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Industrial Networking (Part 1): EtherCAT® Industrial Ethernet SolutionsFTF-IND-F0048
A P R . 2 0 1 4
John Ralston, Alexandra Dopplinger, Olof Lennerstedt
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Contact
• Alexandra Dopplinger, Business Development− Freescale, Microcontroller Group (Canada)− [email protected]
• John Ralston, Applications Engineer− Freescale, Digital Networking Group (UK)− [email protected]
• Olof Lennerstedt, CEO− Rt:labs AB (Sweden)− [email protected]
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Agenda• EtherCAT® Market Overview• EtherCAT Protocol Overview• EtherCAT Slave Solutions• EtherCAT Master Solutions
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EtherCAT Market OverviewWhere and How EtherCAT Technolgy is Used
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Energy
Generation
Transmission
Distribution
Factory
Production
Facility Monitoring
Switchgear
Transport
Rail Systems
Mobility and Logistics
Industrial Vehicles
Buildings
Control
Elevators
HVAC
Infrastructure
Water Treatment
Oil and Gas
M2M Communication
Industrial Scalability, Security, Safety, Connectivity
Targets for Industrial Automation and Control
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Industrial / Factory Logic Blocks
i.MX MPUs
Kinetis MCUs
QorIQMPUsQorIQMPUs
Kinetis MCUs
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Most Significant Industrial Protocols
Organization Members Protocols PhysicalInterface
131MNodes in
2012*
ethercat.org
>2000 vendorsBeckhoff, Omron, ABB, NI, Schneider, Yaskawa
EtherCAT® 10/100 Ethernet
1.2M 18% CAGR (2011-16)
PROFIBUS and PROFINET Internationalprofibus.com
>1400 vendorsSiemens, GE, ABB, Schneider, Fanuc,
Molex
PROFIBUS RS-485 15.9M 8.9% CAGR
PROFINET• PROFINET RT• PROFINET IRT
10/100/GbEthernet
4.9M 16.9% CAGR
Open DeviceNetVendors Association
odva.org
>250 vendorsRockwell, Schneider, Bosch Rexroth, ABB,
Cisco
EtherNet/IP™• CIP™ Sync
• Device Level Ring
10/100/GbEthernet
4.7M14.8% CAGR
DeviceNet™ CAN 5.6M9.3% CAGR
*Source: IMS Industrial Ethernet + FieldBus World 2013
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NRT
RT
IRT
Deterministic1 to 100 ms Cycle Time
Deterministic< 1 ms Cycle Time
Industrial Protocols for Different Applications
Non-deterministic> 100 ms Cycle Time
• Sensors• Data scanner• Inventory
management
• Motor drives• Motion control• Synchronized servos
• Conveyor belts• Picker arms• PLCs, I/O Control• Valves
Target Applications Protocols
NRT
RT
IRT
DeterministicJitter matters for sync1 to 100 ms cycle time
Deterministic< 1 µs jitter
< 1 ms cycle time
Non-deterministicJitter doesn’t matter> 100 ms cycle time
IEEE® 1588 Precision Time ProtocolVERY jitter sensitive; cycle time does not matter
freescale.com/IndustrialNetworking
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EtherCAT Protocol OverviewHow EtherCAT Technology Works
June 2012
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• Founded by Beckhoffin Nov/03
• >2000 members in >50 countries
• Factory and process automation
• Energy generation and distribution
• Transportation and traffic management
• Building control• Elevators, alarms, access
• Entertainment • Amusement rides, lighting
Largest Fieldbus OrganizationWidely-used for Synchronized
Infrastructure Networks
• Real-time performance and flexible topology
• High-precision device synchronization
• Over 10/100 Ethernet
EtherCAT is an International Standard (IEC, ISO, SEMI)
EtherCAT Technology Group (ETG)
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• Master with up to 20K slave devices− Full duplex data− 10/100 Ethernet with
standard IEEE®
802.3 frames• Flexible ring or line
topology− 100BaseT has good
robustness/EMC− LVDS/E-Bus has low
robustness/EMC
• Highly deterministic − Cycle time <50 µs
• Eliminates need for switches and hubs− One master supports
up to 20k slaves• One version for all
applications− TwinCAT, CANopen®
and SERCOS application layers
Characteristics Advantages
• Slaves need high-cost ASIC or FPGA− Standard Ethernet
interface latency too high for slaves
− Masters use standard Ethernet interface
• No gigabit Ethernet• Technology defined
and controlled by Beckhoff− Sometimes an
advantage
Disadvantages
EtherCAT Industrial Ethernetwww.ethercat.org
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Master Slaves
Ethernet
Tx
Rx
EtherCAT Structure
• Slave devices network with a master in line or ring topology− Data from each device extracted and packed into
Ethernet data packet that traverses the entire ring− Devices pass messages through master before
sending to another device− Separate “e-bus” eliminates 1 µs delays in each
slave
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Slave Device
EtherCAT Slave Controller
Slave Device
EtherCAT Slave Controller
Functional Principle is Ethernet On-The-Fly
• Process data extracted and inserted on-the-fly• Process data size per slave almost unlimited
− 1 bit…60 Kbyte, if needed using several frames• Compilation of process data can change in each cycle
− e.g. ultra short cycle time for axis, and longer cycles for I/O update are possible• In addition asynchronous, event-triggered communication
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Freescale EtherCAT Status
• Apr/10: Freescale joined EtherCAT Technology Group
• Jun/10: First EtherCAT master demo and training for QorIQ P2020 MPU− QNX® / koenig-PA (KPA)− Green Hills / acontis /
IXXAT− Reference platforms,
webinars, training, press
PLC Reference Platforms on P1025 QorIQ Tower Module
• Oct/12:− ISaGRAF ® PLC Firmware
and Workbench− KPA EtherCAT master stack− QNX Neutrino® RTOS
• Feb/14:− Codesys EtherCAT master
stack, application and tools− Linux GPOS
• History • Reference Platforms
freescale.com/ethercat
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EtherCAT Reference Designs with Freescale Tower System
EtherCAT slave reference design for Kinetis K60 and K10 MCU (Q2/14)
EtherCAT master and soft-programmable logic controller (PLC) reference design for QorIQ P1025 MPU (now)
TowerGeeks.org
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EtherCAT Slave SolutionsIXXAT EtherCAT Slave Module for Tower System
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EtherCAT Slave Reference Design for Kinetis MCUs
RuntimeAnd Tools
RTOS
Protocols
Hardware
Kinetis MCUs are ideal for end nodes
DemoedNov/13
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KinetisK60 MCU
BeckhoffET1100 ASIC
SPIEthernet
PHY
Ethernet PHY
May2014
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EtherCAT Slave Module From IXXAT Automation GmbH
TWR-EtherCAT-SLV EtherCAT slave module developed and shipped by IXXAT
Features• Compatible with Freescale Tower System− SPI communication with any MCU or MPU
Tower module• Beckhoff EtherCAT ASIC (ET1100)− Easier set-up than Beckhoff EtherCAT eval kit− I²C EEPROM, two Ethernet PHYs and two
galvanic isolation transformers• Order from Freescale Buy Direct web site
Software and tools• EtherCAT slave reference software and
services from RT-Labs
May2014
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EtherCAT Slave Module Processor Support
• EtherCAT slave reference software currently runs on Kinetis K60 MCU (TWR-K60D100M)
• Port EtherCAT slave software to any other MCUs and MPUs included with the Tower System− Kinetis MCUs− Vybrid controllers− QorIQ and PowerQUICC MPUs− Qorivva MCUs− ColdFire MCUs and MPUs
• Do it yourself or with help from RT-Labs
TWR-MCF51AGTWR-MCF51CNTWR-MCF51JETWR-MCF51JFTWR-MCF51MMTWR-MCF51QMTWR-MCF5225XTWR-MCF5441X
TWR-P1025TWR-MPC5125TWR-MPC8309TWR-P1025TWR-PXD10TWR-PXD20TWR-PXN20TWR-PXR40TWR-PXS2010TWR-PXS3020
TWR-KL25Z48MTWR-K20D50MTWR-K20D72MTWR-K21D50MTWR-K40X256TWR-K40D100MTWR-K53N512TWR-K60N512TWR-K60D100MTWR-K60F120MTWR-K70F120MAnd Many More
ColdFire
Power Architecture
Kinetis
Vybrid Controller
TWR-VF65GS10TWR-SOM_BSB
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Web-based Support from Freescale and IXXAT
Item Freescalefreescale.com
/tower
IXXAT ixxat.com
Board overview and introduction Yes YesSoftware example for initial test Yes YesQuick Start Guide Yes YesBoard schematics - YesBill of materials (BoM) - YesFull user guide - YesCommercial SW/HW support services - Yes
IAR Tool Chain links / integration Yes YesList of tested/supported Tower Modules Yes Yes
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Tower Geeks Online Community
• www.towergeeks.org or https://community.freescale.com/community/tower
• Partners respond directly to support requests and community inquiries
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EtherCAT Slave SolutionsRT-Labs EtherCAT Slave Software
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Typical EtherCAT Development Steps
Evaluate½ month
Develop2 months
Test½ month
Certify (optional)1 month
1. Select device @ freescale.com or freescale.com/solutionadvisor2. Engage with stack vendor to port stack (possibly to port your application)
3. Stack vendor port EtherCAT to device and OS (2-5 days)4. Stack vendor training to port your application (2-5 days)5. You or stack vendor to port your application (5-8 weeks typical)
5. Pre-test and debug at stack vendor lab (1-2 weeks)
6. Test at Beckhoff lab and receive test report (1-2 days)
7. EtherCATcertificate
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• TwinCAT from Beckhoff− Including EtherCAT
master stack
• EtherCAT slave stack (and/or master)
• IDE
• Tools for creatingESI, PDO and EEPROM− Required to pass
conformance tests− XML-tool for ESI− C-code generator for
PDO info− HEX editor for
EEPROM data
Development Software Development Tools
• Development board
• Slaves from Beckhoff
Hardware
Typical EtherCAT Evaluation Kit
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Linux/Win PC w/ IDEWin PC w/ TwinCat
Typical EtherCAT Slave Development Steps
JTAGEtherCAT
Win PC w/ Config tools
EtherCAT slave Kit
3. Export EEPROM file
1. Create info aligned PDO info, ESI file & EEPROM data.
6. Read EEPROM, Download & Verify 5. Import header file,
Compile & Download
2. Export PDO header file
7. Execute & Test
4. Export ESI file for Conformance Test Tool
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Observations and Recommendation
Typical Situation:• EtherCAT development involves many different vendors• High threshold for developers new to EtherCAT (> three weeks)• Setup is error-prone and slow due to the several manual steps and
many components involved• Complexity increases significantly for advanced/complex slaves• Potential for high ongoing maintenance cost• Typically not your core business
Recommendation: • Work with an EtherCAT service provider, such as RT-Labs for
EtherCAT porting, testing and productization
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EtherCAT Master SolutionsProgrammable Logic Controller (PLC) Reference Platform for QorIQProcessors
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TWR-P1025PC (Windows) Slaves (Beckhoff)
PLC with Industrial ProtocolIntegration Based on QorIQCommunications Processors in Tech Lab [ FS-G4N-Q5R ]
www.freescale/goplc
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PLC Reference Platform with EtherCAT Master for QorIQ Processors
PLC RuntimeAnd Tools
RTOS
Protocols
Linux / RT
freescale.com/goPLC
QorIQ has Double Precision Floating Point
DemoedOct 2012
DemoedFeb 2013
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PLC Reference Platform Benefits
• Industry leaders integrated Freescale QorIQ processor hardware onto a single PLC Reference Platform− ISaGRAF and CoDeSys PLC firmware− Koenig-PA and CoDeSys EtherCAT master− QNX Neutrino® RTOS and Linux® OS
• Proven performance and headroom− KPA EtherCAT Master stack supports 1 millisecond cycle time
while using <1% of a core on the dual-core QorIQ P1025 processor
− Remaining 99% of the first core, and 100% of the second core available for control application and other protocols such as PROFINET, PROFIBUS, EtherNet/IP
− Scale up and down the QorIQ product portfolio• Customers can use ISaGRAF 6 Workbench development tool− Easily develop or port advanced PLC applications onto the new
PLC Reference Platform
PROFIBUSSlave DevicesPROFIBUS
Slave DevicesEtherCATSlave Device(s)
$199USD
freescale.com/goPLC
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The Original PLC Reference Platform
RUN-TIME SOFTWARE for P1025• USB image or download from web
− www.qnx.com/partners/plc_reference.htmlISaGRAF® PLC FirmwareKPA EtherCAT ® Master stackQNX ® Neutrino ® board support packageDocumentation: Get Started Guide
− One click-through license for all softwareMSRP $0 for evaluation version that times out in 4 hours
OFFLINE TOOLS for WINDOWS PC• ISaGRAF 6 Workbench with KPA EtherCAT Studio
− www.isagraf.com/pages/products/Isagraf/ethercat.htm
• Utility programs− TeraTerm http://ttssh2.sourceforge.jp/
− USB to UART driver http://www.ftdichip.com/Drivers/VCP.htm(FT2232)
freescale.com/goPLC
USB Cable
+5V PSU
$199USD
Supplied by Customer
Supplied in TWR-P1025 Box
TWR-P1025 module
+24V PSU
Beckhoff slave[EK1100, EL1004, EL2004, EL 9011] Ethernet cable
[2 x RJ45]
Electrical wire
Windows PC
USB Flash Drive
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TWR-P1025-KIT, $299 TWR-P1025
TWR-IND-IO
TWR-LCD
RS485
HMI
TWR-ELEV
TWR-P1025-KIT includes schematics and gerber files
optional, not in TWR-P1025-KIT
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Controller Module: TWR-P1025QorIQ P1025 Controller Module
• Hardware:− QorIQ P1025 dual-core processor− JTAG 14-pin debug header− 512 MB of DDR3 memory− Boot from NOR flash− Two RGMII GbE interfaces− One PCIe interface x1 (mini-PCIe+USB)− Two USB 2.0 interfaces− Two UART interfaces (via mini-USB)− One accelerometer (on I2C)− QE UART header (provides RS485 connectivity via
interface card, if needed)• Software:
− Linux® OS− MQX RTOS− CodeWarrior IDE− Support for 5x end applications out of the box− 100% compliant with Tower infrastructure
TWR-P1025
MSRP: $199 USDAvailable Now
QorIQ P1025 Processor• Dual e500 core processors running533 MHz, 2558 DMIPS
• 266 MHz protocol engine• DDR2/3 (32-bit w/ ECC)• 3x 10/100/1000 Ethernet controllers• Dual PCI Express® 1.0a controllers• USB 2.0 OTG• SD/SDIO/MMC $199
USD
freescale.com/TWR-P1025
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P1025/P1016Processor• 2x e500 v2, 32 b, up to 667 MHz• (1x e500v2 in P1016)• 36-bit physical addressingMemory SubSystem• 256 KB frontside L2 cache w/ECC• 32-bit DDR2/3, 800 MHz data rate w/ECCHigh Speed Serial IO• 2 PCIe 1.0a controllers (2.5 GHz)• 2 USB 2.0 with PHY
• Host/device supportNetwork IO• 3 VeTSECs (10/100/1000), up to 2 SGMII
• 1588v2 supportMisc IO• TDM• QUICC Engine
• HDLC, T1/E1, Utopia• 2x 10/100/1000 Ethernet
• Enhanced Local Bus controller supporting NOR and SLC NAND devices
• SD/MMC card controller• 2x Dual UARTs, 2x I2CsAcceleration• SEC 3.3.2 - crypto acceleration 1.5 Gbps
Device• 45 nm SOI Process• 561-pin TEPBGA I• 23 x 23 mm, 0.8 mm pitch
Power • <2.75 W • 0°C to 125°C Tj• -40°C to 125°C Tj option
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TWR-P1025 Block Diagram• P1025
− 2 x e500 cores, 32 KB L1 I & D cache, @ 533 MHz − 256 KB L2 cache − QUICC Engine module − Integrated security engine
• Memory− DDR3 512 MByte− NOR Flash 64 MByte− 2 x EEPROM
• Peripheral− Accelerometer MMA8451Q
• Connectors− 1 x USB (2x) UART to USB − 2 x RJ45 10/100/1000 Ethernet− 2 x USB 2.0 (Hub)− 1 x Micro PCIe− 1 x IEEE®1588 header− 1 x +5V barrel connector− 1 x Micro SD card
• Elevator Connections − 1 x MII 10/100 Ethernet− 1 x RMII 10/100 Ethernet− 2 x Serial − 1 x SPI (2 x Chip selects)− 2 x I2C− 1 x Parallel Bus (LB/LCD)− 1x PCIe (x1)− 1 x SGMII 10/100/1000 Ethernet
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LS1020/1/2A Details LS1021A LS1020A LS1022A
Core Type ARM Cortex™‐A7 MPCore™ + NEON
Cores/Threads 2 / 2
Frequency Up to 1GHz Up to 600MHz
L1 I/D 32kB / 32kB with ECC
L2 (Unified) 512kB Shared with ECC
SRAM 128kB with ECC
DDR 1x(16/32B it+ECC) DDR3L/4 up to 1.3GT/s
1x( 16bit+ECC) DDR3Lup to 1.0GT/s
SerDes 4 up to 6.0GHz 1 up to
Ethernet 3 x 1GE 2 x 1GE
PCIe 2 x Gen 2.0 (up to 5.0GT/s) 1 x Gen 2.0 (up to 5.0GT/s)
SATA 3.0 1 up to 6.0GHz No
USB 1 x USB 3.0,1 x USB 2.0 1 x USB 2.0
CAN Up to 4 0 Up to 4
TDM/HDLC 2 No
UART/I2C/SPI Up to 8 / 3 / 2
I2S Up to 4
LCD 1 x Controller No
Acceleration SEC,QE No
Trusted architecture
Pin Compatible 19x19mm, 0.8mm pitch
Low Power < 3W
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Generic Controller 1
24V
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Generic Controller 1
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Industrial Software Support for QorIQ Processors
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EtherCAT Solutions SummaryWrapping up
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• www.freescale.com/ industrialnetworking
/ethercat
/profinet
/profibus
/CAN
/IEEE1588
• www.freescale.com/goplc
All Industrial Protocols EtherCAT Master PLC Reference Platform
• www.freescale.com/tower
• Questions?www.TowerGeeks.org
EtherCAT Slave Reference Platform
Industrial Protocol Solutions from FreescaleMay2014
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Summary
• EtherCAT reference designs are available with the Freescale Tower System development platform− EtherCAT master for QorIQ P1025 (now)− EtherCAT slave for Kinetis K60 with Beckhoff ASIC (May/14)
• Reference designs include hardware schematics, software source, documentation, tools and support
• Port easily to other QorIQ MPUs and Kinetis MCUs− Freescale partners are ready to help
Thank-you for considering Freescale!
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© 2014 Freescale Semiconductor, Inc. | External Use
www.Freescale.com
