) doesnt stop
Somebody who sees the train through a narrow window, sees
the whole train
railway car (Sub telegramms) have variable length
Single people (bits) or tour groups (x kbyte) can be removed
and/or inserted.
15.03.2012
EtherCAT Training
40
Performance
Processing on the fly
Data is modified
and/or added while
telegram passes
through
From
vomMaster
Master
Without buffering,
storing the telegram
to Master
minimal
telegram delay
per node
Optimal
performance
15.03.2012
EtherCAT Training
41
Performance
processing times
Runtimes by the cable length are nearly irrelavant,
100 m Ethernet cable need approx. 550 ns.
Processing time of one or more Ethernet frame through all real
slaves on the foreward path and return path. As order of magnitute
for each slave can be taken:
For an Ethernet device:
approx.1 s
approx. 300 ns
EtherCAT Training
42
15.03.2012
EtherCAT Training
43
node 1
node 1
Data n
PLC Data
node 2
node 2
NC Data
node 3
node 4
node 3
Mapping
node 4
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EtherCAT Training
44
node 1
node 1
node 2
node 2
Process
Data
node 3
node 4
node 3
Mapping
node 4
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EtherCAT Training
45
..
..
DVI
232
Telegram structure
Ethernet HDR
HDR 1
PLC Data
HDR 2
NC Data
HDR n
Data n
CRC
Data n
PLC Data
NC Data
Sub
Telegram 1
Sub
Telegram 2
Sub
Telegram n
15.03.2012
EtherCAT Training
46
Control task
PCI
bus
15.03.2012
EtherCAT Training
CPU
memcopy
PC RAM
Control task
PCI
bus
DMA
47
Tmpd
Bus Cycle
TI/O
TI/O
Bus Cycle
TI/O
TI/O
Bus Cycle
TI/O
TI/O
Bus Cycle
TI/O
TI/O
TI/O
Bus Cycle
TI/O
TI/O
Bus Cycle
TI/O
TI/O
Bus Cycle
TI/O
TI/O
Input
(best case)
Output
Tmpd: Master Processing Delay
TI/O: Local I/O Update Time
(local Extension Bus + Firmware)
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EtherCAT Training
48
I PLC task O I PLC task O I PLC task O I PLC task O I PLC task
No dedicated master device any more
Tmpd
bus cycle
TI/O
TI/O
bus cycle
TI/O
TI/O
bus cycle
TI/O
TI/O
bus cycle
TI/O
TI/O
TI/O
bus cycle
TI/O
TI/O
bus cycle
TI/O
TI/O
bus cycle
TI/O
TI/O
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EtherCAT Training
49
I PLC task O I PLC task O I PLC task O I PLC task O I PLC task
neglectible
15.03.2012
EtherCAT Cycle
EtherCAT Training
50
I PLC task O I PLC task O I PLC task O I PLC task O I PLC task
worst case
Reaction Time
Input
(Worst case)
best case
Input
(best case)
Output
EtherCAT Training
51