Embedded TechCon Synchronizing mechatronic systems in real-time using FPGAs and Industrial Ethernet Sari Germanos [email protected]

Embedded TechCon

Synchronizing mechatronic systems in real-time using FPGAs and Industrial Ethernet

Sari [email protected]

Technology MarketingEthernet POWERLINK Standardization Group

Video

• Video Example

http://EIEC2011.4.AVI/

Everything Connected to one network• Integrated System Architecture

remote I/Os Safety Logic

Motion Systems

Vision

Robotics

Pneumatics

Controller

Visualization

Robotics

Sensor

CSMA/CD• Ethernet Medium access: CSMA/CD

– Carrier-Sense Multiple Access with Collision Detection– Collisions generate repeat after random delay – Induces unpredictable delays

• Standard Ethernet is not deterministic– Designed for office applications

Fieldbus Technology

• Traditional fieldbuses– RS485 or CAN based– Reliable, field proven– Cheap– Very limited bandwidth

• Need a faster solution: Industrial Ethernet

Switched Ethernet• Switched Ethernet networks

– Traffic separation in collision domains– Messages managed in queues– Collisions are moved from network to queues– Queues generate delay– Packets are dropped in case of congestion – Switches introduce latency thus not deterministic!

Ideal Machine Network Requirements

1. Real-time performance, high efficiency

2. Large asynchronous bandwidth

3. One single Network for all automation

4. Flexible network topology

5. Hot pluggable

6. High availability

7. Electromagnetic Compatibility (EMC)

8. Easy commissioning, maintenance and diagnostic





5. Hot pluggable




Ideal Network Requirements





5. Hot pluggable








5. Hot pluggable




POWERLINK Technology• Network master

– 1 Managing Node (MN)

• Network slaves– Up to 239 Controlled Nodes (CN)

CYCLE TIME

POWERLINK TechnologySynchronization and communication during each cycle

Async. data

Synchronous phase Asynchronous phase

SoCPReq CN1PReq CN2PReq CNnSoA

Easy and robust functionality

No complex time synchronizationAll on one medium

I/O Axis I/O

PRes CN1 PRes CN2 PRes CNn

PLC

POWERLINK Technology• Cross communication

PRes CN1

SoCSoCSoCPReq CN1PReq CN1PReq CN1PReq CN1

PRes CN1PRes CN1PRes CN1

SoC

Encoder Axis Encoder

PLC

Axis

Extremely fast axis synchronizationCentralized and decentralized architectures






5. Hot pluggable



8. Easy commissioning, maintenance and diagnostics





5. Hot pluggable



8. Easy commissioning, maintenance and diagnostics

Requirement 3

• Multiplexed slot assignment–No need to exchange all data at fastest cycle time–Ideal for Integrated Automation

More Efficient Mechanism• Poll Response Chaining

– Position Control Loop– Current Control Loop






5. Hot pluggable








5. Hot pluggable




Requirements 4 & 5• Hot Plug

– Higher productivity, modular system concepts

• Topology flexibility– 100% free choice of star, tree, ring, or daisy chain – No limits on system extensions






5. Hot pluggable








5. Hot pluggable




Requirement 6• High Availability

– Ring redundancy– Full medium redundancy– Redundant master






5. Hot pluggable








5. Hot pluggable




Requirement 7• Electromagnetic Compatibility

– New machines include noisy electric power components






5. Hot pluggable








5. Hot pluggable




Requirement 8• Network Diagnostics

– Unambiguous diagnostics – Total view of the network– No data manipulation on path-transmission– Standard office diagnostic-tools– PC with on-board Ethernet interface using Wireshark, Omnipeak, etc.

Performance• Timing characteristics

– 0.1 µs system synchronization– 100 µs cycle time

• High capacity– High data throughput– 239 Controlled Nodes– 480 synchronized axes– 460,000 digital I/O data points

• Exceptional performance– Example : 17 stations, 800 digital I/O, 180 analog I/O, 24 axes -> cycle

time of 200 µs

POWERLINK implementation• Hardware Choices

• Operating Systems

POWERLINK Frame Structure• POWERLINK frame

– Fully compliant with IEEE 802.3– Ether Type = 0x88AB

POWERLINK OSI model• POWERLINK OSI model

– POWERLINK sits on top of the standard Ethernet MAC layer– Full integration with TCP/IP

CANopen Reference Model • POWERLINK interface is CANopen over Ethernet

– Same device profiles– CANopen application layer– Same mechanisms (PDO, SDO, Object Dictionary…)

The fastest network in the world!• 728 axes in 400µs

Topology comparison - Conventional structure

Different engineering toolsMany bus systems

Complex diagnostics and maintenance

Bus 1 Bus 2

Bus 3

Motioncontroller

I/O I/O

SensorSensor

PLC

Bus 4

VisionBus 5

<1ms jitter<1ms jitter

>100 bytes>100 bytes

<10$<10$

>1Mbits/s

<5ms cycle time<5ms cycle time

Topology comparison - Integrated automation

I/O I/O

SensorSensor

PLC

Vision

One technologyUnmatched performanceUnlimited freedom in machine design

• 100ns jitter• 100µs cycle time• 1 to 1490 bytes• 100 Mbit/s• <10$

• 100ns jitter• 100µs cycle time• 1 to 1490 bytes• 100 Mbit/s• <10$

Easy diagnostics and maintenance

Standards• EPSG is an open vendor group

– Maintaining openPOWERLINK– openSAFETY

• POWERLINK is an open protocol– No license fees– No patents– Free specification:

• http://www.ethernet-powerlink.org/– Open-source protocol stack available for download on SourceForge

• Open standards– IEEE 802.3– IEC 61784-2

http://www.ethernet-powerlink.org/

openPOWERLINK• Open-source POWERLINK stack (MN and CN)

– BSD license– Developed for Linux– Ported to Windows and VxWorks– Other platforms under development

• Project hosted at SourceForge.net:– http://sourceforge.net/projects/openpowerlink/

http://sourceforge.net/projects/openpowerlink/

Market Share

• 3,100 OEMs developing POWERLINK systems

• More than one Million POWERLINK systems deployed

Source IMS Research 2013

Government Recommended Standard

Industrial Ethernet National Standard GB/T-27960

openSAFETY

TÜV certificationIEC 61508 SIL3, PL e

Certified safe motion profiles IEC 61800-5-2

International safety standard IEC 61784-3

TÜV certificationIEC 61508 SIL3, PL e

Certified safe motion profiles IEC 61800-5-2

International safety standard IEC 61784-3

certified product

POWERLINK news

www.ethernet-powerlink.org/

www.linkedin.com/groups?about=&gid=2331103

http://www.ethernet-powerlink.org/

http://www.linkedin.com/groups?about=&gid=2331103

Embedded TechCon

Thank you for your attention!

Sari [email protected]

Technology MarketingEthernet POWERLINK Standardization Group

Documents

Embedded TechCon Synchronizing mechatronic systems in real-time using FPGAs and Industrial Ethernet Sari Germanos [email protected]