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EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
EtherCAT –The Ethernet Fieldbus.
Oliver Fels
Technology Marketing
EtherCAT Technology Group
ETG Headquarters, Germany
September 2016
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
Ethernet is a great technology –But it is challenging to use it on the fieldbus level:
Switch + Router Configuration (+ Costs)
MAC + IP-Address Handling
Star Topology
Complex Protocols
Diagnostics
Performance
ComprehensiveIT Know-HowRequired
EtherCAT – The Ethernet Fieldbus.
September 2016
Router
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
3 Main Performance Problems:
1. Bandwidth Utilization
2. Stack Delays
3. Switch Delays
Ethernet for Real-Time Communication
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Minimum Ethernet Frame: 84 Bytes
Example: with 4 Bytes Process Data (32 I/O): 4/84 =
4.75 % Application Data Ratio
1. Industrial Ethernet Bandwidth Utilization
Ethernet Frame Payload: min. 46 BytesEthernet HDR
14 Bytes
Process
Data
Process Data, e.g. 1..4 Bytes
FCS
CRC
4 Bytes
Interpacket Gap
14 Bytes
≥ 84 Bytes, regardless which Protocol
Ethernet HDRUDP
HDR
Ethernet/IP
CIP HDR
14 Bytes 20 Bytes 8 Bytes 20 Bytes
Process
Data
Payload,
e.g. 4 Bytes
FCS
CRC
4 Bytes
IP HDR Interpacket Gap
14 Bytes
≥ 84 Bytes, e.g. with
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
1. Industrial Ethernet Bandwidth Utilization
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Industrial Ethernet Protocol Stacks are
BIG
Processing them needs
TIME
2. Industrial Ethernet Stack Delays
Ethernet
MAC
IP
TCP UDP
Encapsulation
CIP Message Encapsulation
Implicit Msg
Explicit Msg
CIP Network & Transport
Device Profile Application Objects (e.g. I/O)
I/O Ports
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT is
LEAN
2. Industrial Ethernet Stack Delays
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
Stack performances of the Ethernet technologies differ substantially, due to the different complexity of the stacks
Softing, a German specialist for field bus technology published* the following comparison of the stack delay times:
All three protocols were implemented on the same hardware (interface board with FPGA + Softcore CPU) and by the same team, so they are indeed comparable
* Source: „Einer für alle; Flexible Real-Time-Ethernet Anschaltung mit FPGA“, messtec drives Automation Real-Time Ethernet Sonderheft 2010, by Frank Iwanitz, Business Development Manager Real-Time Ethernet at Softing GmbH, Munich, Germany
Stack Time Profinet IO Ethernet/IP EtherCAT
Average 0.58 ms 1.89 ms 0.11 ms
Max. 0.74 ms 2.96 ms 0.18 ms
Min. 0.54 ms 1.23 ms 0.05 ms
September 2016
Stack Performance Comparison (I)
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
3. Industrial Ethernet Switch Delays
Switch Buffer Delay:
Unpredictable “by Nature”
Buffer delay depends
on buffer load @ frame
arrival.
QoS (Quality of
Service) eases the
pain by introducing
multiple priorities (and
buffers), but does not
resolve the issue.
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
Substantial accumulated delay and jitter even without buffer delay (if switches are idle)
Typical Store & Forward Delay per switch: Frame length (7…122 µs) + 3 µs
Example: Full frame, 20 nodes in line topology: 2.5 ms
September 2016
3. Industrial Ethernet Switch Delays
Almost all Switches use “Store & Forward”
Line Topology means cascaded Switches
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Quote: “RT in Profinet provides similar Real-Time properties like Profibus”
Source: Profibus International
http://www.profibus.org.pl/index.php?option=com_docman&task=doc_view&gid=28
Quote: “When tested up to 80 percent network bandwidth utilization, using both managed and unmanaged switches, the system managed 16 position configured axes with an 8 ms coarse update rate.”Source: Rockwell Automation, White Paper: “Scalability-The Best Approach to Change”, Aug 2012
http://literature.rockwellautomation.com/idc/groups/literature/documents/wp/ia-wp002_-en-p.pdf
Ethernet for Real-Time Communication?
20ms
8msCycle times can be realized in the range of 5 to 10 ms
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT: Performance Breakthrough
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
The fastest Industrial Ethernet Technology
1000 distributed digital I/O in 30 µs
100 Servo-Axis every 100 µs
EtherCAT directly to the I/O Slice, no Sub-Bus
Optimal Usage of the Standard Ethernet Port in the Controls, no extra hardware
Reason for this Unique Performance:
The EtherCAT Functional Principle (Ethernet on the Fly)
EtherCAT: highest Performance
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Functional Principle: Ethernet “on the fly”
Analogy Fast Train:
“Train” (Ethernet Frame) does not stop
Even when watching “Train” through narrow window one sees the entire “Train”
“Car” (Sub-Telegram) has variable length
One can “extract” or “insert” single “persons” (Bits) or entire “groups” (Bytes) – even multiple groups per train
Car
27
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
Functional Principle: Ethernet “on the fly”
September 2016
Efficient: Typically only one Ethernet Frame per Cycle
Ideal Bandwidth Utilization for maximum Performance
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Process data is 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 possible
in addition asynchronous, event triggered communication
Functional Principle: Ethernet “on the fly”
Slave Device
EtherCAT Slave
Controller
Slave Device
EtherCAT Slave
Controller
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Minimal protocol overhead via implicit addressing
Optimized telegram structure for decentralized I/O
Communication completely in hardware: maximum(+ predictable!) performance
No switches needed if only EtherCAT devices in the network
Outstanding diagnostic features
Ethernet-compatibility maintained
Functional Principle: Ethernet “on the fly”
Master
Ethernet Header ECAT HDR CRCPLC Data 1
HD
R 1
NC Data
HD
R 2
PLC Data 2
HD
R 3
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
3 Main Performance Problems:
1. Bandwidth Utilization
2. Stack Delays
3. Switch Delays
EtherCAT resolves the Performance Problems
Resolved!
Resolved!
Resolved!
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT – The Ethernet Fieldbus.
EtherCAT is real time down to the I/O level
No underlying sub-systems any more
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
Fie
ldb
us
Con
tro
ller
I/O
CPU
RAM
Flash
Drive
r
September 2016
Other technologies need local I/O cycles + gateways
EtherCAT – The Ethernet Fieldbus.
Fie
ldb
us
Con
tro
ller
Ma
ste
r fo
r L
oca
l
Exte
nsio
n B
us
CPU
RAM
Flash
Drive
r
I/O
I/O
I/O
I/O
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT: Real time down to the I/O
EtherCAT – The Ethernet Fieldbus.
Eth
erC
AT
Con
tro
ller
Eth
erC
AT
Con
tro
ller
Drive
r
Eth
erC
AT
Con
tro
ller
Eth
erC
AT
Con
tro
ller
Eth
erC
AT
Con
tro
ller
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT – The Ethernet Fieldbus.
EtherCAT is real time down to the I/O level
No underlying sub-systems any more
No delays in gateways
In- and outputs, sensors, actuators, drives, displays: everything in one system!
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Transmission Rate:
2 x 100 Mbit/s (Fast Ethernet, Full-Duplex)
Update Times:
256 digital I/O in 11 µs
1,000 digital I/O distributed to 100 nodes in 30 µs = 0.03 ms
200 analog I/O (16 bit) in 50 µs, 20 kHz Sampling Rate
100 Servo-Axis (each 8 Byte In + Out) in 100 µs = 0.1 ms
12,000 digital I/O in 350 µs
EtherCAT is faster
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Reaction time with legacy fieldbus I/O:
‘Slow’ Control Systems benefit, too
Tmpd
Bus Cycle Bus Cycle Bus Cycle Bus CycleBus CycleBus Cycle Bus Cycle
Input (worst case) Input (best case)
Worst case reaction time
Best case reaction time
Output
Tmpd: Master Processing Delay
TI/O: Local I/O Update Time
(Local Extension Bus + Firmware)
PLC Task OI PLC Task OI PLC Task OI PLC Task OI PLC Task OI
TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/OTI/OTI/OTI/O
Emoji provided free by EmojiOne
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
System Architecture with EtherCAT:
‘Slow’ Control Systems benefit, too
Bus Cycle Bus Cycle Bus Cycle Bus CycleBus CycleBus Cycle
Tmpd
PLC Task OI PLC Task OI PLC Task OI PLC Task OI
Bus Cycle
PLC Task OI
no underlying extension bus any more
no dedicated Master Device any more
TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/OTI/OTI/OTI/O
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
System Architecture with EtherCAT:
‘Slow’ Control Systems benefit, too
PLC Task OI PLC Task OI PLC Task OI PLC Task OI PLC Task OI
TDMA (NIC)
TEtherCAT Cycle
TDMA = Time for Data Transfer
from/to Ethernet Controller via
Direct Memory Access:
neglectible
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Control System is unburdened, master becomes very simple
Data is transmitted according to the application requirements: extremely fast, flexibly and efficiently
EtherCAT: Mapping moved into Slave Devices
Master
Ethernet Header ECAT HDR Enet FCSPLC Data
HD
R 1
NC Data
HD
R 2
Data n
HD
R 3
PLC Data
Data n
NC Data
logical
process
images up
to 4 Gbyte
Datagram 1 Datagram 2 Datagram n
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Synchronization
Sourc
e:
konflik
ty.p
l
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT Node measures time difference between leaving and returning frame
EtherCAT Propagation Delay Measurement (1)
EtherCAT FrameProcessing Direction
EtherCAT FrameForwarding Direction
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT Node measures time difference between leaving and returning frame
EtherCAT Propagation Delay Measurement (2)
Master
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Precise Synchronization (<< 1 µs!) by exact adjustment of Distributed Clocks
Distributed Clocks
MS
S
S S S S
S
Master ∆t
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Long Term Scope View of two separated devices
300 Nodes in between, 120 m Cable Length
Distributed Clocks
Jitter: ~ +/-20 ns
Simultaneousness:
~15 ns
Interrupt
Node 1
Interrupt
Node 300
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Synchronization with Distributed Clocks
Sample
Point
100 µs Cycle Time
100 µs 100 µs 100 µs 100 µs
Velocity
= x‘
DC
Sync
Position
Signal
= x
EtherCATIn Calc. Out
Sync In
In
A/DA/D
D/A
Calc. Out In
A/D
D/A
Calc. Out In
A/D
D/A
Sync Out
Calc. Out
D/A
equidistant
No sampling
Error
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT networks can be coupled via EtherCAT Bridge
Bridge provides hardware synchronization of several networks
Synchronization of multiple Networks
SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE
SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE
SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE
SLAVE SLAVE SLAVE
SLAVE
SLAVE
SLAVE
MASTER
1
MASTER
2
MASTER
3
1
2
3
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
S
Y
N
C
H
R
O
N
O
U
S
September 2016
EtherCAT networks can be coupled via EtherCAT Bridge
Bridge provides hardware synchronization of several networks
Synchronization of multiple Networks
SLAVE
SLAVE
SLAVE
SLAVE
SLAVE
SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE
SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE
SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE SLAVE
SLAVE SLAVE SLAVE
1
MASTER
1
MASTER
2
MASTER
3
1
2
3
1
S
Y
N
C
H
R
O
N
O
U
S
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Switchport with integrated IEEE 1588 Boundary Clock
External Clock Synchronization: IEEE 1588
MS
S
S S S S
Boundary
Clock
S
Master
IEEE 1588
Grandmaster
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT uses Standard Ethernet Frames: IEEE 802.3
Alternatively via UDP/IP (if IP Routing is needed)
no shortened frames
EtherCAT is Industrial Ethernet!
Embedded in Standard Ethernet
Frame, EtherType 0x88A4 1…n EtherCAT Datagrams
TypeRes.Length
1 Bit 4 Bit11 Bit
Or: via UDP/IP
UDP Port 0x88A4
Destination EtherTypeSource
16 Bit
Header EtherCAT Datagrams CRC
48 -1498 Byte
MTU: max. 1514 Byte
48 Bit 48 Bit 16 Bit 32 Bit
16 Bit
IP Header UDP H.
160 Bit 64 Bit
Header EtherCAT Datagrams CRC
48 -1470 Byte
Ethernet Header
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
fully transparent for TCP/IP
all Internet technologies (HTTP, FTP, Webserver,…) available without restricting the real time capabilities!
EtherCAT is Industrial Ethernet!
EtherCAT Slave Device
TCP
Ethernet Application
UCP
IP
Real Time Application
Acyclic Data
EtherCAT MAC / DLL
Ethernet PHY
Mailbox Process Data
Ethernet PHY
Standard TCP/IP Stack
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Any Ethernet Device can be connected to Switchport
Access to Webserver with Standard Browser
EtherCAT is Industrial Ethernet!
Virtual Ethernet Switch
Functionality
Switchport
Webserver
Master
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Any Ethernet Device can be connected to Switchport
Access to Webserver with Standard Browser
EtherCAT is Industrial Ethernet!
Master TCP/IP Stack
provides access to Mailbox
protocol
SwitchportMaster
Online access to
device
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
EtherCAT Switchport
September 2016
Interface to any Ethernet Device or Network
Ethernet Frames are inserted into EtherCAT Protocol:
‘Ethernet over EtherCAT’
Switchport: Any Ethernet Protocol
Ethernet MAC PHY
μC
EtherCAT MAC / DLL
Fragmentation
Mailbox Process DataPHY PHY
TXRX1RX2RX3RX4
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT wiring is more flexible
Standard Ethernet Topology: Star
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Flexible tree structures – arbitrarily extendable
Topology variants like Line, Star, Tree, Daisy Chain+ Drop Lines possible; can be used in any combination!
Up to 65,535 nodes for each EtherCAT segment
Standard Ethernet cabling
Your Selling Point: Expandability
Master
Line
Drop LineStar/Tree
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT Extra Large System Test
10.056
EtherCAT Nodes
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Ethernet Signal Variants of EtherCAT:
100BASE-TX (up to 100 m between 2 nodes)
100BASE-FX (up to 20 km between 2 nodeswith single mode fibre)
LVDS (for modular devices)
Any number of physical layer changes allowed *LVDS: Low Voltage Differential Signaling according to ANSI/TIA/EIA-644,also used in IEEE 802.3ae (10 Gigabit Ethernet)
EtherCAT wiring is more flexible
Ethernet on LVDS*
physical layer:
for modular devices
LVDS*
20 km
100 m
Ethernet on
100BASE-FX
(fibre optics)
up to 20 km
Ethernet on
100BASE-TX up
to 100 m with
transformer
coupling
Master
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Less Cabling on the field level
Cascadable in all topologies (star, line, tree)
100 % EtherCAT-compatible
100 Mbit/s full duplex, Processing on the Fly, Distributed Clocks etc.
Dual power supply: US (system and sensors) and UP (peripheral voltage for actuators) = 24 V DC/3 A
Daisy-chained power supply through EtherCAT P devices
EtherCAT P: Communication & Power combined
TX-US
RX+
GNDP
TX+
GNDS
RX-
UP
Communication & Power combined:
EtherCAT P
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT P connectors
M8, EtherCAT-P-coded
Symmetrical connector design
Mechanical keying: Sockets and plugs are polarized to prevent improper connection.
Easy field assembly
Cables
Standard: industrial CAT5 cables in AWG22/7
AWG24/7 cables for short distances available
Ultrathin cables for short distances are in consideration
EtherCAT P: Connectors and cables
EtherCATPower
Black and red
EtherCAT P cable
Mechanical
EtherCAT P
keying
Red EtherCAT P
plugs and
sockets
4 poles:
EtherCAT
+ 2 x 24 V DC/3 A
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT P: Makes EtherCAT even simpler!
24 V DC
EtherCAT P …
… for actuators
AC and DC motors
Actuators
Valve terminals
… for sensors
Proximity switches
Light barriers
Shaft encoders
… for vision
Cameras
Barcode scanners
3-D scanners
… for I/O components
IP 67
IP 20
…
EtherCAT master
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Optimized for direct connection of EtherCAT P devices in the field
Time savings through reduced wiring requirements
Reduced number of error sources
Smaller sensors and actuators through the elimination of separate supply cables
Simplified connection of components
EtherCAT P: The sensor, actuator and measurement bus
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Trapezoidal EtherCAT P element enables high packing density
Resulting in improved current-carrying capacity and dielectric strength of the power pins
Seamless and consistent 360°shielding of the connector
Uniform EtherCAT P element for all sizes, from B12…B36
Outlook: From 24 V sensors to 600 V drives
EtherCAT
2 x 24 V DC, 3 A
M8
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT P: Matching connectors for every performance class
B36
630 V AC/
850 V DC,
64 A
M8
2 x 24 V DC,
je 3 AB12
90 V DC,
10 A
B23
630 V AC/
850 V DC,
30 A
B17
630 V AC/
850 V DC,
16 A
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT P: Communication & Power combined
US: 24 V DC,
UP: 24 V DC
400 V AC
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
March 2016: ETG Technical Committee accepts EtherCAT P as Extension to the EtherCAT Technology Portfolio
September 2016:First Draft Specification (M8 Variant) will be presented at ETG Technical Committee Meeting
EtherCAT P: Timeline
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Topology:
Automatic Topology Expected/Actual Comparison
Diagnosis:
Diagnosis with exact Localization
EtherCAT is easier to configure
M
Every node
constantly
monitors
checksum
Bit errors are
detected and
localized
Even Timing Errors (e.g. Time Window for Actual Values
missed) are detected and stored locally in the chip
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Network planning:
Performance independent of:
Slave implementation (no Stacks involved in Process Data Communication)
Topology (no Switches/Hubs)
Addressing:
No manual address setting required
No IP- or MAC-Address Handling required
Addresses can be assigned automatically
Addresses can be kept
no new addressing if nodes are added
EtherCAT is easier to configure
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Less effort for Network planning:
Simplified configuration
Default settings will work, no network tuning
Improved Diagnosis:
Faster error handling leads to less downtime
Faster Setup:
No address setting required
Implementation / Tools:
Standard Network Monitor Tools, e.g. MS Network Monitor or Wireshark: free of charge
Parser Software: free of charge
EtherCAT is lower costs (1): Engineering
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
Master:
no dedicated plug in card (co-processor)
on-board Ethernet Port is fine
Slave:
low cost Slave Controller
FPGA or ASIC
for simple devices: no µC needed at all
no powerful µC + lots of memory needed
Infrastructure:
no Switches/Hubs required
Standard Ethernet Cabling + Connectors
32 Bit
µC
September 2016
EtherCAT is lower costs (2): Hardware
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Slave Implementation:
All time critical functions implemented on ASIC or FPGA
ESC handles Real-time Protocol in Hardware
Integrated Communication State Machine
Network Performance independent of
Slave-µC Performance
Protocol Stack
For usage with or without µC (Host CPU)
Integrated DPRAM (1…8 kByte)
Integrated Distributed Clock Handling
Ultra precise interrupts to µC
EtherCAT is easier to implement
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT Chips from Multiple Sources
84
ESC10/20:Altera
®Cyclone
™-I
IP-Core forAltera
® Cyclone
™-II
BeckhoffET1100
BeckhoffET1200
HilschernetX
®100/500
HilschernetX
® 50
IP-CoreXilinx
®
Spartan™
-3
IP-Core forAltera
®Cyclone
™-III
IP-Core forXilinx
®
Spartan™
-6
IP-Core forAltera
® Stratix
™-IV
IP-Core forAltera
®Cyclone
™-IV
IP-Core forXilinx
® Kintex
™-7
IP-Core forAltera
® Stratix
™-V
IP-Core
for FPGA
ofIntel
®Atom
™
E6x5C
TI Sitara™
ARM® Cortex® A8
AM335x
ASIC
FPGA
µC, µP
HilschernetX
®51/52/6
IP-Core forXilinx
® Artix
™-7 + Zync
™
RenesasR-IN32M3-EC
HMSAnybus
NP40
IP-Core forAltera
®
Cyclone™
-V
IP-Core forAltera
® Max10
™
TI Sitara™
ARM® Cortex®
A9 AM435x
MicrochipLAN9252
RenesasRZ/T1
InnovasicFido5000
InfineonARM® Cortex®-M
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
8/16-bit µC Interface
Demultiplexed
Intel Signal Types
Polarity configurable (BUSY, INT)
Typical µC:
Intel 80x86, Infineon 80C16x, Hitachi SH1, ST10, ARM, TI TMS320 Series, …
SPI
Up to 10 MBaud
µC is SPI Master
Typical µC:
Microchip PIC, DSPic, Intel 80C51,…
EtherCAT Slave Controller with Host Controller
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Protocol is disclosed completely:
EtherCAT is IEC, ISO and SEMI Standard (IEC 61158, IEC 61784, ISO 15745, SEMI E54.20)
Slave Controller from several sources available
Slave Controller provides interoperability
ETG organizes Interoperability Testing (“Plug Fests”), Workshops and Seminars
Conformance Testing + Certificates
EtherCAT is an open technology
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Foundation: November 2003
Tasks: Support, Advancement and Promotion of EtherCAT
The worlds largest fieldbus organization
More than 3900* member companies from 62 countries in 6 continents:
Device Manufacturers
End Users
Technology Providers
Membership is open to everybody
EtherCAT is an open technology
* as of Sept 2016
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
ETG Membership Development
September 2016
0
500
1000
1500
2000
2500
3000
3500
4000
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
0
100
200
300
400
500
0
500
1000
1500
2000
2500
3000
3500
4000
ETG Membership Development
September 2016
2016: exceeding
500 new members/year
2008:
1 new Member every
business day
2013:
1 new Member every
calendar day
12 months
Growth
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
As of Sept 6th, 2016:
ETG members from
62* countries and 6 continents
ETG Members worldwide
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
62 Countries, 6 Continents
Austria
Hungary
Spain
Columbia
Liechtenstein
India
Czech Rep
Netherlands
Belarus
Israel
Denmark
Russia
BelgiumAustralia
Korea
GermanyChina
Slovenia
Japan
France
Canada
Slovakia
Italy
Finland
Singapore
Brazil
South AfricaSerbia
Norway
Greece
Poland Portugal RomaniaMexico
Bosnia and
Herzegovina
Lithuania
New Zealand
Croatia
Bulgaria
Lebanon
Iran
Argentina
Ireland
Latvia
San Marino
Luxemburg Macedonia Malta
Qatar
Malaysia
Estonia
United Kingdom
Sweden
USA
Switzerland
UkraineTurkeyTaiwan Thailand VietnamUAE
Indonesia
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
ETG Membership Distribution
September 2016
EtherCAT Technology Group:
a truly Global Organization!
Germany
Europew/o Germany
America
Asia
33 members >3900 members
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Liechtenstein!
Most important EtherCAT Country
13.9 ETG members
per 100,000 inhabitants
The equivalent of 180,000
Chinese members…
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
ETG Team Worldwide
Dr. Guido
Beckmann, GER
Andrea Bock,
GER
Bin (Beryl) Fan,
CHN
Oliver Fels,
GER
Florian Hammel,
GER
Florian Häfele,
GER
Rainer Hoffmann,
GERLiliane Hügel,
GER
Dr. YanQiang Liu,
CHN
Prof Dr. Yong-Seon
Moon, KOR
Masanori Obata,
JPN
Thomas Rettig,
GER
Martin Rostan,
GER
Joseph P. Stubbs,
USAKey Yoo,
KOR
Makiko Hori,
JPNFengjiao (Jojo) Fu
CHN
Geng Cheng,
CHN
Christiane Heubusch,
GER
Michele Beers,
USA
Burkart Lingner,
GER
Dr. Karl Weber,
GER
Emma Lee,
KOR
Alessandro Figini,
GER
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT Technology Group Structure
ETG HeadquartersGermany
ETG OfficeNorth America
ETG RegionalCommittee Korea
ETG OfficeChina
ETG OfficeJapan
ETG Office Korea
ETG Membership AssemblyETG Members
Task Forces (TF)Technical Working
Groups (TWG)ETG RegionalCommittee Japan
Marketing Committee (MC)
Technical Committee(TC)
CiA402 Drive Profile
Device & Network Description
Conformance
Semiconductor
FDT/DTMEAP
Master Classes Safety
Vision Sensor
Technical Advisory Board (TAB)
EtherCAT Test Center(ETC)
Kyoto, Japan
EtherCAT Test Center(ETC)
Nuremberg, Germany
EtherCAT Test Center(ETC)
Beijing, China
EtherCAT Test Center(ETC)
Savage, USA
Board of Directors
Executive
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT Versioning
There is only one
EtherCAT Version,
not one every year…
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
One indicator: implementation kits sold.
Until now, Beckhoff alone has sold over 2000 kits (80% slave kits, 20%(!) master kits)
+ there are slave implementation kits + master stacks from many other vendors*, such as
How many members invest in the technology?
* Only those listed that have entered their
offering in the EtherCAT Product Guide at
www.ethercat.org/products
Avnet
Beck IPC
Deutschmann
EBV Elektronik
Hilscher
Infineon Technologies
Microchip Technology
Red one technologies
Renesas
Soft Servo Systems
Softing Industrial Automation
Spansion
STMicroelectronics
Terasic Technologies
Texas Instruments
TRINAMIC Motion Control
Xilinx
…
Sla
ve acontis
esd
HMS Industrial Networks
igH
Kithara
Koenig-pa
MicroSys Electronics
Profimatics
Sybera
…
Maste
r
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT Adoption Rate
EtherCAT Master Vendors
EtherCAT Drive Vendors
EtherCAT I/O Vendors
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT Masters implemented on wide range of RTOS*
EtherCAT Master OS Technology Variety
eCos
FreeRTOS™
INTEGRITY®
INtime®
Linux (with RT-Preempt)
Microware® OS-9
MQXTM
On Time RTOS-32
Oracle® Solaris (SunOS)
PikeOS
Proconos OS
QNX®
RMOS
ROS (Robot Operating System)
RTKernel
RTLinux
RTX
RTXC
RTAI-Linux
SCALE-RT
TKernel
VxWin® + CeWin®+ RTOS32Win®+LxWin
VxWorks®
Windows® CE
Windows® Embedded with IntervalZero RTX
Windows® XP/XPE with CoDeSys SP RTE
Windows® XPE/WES7/ WES8 with TwinCAT RT-Extension
Windows® NT/2000/XP/ Vista/7/8 with TwinCAT RT-Extension
XOberon
XENOMAI Linux
µC/OS-IITM
µITRON* as of March 2014
33
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT Master (Controller) Vendors 193
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT Drive Vendors 156
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
ABB
Ackermann
ACS Motion Control
ADDI-DATA
Adlink
AFT Fahrzeugtechnik
Algo System
Amoy Dynamics
Anca Motion
AutomationX
B&R
Balluff
Baumüller
BBH
Beckhoff
Belden
Berghof
Brunner Elektronik
Bosch Rexroth
CEC
Cosworth
CREVIS
CSM
Deif
DEWESoft
Dina Elektronik
dSPACE
Eckelmann
ectronic
elobau
esd
Festo
Foshan ShundeGather Win Information Tech.
Galil Motion Control
Gantner
GE Intelligent Platforms
Gefran
Grossenbacher
HBM
Helmholz
Hitachi
IDS
Imc/Additive
IPC DAS
ISAC
IXXAT
Jäger Messtechnik
Jetter
Jumo
KEB
KEBA
Keyence
kk-electronic
Knestel
Kolektor Synatec
Kollmorgen
Kuhnke
Lenze
M-System
MaVi
Messung
NEXCOM
MicroControl
Microinnovations/ Eaton
Mikrap
MKS Instruments
MKT Systemtechnik
MSC
MTT
Murrelektronik
M-System
National Instruments
NCT
Omron
Panasonic SUNX
Parker Hannifin
Pilz
Phoenix Contact
Power Instruments
Prima Electro
Renesas
Schaeffler Engineering
Schweitzer Engineering Laboratories / SEL
SERAD
SEW Eurodrive
SIPRO
Shanghai Xinhua
SHF
SMC
SOFTLINK
Sontheim IndustrieElektronik
TETRA
TexComputer
TR Elektronik
Turck
UFG Elettronica
Unidor
Unitro
VIPA
Wachendorff
WAGO
Watlow
Weidmüller
Wenglor
Wieland Electric
EtherCAT I/O Vendors 105
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT: Largest Product Selection
I/O, Controller, HMI, Servo Drives, Variable Speed Drives
Sensors, Slave + Master Development Kits
Control Panels, Hydraulic Valves
and Pneumatic Valves,
…
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Conformance and interoperability are very important factors for the success of a communication technology
Conformity to the specification is an obligation to all users of the EtherCAT technology
Therefore the EtherCAT Conformance Test Tool (CTT) is used
Test Cases for the CTT are provided by the Working Group “Conformance” within the ETG community
The EtherCAT Conformance Test proves conformance with issuing a certificate after passing the test at an official EtherCAT Test Center (ETC)
Conformance and Interoperability
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Safety over EtherCAT
Material feeding
Muting
Two-Hand control
Protection of workspace
e.g. with Laser scanner
Safety guardDoor guarding with
Interlocking
Safely-limited
Position / Speed Setup /
Maintenance
Operator
Diagnosis
Emergency
stop
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Safety by safety I/O-Connections
DVI
SPS
....
M
Safe
Logic
Relais-
Logic
M MM M
Standard fieldbus Standard
I/O…
… Safe
Outputs
Safe
Inputs…
… Standard
Drives
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Modern Machine Safety Concepts
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT is used as a “black channel”
It contains safety and standard information
Safety over EtherCAT: Software Architecture
Device 1
Safety over
EtherCAT
Protocol
Safety
Application
Standard
Application
Safety over
EtherCAT
EtherCAT
DLL and AL
EtherCAT Telegram
Safety data container (FSoE Frame)
Device 2
Safety over
EtherCAT
Protocol
Safety
Application
Standard
Application
EtherCAT
Communication InterfaceEtherCAT
Communication Interface
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Safety over EtherCAT: Software Architecture
Device 1
Safety over
EtherCAT
Protocol
Safety
Application
Standard
Application
EtherCAT
Communication Interface
CMDSafe
Data 0CRC_0
Safe
Data 1CRC_1
Safe
Data nCRC_n Conn ID
EtherCAT Frame
Ethernet
Header
EtherCAT
Header
1. Data-
gramFCS2. DatagramProcess Data
HD
R
FS
oE
FSoE Frame
FSoE Frame
The FSoE Frame is
embedded as a
Container in the
process data of the
device.
Each device detects a
new FSoE Frame, if at
least one Bit in the
FSoE Frame is
changed.
Every 2 Byte SafeData
are checked by a
2 Byte CRC
The maximum number
of SafeData is therefore
not restricted by the
protocol.
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Fully integrated solution:
safe and standard communication in one channel
Reduction of fieldbuses and interfaces
Central configuration, diagnosis and maintenance for safe and ‘unsafe’ I/O in one tool
Safety application makes full use of EtherCATadvantages:
Short reaction times
Almost unlimited number of nodes
Large network extensions
Cable redundancy options
High Flexibility with Hot Connect
Safety over EtherCAT: Advantages
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Decentralized Safety-Logic
Standard PLC routes the safety messages
Safety over EtherCAT: Implementation Example
Standard
PLC
Safety Inputs
Safety Logic
Safety Outputs
Safety Drives
Safety Sensors
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Safety over EtherCAT Vendors 27
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
……
September 2016
Without Redundancy: Normal Operation
Slave 1
RX TX
RXTX
Slave 2
RX TX
RXTX
Slave N
RX TX
RXTX
EtherCAT Master
MAC 1
RX TX
RX Unit TX Unit
TXRX
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
……
September 2016
Without Redundancy: Cable Failure
Slave 1
RX TX
RXTX
Slave 2
RX TX
RXTX
Slave N-1
RX TX
RXTX
Slave N
RX TX
RXTX
EtherCAT Master
MAC 1
RX TX
RX Unit TX Unit
TXRX
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
……
September 2016
Without Redundancy: Node or Cable Failure
Slave 1
RX TX
RXTX
Slave 2
RX TX
RXTX
Slave N-2
RX TX
RXTX
Slave N-1
RX TX
RXTX
Slave N
RX TX
RXTX
EtherCAT Master
MAC 1
RX TX
RX Unit TX Unit
TXRX
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
……
September 2016
With Redundancy: Normal Operation
Slave 1
RX TX
RXTX
Slave 2
RX TX
RXTX
Slave N
RX TX
RXTX
EtherCAT Master
MAC 1 MAC 2
RX TX RX TX
RX Unit TX Unit
TXRX
Only 2nd Ethernet
Port required – no
special Interface Card
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
……
September 2016
With Redundancy: Cable Failure
Slave 1
RX TX
RXTX
Slave 2
RX TX
RXTX
Slave N-1
RX TX
RXTX
Slave N
RX TX
RXTX
EtherCAT Master
MAC 1 MAC 2
RX TX RX TX
RX Unit TX Unit
TXRX
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
……
September 2016
With Redundancy: Node or Cable Failure
Slave 1
RX TX
RXTX
Slave 2
RX TX
RXTX
Slave N-2
RX TX
RXTX
Slave N-1
RX TX
RXTX
Slave N
RX TX
RXTX
EtherCAT Master
MAC 1 MAC 2
RX TX RX TX
RX Unit TX Unit
TXRX
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Cabling redundancy
2nd Ethernet port needed on master side only
Hot Swap of devices
Hot Connect of network segments
Master Redundancy with Hot Stand By
Your Selling Point: Availability
Master
Hot Connect
Group
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Master to Slave
Slave to Slave
Master to Master
EtherCAT: versatile system architecture
Switchports
Gateways
S2S
M2S
M2S
Master
Master
M2M
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT Automation Protocol
Fie
ldb
us
-Ne
two
rkF
ac
tory
-Ne
two
rk
EtherCAT Automation Protocol
EtherCAT Device Protocol (processed on the fly)
Configuration/
Diagnosis
MES
HMI
Remote
Access
Central Computer
SCADA
Handheld
WiFi
Automated
Guided Vehicle
(AGV)
PLC PLC PLC
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
EtherCAT Automation Protocol: Application
September 2016
Einschleusen Einschleusen Prozess-
KammerAusschleusen Ausschleusen AusschleusenProzess-
Kammer
Prozess-
Kammer
Prozess-
Kammer
Prozess-
Kammer
Je Verbindung:
10ms cycle
IN 1kByte
OUT 1kByte
Ethernet Connection
EtherCAT Segment
EtherCAT Automation Protocol
OPC
OPC
10 ms cycle
zum Controller und
allen Stationen
Visu
MES
Controller
IN 600 Byte
OUT 600 Byte
IN 600 Byte
OUT 600 Byte
IN 600 Byte
OUT 600 Byte
IN 600 Byte
OUT 600 Byte
IN 600 Byte
OUT 600 Byte
IN 600 Byte
OUT 600 Byte
IN 600 Byte
OUT 600 Byte
IN 600 Byte
OUT 600 Byte
IN 600 Byte
OUT 600 Byte
Stations-
Master
Stations-
Master
Stations-
Master
Stations-
Master
Stations-
Master
Stations-
Master
Stations-
Master
Stations-
Master
Stations-
Master
Stations-
Master
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Wireless Devices can be connected via Switchport
Wireless segment does not slow down EtherCATcommunication
Protocol: EtherCAT Automation Protocol
Pushed and/or Pulled Process Data Exchange
Wireless Segment transparent for Master Device
EtherCAT and Wireless Communication
SwitchportMaster
e.g. Card or RFID Reader
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Wireless Devices can be connected via Switchport
Wireless segment does not slow down EtherCATcommunication
Protocol: EtherCAT Automation Protocol
Pushed and/or Pulled Process Data Exchange
Wireless Segment transparent for Master Device
EtherCAT and Wireless Communication
SwitchportMaster
e.g. Card or RFID Reader
Master with or
without control
application
Master sees
process data of
underlying system
as local I/O data
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
High Performance
EtherCAT is the fastest Industrial Ethernet technology
Flexible Topology
Benefit not only for widely distributed applications
Ease of Use
Easy configuration and maintenance
Low Cost
Inexpensive implementation & infrastructure
Functional Safety
Safety communication integrated
Product Variety
Great variety of available EtherCAT products
Why do Companies choose EtherCAT?
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Crucial for Dynamics: Performance ofControl- and Communication System
Example: Humanoid Robots
MARLO, bipedal robot build by Jonathan Hurst at Oregon State University for Prof. Jessy Grizzle, University of Michigan
Medulla microcontroller board
It provides an interface between the varied input and output protocols used on the robot and the unified EtherCAT interface used by the control computer.
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
Walking EtherCAT Robot “MARLO”
September 2016
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Example: Radio Telescope
Robert C. Byrd Green Bank Telescope, VA: Retrofit of Positioning System of the world's largest fully steerable single aperture antenna.
Decisive Factors: Performance, Topology
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Example: Robotics
DLR, Germany: Rollin Justin
Decisive Factors: Fieldbus Integration, Performance
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
Decisive Factors: Fieldbus Integration, Performance
September 2016
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
EtherCAT in Space: RJo Joystick by DLR
2 Slave Devices, 1 ms Cycle Time
Beckhoff EtherCAT Chip passed extensive irradiation tests
Decisive Factors: Robustness
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Decisive Factors: Performance
Example:
European XFEL X-Ray Laser,
Hamburg, Germany
91 EtherCAT controlled
magnet assemblies
(undulators)
in the accelerator
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Dr. Suren Karabekyan, XFEL:
“EtherCAT communication is a key component of our facility. It enables us to configure a very robust and reliable control system with redundant ring topology, even in a large installation such as ours. Overall, it is a very cost-effective solution, which is particularly important in the context of research projects funded via public institutions.”
Decisive Factors: Performance
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Control Configuration for an Undulator Section
Decisive Factors: Performance
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement
Well proven
Open
Conformance
Safety
Redundancy
Versatile
September 2016
Why go for something slower, just because it is more expensive?
EtherCAT – The Ethernet Fieldbus.
