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Industrial Networks: the Choices for Real Time Motion Control

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Among the versions of Ethernet for real-time motion update, two are leading the industry today: EtherCAT, Ethernet/IP, and Powerlink. Each handles real-time messaging differently, and the differences …

Among the versions of Ethernet for real-time motion update, two are leading the industry today: EtherCAT, Ethernet/IP, and Powerlink. Each handles real-time messaging differently, and the differences affect your design choices. The leading vendors behind these networks will discuss the ways each handles real-time updates. By watching this special, free 1-hour on-demand webinar you will gain a better understanding of the key factors necessary to make the best network choice for your motion application.

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  • 1. Industrial Networks -the Choices for Real Time Motion Control
  • 2. Before We Start This webinar will be available afterwards at designworldonline.com & email Q&A at the end of the presentation Hashtag for this webinar: #IndNet
  • 3. Moderator Presenters Leslie Langnau Shaun Kneller Joey Stubbs Design World B&R Industrial Automation EtherCAT Technology Group
  • 4. EtherCAT for Motion Control Overview Joey Stubbs, PE, PMP North American Representative EtherCAT Technology Group
  • 5. Functional Principle -- Ethernet “on the fly” Slave Device Slave Device EtherCAT Slave Controller EtherCAT Slave Controller • 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
  • 6. Frame Processing within Each Node Master EtherCAT Segment (Slaves) IPC .. .. DVI Node n Node n+1 DPRAM DPRAM EtherCAT Slave Controller EtherCAT Slave Controller Ethernet Frame
  • 7. 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
  • 8. Frame Processing order in the EtherCAT network EtherCAT Segment Master Ethernet cable Path of EtherCAT Frame
  • 9. Functional Principle -- Ethernet “on the fly” PLC Data NC Data HDR 2 ECAT HDR HDR 2 Ethernet Header HDR 1 Master Data n Ethernet • 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
  • 10. EtherCAT: Mapping moved into Slave Devices PLC Data NC Data HDR 3 ECAT HDR HDR 2 Ethernet Header HDR 1 logical process images up to 4 GByte Master Data n Ethernet Data n PLC Data NC Data Datagram 1 • • Datagram 2 Datagram n Control System is unburdened, master becomes very simple Data is transmitted according to the application requirements: extremely fast, flexible and efficient
  • 11. Distributed Clocks: EtherCAT Propagation Delay Measurement • EtherCAT Node measures time difference between leaving and returning frame EtherCAT Frame Processing Direction EtherCAT Frame Forwarding Direction
  • 12. EtherCAT Distributed Clocks • EtherCAT Node measures time difference between leaving and returning frame IPC Master
  • 13. EtherCAT Synchronization • Precise Synchronization (<< 1 µs!) by exact adjustment of Distributed Clocks M S ∆t IPC Master S S S S S S
  • 14. Precision of EtherCAT • • Long Term Scope View of two separated devices 300 Nodes in between, 120m Cable Length Interrupt Node 1 Simultaneousness: ~15 ns Jitter: ~ +/-20ns Interrupt Node 300
  • 15. EtherCAT in IEC 61800-7: Profiles for electrical power drive systems IEC 61800-7: Generic Interface and use of profiles for power drive systems IEC 61800-7-1: Interface Definition Annex A: Annex B: Annex C: Annex D: Mapping to Mapping to Mapping to Mapping to DS402 CIP PROFIdrive SERCOS IEC 61800-7-200: Profile Specifications IEC 61800-7-201: IEC 61800-7-202: IEC 61800-7-203: IEC 61800-7-204: Profile CiA 402 Profile CIP Motion Profile PROFIdrive Profile SERCOS IEC 61800-7-300: Mapping of Profiles to Network Technologies IEC 61800-7-301 Mapping toMapping to Mapping to CANopen EtherCAT EPL B C ... ... IEC 61800-7-304 Mapping to Mapping to Mapping to SERCOS I/II SERCOS III EtherCAT
  • 16. Adoption Rate in Drive Suppliers
  • 17. Adoption Rate in Master Controllers
  • 18. Record setting number of vendors on one network 35 different Axes 24 different Vendors 1 EtherCAT Network
  • 19. 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
  • 20. Plus safety with FSoE, even on motion control systems • • Decentralized Safety-Logic Standard PLC routes the safety messages Standard PLC Safety Inputs Safety Outputs S S S Safety Drives Safety Logic S
  • 21. For additional information: www.EtherCAT.org
  • 22. EthernetPowerlink in Real-Time Motion Control EthernetPowerlink in Real-Time Motion Control Presented by Shaun Kneller Key Account Manager B&R Industrial Automation
  • 23. EthernetPowerlink in Real-Time Motion Control • Network Features • 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
  • 24. EthernetPowerlink in Real-Time Motion Control • Data frames and sequencing •Multiplexed Controlled Nodes cycle in a set sequence Async Node Sends network reply •Master Data initiatesControlled Nodes Reply in set Nodes • All nonNodePortion data to Multiplexed Controlled sequence Master Multiplexed
  • 25. EthernetPowerlink in Real-Time Motion Control • 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
  • 26. EthernetPowerlink in Real-Time Motion Control • Multiplexing Axes Cycle 1 2 3 Cyclic Node Cyclic Node Cyclic Node Multiplexed Node Multiplexed Node Multiplexed Node
  • 27. EthernetPowerlink in Real-Time Motion Control • Multiplexing Axes
  • 28. EthernetPowerlink in Real-Time Motion Control • Topology – Network matches machine requirements not the other way around Star Daisy • Ring Chain
  • 29. EthernetPowerlink in Real-Time Motion Control • Topology – Combinations of distribution types are freely available
  • 30. EthernetPowerlink in Real-Time Motion Control • Redundancy • Ring • Wire break detection and recovery • Slip rings
  • 31. EthernetPowerlink in Real-Time Motion Control •Distributed or Central Control Controller Scan Position Loop Setpoint Generation Position Loop Velocity Setpoint Generation Current Loop Velocity Loop Current Loop
  • 32. EthernetPowerlink in Real-Time Motion Control •Synchronized Loops and Scans Control Scan Loop Update
  • 33. EthernetPowerlink in Real-Time Motion Control •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
  • 34. EthernetPowerlink in Real-Time Motion Control •EthernetPowerlink Meets Requirements EthernetPOWERLINK Dist I/O+ Safety Hubs and Switches Bridges Third Party Drive Products Dist I/O + Safety Motion Operator Encoders Interfaces PCI Interfaces Diagnostic Tools Displays Safety VFD Safe Motion TCPIP Bridge EPL EPL Master OR Slave (MN) (CN)
  • 35. EthernetPowerlink in Real-Time Motion Control • Multiplexing and Crosstalk • Allow fast communication between axis without Manager involvement • Electronic Gears, Cams, Axis synchronization • Reduces Network Cycle time • 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.
  • 36. EthernetPowerlink in Real-Time Motion Control • 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 • High speed network • I/O networks and drives <200µs
  • 37. EthernetPowerlink in Real-Time Motion Control Thank You for your time and Attention Presented by Shaun Kneller Key Account Manager B&R Industrial Automation
  • 38. Questions? B&R Industrial Automation Design World Leslie Langnau lllangnau@wtwhmedia.com Phone: 440.234.4531 Twitter: @wtwh_rapidmfg Shaun Kneller shaun.kneller@br-automation.com Phone: 770-410-3212 LinkedIn: http://linkd.in/q6ibLY Twitter: @BR_Automation EtherCAT Technology Group Joey Stubbs j.stubbs@ethercat.org
  • 39. Thank You  This webinar will be available at designworldonline.com & email  Tweet with hashtag #IndNet  Connect with  Twitter: @Design_World  Facebook: /engineeringexchange  LinkedIn: Design World Group  YouTube: /designworldvideo  Discuss this on EngineeringExchange.com

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