Industrial Networks: the Choices for Real Time Motion Control

Industrial Networks -the Choices for Real Time Motion Control

This webinar will be available afterwards at

designworldonline.com & email

Q&A at the end of the presentation

Hashtag for this webinar: #IndNet

Before We Start

http://www.designworldonline.com/

Moderator

Leslie Langnau Design World

Shaun Kneller B&R Industrial Automation

Presenters

Joey Stubbs EtherCAT Technology Group

Joey Stubbs, PE, PMP

North American Representative

EtherCAT Technology Group

EtherCAT for Motion Control Overview

© EtherCAT Technology Group, 2009 6

Slave Device

EtherCAT Slave Controller

Slave Device


• 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 axes, and longer cycles for I/O updates possible

– in addition: asynchronous, event-triggered communication

Functional Principle -- Ethernet “on the fly”

Frame Processing within Each Node

10.07.2008 EtherCAT Communication 7

DVI

IPC

.. ..

EtherCAT Segment (Slaves) Master

Node n


DPRAM

Node n+1


DPRAM

Ethernet Frame

The fastest Industrial Ethernet Fieldbus available today

Transmission Rate: 2 x 100 Mbit/s (Fast Ethernet, Full-Duplex)

Update Times:

256 digital I/O in 11 microseconds (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-Axes (each 8 Byte In + Out) in 100 µs = 0.1 ms 12,000 digital I/O in 350 µs

EtherCAT Segment

Master

Ethernet cable Path of EtherCAT Frame

Frame Processing order in the EtherCAT network

• 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 are in the network

– Outstanding diagnostic features

– Ethernet-compatibility maintained

Master

Ethernet Header ECAT HDR

PLC Data NC Data Data n Ethernet HD

R 1

HD

R 2

HD

R 2

Functional Principle -- Ethernet “on the fly”

EtherCAT: Mapping moved into Slave Devices

• Control System is unburdened, master becomes very simple

• Data is transmitted according to the application requirements: extremely

fast, flexible and efficient

PLC Data NC Data Data n Ethernet

log

ical

pro

cess

im

ages

up

to

4 G

By

te

HD

R 1

HD

R 2

HD

R 3

Datagram 1 Datagram 2 Datagram n

PLC Data

Data n

NC Data

Master

Ethernet Header ECAT HDR

• EtherCAT Node measures time difference between leaving and

returning frame

EtherCAT Frame Processing Direction

EtherCAT Frame Forwarding Direction

Distributed Clocks: EtherCAT Propagation Delay Measurement

EtherCAT Distributed Clocks


IPC

• EtherCAT Node measures time difference between leaving

and returning frame

Master

EtherCAT Synchronization


• Precise Synchronization (<< 1 µs!) by exact adjustment of Distributed Clocks

M

∆t IPC S

Master

S

S S S S

S

Precision of EtherCAT

• Long Term Scope View of two separated devices

• 300 Nodes in between, 120m Cable Length

Jitter: ~ +/-20ns

Simultaneousness: ~15 ns

Interrupt Node 1

Interrupt Node 300

EtherCAT in IEC 61800-7: Profiles for electrical power drive systems

IEC 61800-7-304

IEC 61800-7-301

Mapping to CANopen

Mapping to EtherCAT

Mapping to EPL

Mapping to SERCOS I/II

Mapping to SERCOS III

Mapping to EtherCAT

IEC 61800-7-201:

Profile CiA 402

IEC 61800-7-202:

Profile CIP Motion

IEC 61800-7-203:

Profile PROFIdrive

IEC 61800-7-204:

Profile SERCOS

Annex A: Mapping to

DS402

Annex B: Mapping to

CIP

Annex C: Mapping to PROFIdrive

Annex D: Mapping to

SERCOS

IEC 61800-7-1: Interface Definition

IEC 61800-7-200: Profile Specifications

IEC 61800-7-300: Mapping of Profiles to Network Technologies

B ...

C ...

IEC 61800-7: Generic Interface and use of profiles for power drive systems

Adoption Rate in Drive Suppliers

Adoption Rate in Master Controllers

Record setting number of vendors on one network

35 different Axes 24 different Vendors 1 EtherCAT Network

Additional Tools for Easy Drive implementation

Slave Sample code now contains CiA402 Drive implementation Conformance Test Tool (CTT)

• tests EtherCAT slave conformance to the specification • now tests drive profile conformance

CiA402 Drive Implementation Directive

• document referencing all CiA402 objects and how to implement them in an EtherCAT Servo Drive

Plus safety with FSoE, even on motion control systems


• Decentralized Safety-Logic

• Standard PLC routes the safety messages

S

S

S

Standard PLC Safety Inputs

Safety Logic

Safety Outputs

Safety Drives S

www.EtherCAT.org

For additional information:

EthernetPowerlink in Real-Time Motion Control


Presented by Shaun Kneller Key Account Manager

B&R Industrial Automation

• 250 Axes per segment

• Network updates of less than 400µs with 250 Nodes

• Operating System, System configurations and Setups Automatically downloaded across the network

• Fast swap out of axes in the field • Easy update of axes • No requirement to preconfigured hardware from OEM.

•Worldwide available directly to User


• Network Features

• Master Node Sends data to Multiplexed Controlled Nodes • Async Data Portion •Multiplexed Controlled Nodes reply in a set sequence •Master Node initiates network cycle • All non Multiplexed Controlled Nodes Reply in set sequence


• Data frames and sequencing


• Crosstalk between Axes • Slave axes can monitor Master axis data • Inter Axis communications without passing through central control

Master 1 Axis

Slave to

Master 1 Axis

Slave to

Master 1 Axis

Slave to

Master 2 Axis

Master 2 Axis

Cycle 1


• Multiplexing Axes

Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3

Cyclic Node

Cyclic Node

Cyclic Node

Multiplexed Node

Multiplexed Node

Multiplexed Node


• Multiplexing Axes

• Ring • Star • Daisy Chain


• Topology – Network matches machine requirements not the other way around


• Topology – Combinations of distribution types are freely available

• Ring • Wire break detection and recovery • Slip rings


• Redundancy


•Distributed or Central Control

Controller Scan Position Loop Setpoint Generation

Velocity Loop Current Loop

Controller Scan Position Loop

Setpoint Generation

Velocity Loop Current Loop


•Synchronized Loops and Scans

Control Scan

Loop Update


•Safe Motion and Network Safety

•STO Safe Torque Off

•SOS Safe Operating Stop

•SS1 Safe Stop 1

•SS2 Safe Stop 2

•SLS Safe Limited Speed

•SMS Safe Maximum Speed

•SDI Safe Direction

•SBC Safe Brake Control


•EthernetPowerlink Meets Requirements

+ Safety Dist I/O

EthernetPOWERLINK

Motion Displays

Safety

Dist I/O + Safety

Safe Motion

VFD

Third Party Drive Products

Encoders Operator Interfaces

PCI Interfaces

Bridges

Hubs and Switches

EPL Master (MN)

EPL Slave (CN)

OR

Diagnostic Tools TCPIP Bridge

• Synchronized Loops, Scans and Updates • Allows simple access to drive parameters in sync with motion functions

• Network Safety Motion features

• Eliminating Safety relays and E-Stop wiring

• Limitless capabilities on one network • I/O, VFDs, Visualization, Motion, Safety, etc.


• Multiplexing and Crosstalk • Allow fast communication between axis without Manager involvement

• Electronic Gears, Cams, Axis synchronization

• Reduces Network Cycle time

• High speed network

• I/O networks and drives <200µs


• Flexibility in Network Architecture • Bus, Star, Ring and Daisy Chain • Cable Redundancy

• Centralized or Distributed control • High integrity localized control • High Speed centralized control • Distributed control speed not limited by the network


Thank You for your time and Attention

Presented by Shaun Kneller Key Account Manager

B&R Industrial Automation

Questions?

Design World Leslie Langnau [email protected] Phone: 440.234.4531 Twitter: @wtwh_rapidmfg

B&R Industrial Automation Shaun Kneller [email protected] Phone: 770-410-3212 LinkedIn: http://linkd.in/q6ibLY Twitter: @BR_Automation

EtherCAT Technology Group Joey Stubbs [email protected]

mailto:[email protected]





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