Real-time Ethernet for Machine Control


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View this webinar to learn how to apply industrial networks for real-time machine control.
The webinar will highlight:
• A comparative look at industrial automation networks, assessing speed, performance and precision for machine control applications
• Real-world applications and the benefits that result from using a real-time Ethernet-based solution
• An in-depth examination of how the EtherCAT industrial Ethernet network can be applied to all aspects of production – from design, development and deployment through to production and maintenance on the factory floor
• How Omron uses EtherCAT to integrate HMIs, servos, AC drives, I/O, vision, and PLC-based or stand-alone controllers

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Real-time Ethernet for Machine Control

  1. 1. Educational Webcast Real-time Ethernet for Machine Control Moderated by David Greenfield, Director, Media & Events at Automation World 1 © Omron
  2. 2. Real-time Ethernet for Machine Control • Wide acceptance in IT and Manufacturing • Enterprise connectivity • Growing integration with field devices • Remote diagnostics • Determinism/True Real-time? 2 © Omron
  3. 3. Real-time Ethernet for Machine Control Webcast Objectives • A comparative look at industrial automation networks, assessing speed, performance and precision for machine control applications • Real-world applications and the benefits associated with real-time Ethernet • How can be applied in design, development, deployment, production and maintenance on the factory floor • How Omron Industrial Automation uses to integrate Servos, AC drives, I/O, Vision, as well as PLC-based and stand-alone controllers 3 © Omron
  4. 4. Real-time Ethernet for Machine Control Bill Faber, Commercial Marketing Manager – Motion, Drives, Vision Omron Industrial Automation Dennis Hydock, President – High-end Motion/Robot/Vision Integration Integrated Industrial Technologies Keith Grey, Strategic Account Manager – Automotive Omron Industrial Automation 4 © Omron
  5. 5. Real-time Ethernet for Machine Control Bill Faber Commercial Marketing Manager – Motion, Drives, Vision Omron Industrial Automation 5 © Omron
  6. 6. What is Real-time? Real-Time Computing Operational Deadlines from Event to system response. Real-time programs must guarantee response within strict time guidelines. Example Application Response Time Temperature PID Loops  Seconds Feed-To-Length Indexing with PLS* outputs  Milliseconds Servo Line Shafting – Master/Slave Gearing  Microseconds *PLS = Programmable Limit Switch 6 © Omron
  7. 7. Context of Machine Control SCADA Information Layer Visualization Database Control Layer Motion Layer Device I/O Layer 7 © Omron Interconnection PLC HMI PLC Control Safety Motion Controller RFID Temperature Sensors I/O Vision Sensing Servo Inverter Actuation
  8. 8. Applications that Require Real-time Application: • Rotary Knife • Linear Flying Cutoff Problems: • Large inertia knife loads can cause overshoot inaccuracies  Use electronic CAM with registration adjust • Cost of hardwiring multiple cutter stations can be high  Use a network • Cutter axis is slaved off of the master which may be irregular unsynchronized cycles  Use a real-time network 8 © Omron
  9. 9. Applications that Require Real-time Application: • 4-Color Printing • Line Shafting • Converting • Contouring • Pattern Cutting • Robotic • Other multi-axis coordinated motion control applications 9 © Omron
  10. 10. Architecture Trends – Real-time Ethernet • Ethernet Networks are Expanding to Device Level ARC: ―Industrial Ethernet—already established at the factory level of industrial automation hierarchies—is now becoming a viable networking protocol at the I/O or field level.‖ 30% CAGR thru 2012 Motion Controller Device I/O Layer RFID Temperature Sensors 10 © Omron I/O Vision Servo Inverter To achieve synchronous motion control, the network must be real-time
  11. 11. Architecture Trends – Converging Controls • Ethernet Networks are Expanding to Device Level • Control Technology Platforms are Converging PMMI: ―There is a growing trend towards integrated controllers that perform more than one function… this eliminates the need to create communications between two controllers, simplifying programming and maintenance.‖ Motion Motion Layer 11 © Omron Logic (PLC)
  12. 12. Architecture Trends – Converging Controls • When logic converges with Motion & Vision it becomes a MOVi application Application Examples: – Move – Inspect – Reject – Move – Inspect – Orient – Inspection in Motion – Vision Servo-ing – Storage & Retrieval Motion Vision 12 © Omron Logic
  13. 13. Driving Factors for Real-time Ethernet Landscape of Automation Pain: OEMs Drive Toward Efficiencies of: • Time to Market • Complexity of Design/Development Machine Development • Setup, Configuration, Programming • Field Expansion Options Machine Deployment • Bottlenecks in Throughput & Yield • Data Exchange (C2C, Enterprise) Machine Production • Troubleshoot & Error Reporting • Uptime 13 © Omron Machine Maintenance Converging platforms require real-time networks to eliminate system level latencies and bottlenecks At the same time, networks allow for smarter machines
  14. 14. What Makes a Network Real-time? Not Real-time • Node control and feedback data updates slower than control system • Network is faster than the control system • Update jitter exceeds node synchronization requirements at maximum machine speed • Deterministic (Repeatable) • Controller, Network and Slave nodes updating at different times • Synchronization across the platform • Data volume exceeds network transport capacity 14 Real-time • Must meet data throughput requirements for the intended application © Omron
  15. 15. Comparative Look at Ethernet Networks EtherCAT Line, star, ring, tree, On-the-fly frame Processing Slave map Hub Line, star, ring, tree Polling (half duplex) Line, ring Polling Switch Line, branch, tree Polling Star, ring Polling (producer consumer) Managed Switch Star, ring Polling (producer consumer) Switch ** Branch Slave Switch <<1 usec Star Polling & master map Distributed Clocks PowerLink 1 usec ** Depends on frames Sercos III 1 usec ** IEEE1588 Profinet IRT 1 usec * IEEE1588 EtherNet/IP EtherNet/IP CIP Synch Modbus TCP/IP ~1 usec IEEE1588 * Depends on number of cascaded switches, practical limit around 20 nodes ** Depends on communication jitter of frames from the master 15 © Omron
  16. 16. Ethernet Optimized for Machine Control • Fast & Efficient • Open & Accepted • Deterministic & Repeatable • 40 axis + 2200 I/O Test 16 © Omron
  17. 17. Ethernet Optimized for Machine Control Deterministic & Repeatable • Distributed Clock • <<1usec jitter (repeatability) • Learns the topology & delays Distributed Clock Synchronization 17 © Omron
  18. 18. One Real-time Network for Machine Control One Real-time Network enables Faster, Simpler, Smarter Machines One Factory Network For Information  Most accepted open network One physical layer Two Protocols One Purpose for Machine Automation One Machine Network For Real-time Control  Fastest open network 18 © Omron
  19. 19. Dial Table Vision Inspection Dennis Hydock High-end Motion/Robot/Vision Integration Integrated Industrial Technologies 19 © Omron
  20. 20. Customer Requirements Challenge: • High-speed bolt inspection for automotive • Achieve 500 inspections per minute • Two cameras to inspect top and side of bolt • Another camera to inspect threads while rotating • Control the rest of the machine (14 other axis) • Control 150 points of process I/O • Display machine status, setup, machine faults, common rejects, etc. on a networked HMI 20 © Omron
  21. 21. Bolt Inspection Dial Table Indexing Machine Servo Motor 3 From Bowl Feeder Dial Index Table Linear Feed Conveyor Camera 1 Head Inspection Length, Diameter, & Thread Inspection Camera 2 Servo Motor 1 Camera 3 Servo Motor 2 Rotate Thread Inspection 21 © Omron
  22. 22. Previous Solution Camera HMI Frame Grabber PC with Imaging Software Frame Grabber PLC Camera Stepper Indexer Rotate Frame Grabber Camera 22 © Omron Index Table Stepper Amp Stepper Amp Programming Software Complex Solution • • • • Different protocols Different hardware Noise issues Slow!!!
  23. 23. Motion & Vision on Latest EtherCAT Solution: • • • • • • • 23 © Omron Trajexia TJ2-64 motion controller FZM1 camera & controller 16-Axes G5 Servo Motors NS HMI via Ethernet EtherCAT Network EtherCAT I/O Single Program .
  24. 24. Motion & Vision on EtherCAT Solution Advantages • • • • • • • • 24 © Omron No Noise Issues Easier Maintenance Reduced Wiring Single Supplier Standard Hardware Fast Changeover Saves Time Saves Money .
  25. 25. Quicker Setup with One Integrated Network Easy Setup Slave Configuration Communication Setting Camera Setting Select Motion Control Type Robot – XY, XYӨ Stage – XYӨ,UVW,UVWR Sampling position Automatic setting of Calibration Parameters 25 © Omron Camera Image Calibration Screen
  26. 26. Application Example Simple Program Configuration IF NOT ETHERCAT($66,0,1000,1000,5,1010,12) THEN 26 © Omron
  27. 27. Faster Performance with Real-time Network Operation EtherCAT System Time (msec) Previous System Time (msec) 1 17 Capture image and process 50 50 Network cycle 1 17 configuration on one Ethernet PHY network is simple TOTAL vision cycle 52 84 • YES: Real-time is needed for Motion controller Scan 1 1 Initiate Motion 0.5 0.5 the motion axis, required if everything is on the same network 9 degree move 50 50 Settling time 2 2 TOTAL motion cycle 53.5 53.5 TOTAL CYCLE TIME 105.5 137.5 Network cycle (capture command) (send 4 read 12) 27 © Omron Does Real-time Matter? • YES: Separate non-real-time network scan is almost as high as the motion cycle (37msec) • YES: Simple setup and Bottleneck is a System Issue. Network is not the bottleneck.
  28. 28. Summary – Dial Table Vision Inspection • Ethernet wiring is common and easy • One real-time network and integrated motion/vision platform provides: • Quicker setup without sacrificing performance • Synchronization amongst slaves (vision, motion, I/O) • Reduced overall latencies and higher throughput • Less time commissioning • High noise immunity • Initial and long term savings 28 © Omron
  29. 29. Preventive Maintenance for Automotive Keith Grey Strategic Account Manager – Automotive Omron Industrial Automation 29 © Omron
  30. 30. Preventive Maintenance with Challenge – Automotive Plant Downtime (average servo issue takes 45 minutes to fix) – Maintenance – must be easy enough for 3rd shift to use without training Solution – CJ2H PLC with NC882 ECAT Module – NS15 HMI with Template Screens – S8VS power supply with indicator – 2 axis G5 Servo – EtherCAT Network for machine control – EtherNet/IP Network for information 30 © Omron AUTOMOTIVE
  31. 31. One Network – One HMI Benefit • Servo, Drive, Vision, I/O slave devices on one real-time EtherCAT Network (no sacrificing performance) • HMI on EtherNet/IP information network tunnels into EtherCAT • No additional engineering time setting up slave monitoring - Pre-Programmed HMI Screens – Servo utility screen – Inverter utility screen – Vision utility screen – Network health 31 © Omron
  32. 32. View Data Real-time on Benefit • EtherCAT allows preventive maintenance • View speed/torque data real-time, +/- values • View all parameters real-time • Instant for the user 4msec deterministic data update rate 32 © Omron <torque/speed curve here>
  33. 33. Simple to Use on Benefit • Don’t need an expert to replace an absolute encoder motor or servo drive – Just push buttons, follow step-by-step procedure with pictures – No additional training required • Easily change motion profile (teach profile) 33 © Omron
  34. 34. Summary – Preventive Maintenance • One real-time network and integrated motion/vision platform provides: – Centralized error reporting via operator interfaces – Simplified maintenance – Quick updates of time critical data • Preventive maintenance is possible without sacrificing performance • Pre-programmed solutions give confidence and quicker commissioning 34 © Omron
  35. 35. Summary & Key Takeaways • Machine builders face constant demands for: – More efficient machine design/development – Faster deployment – Higher throughput and yield – Simpler maintenance • Real-time networks are required to achieve true complete machine automation without sacrificing performance • Converging technology platforms are putting higher demands on real-time networks and control systems • Putting all real-time devices on one network protocol ensures performance and simplicity 35 © Omron
  36. 36. Call to Action • Learn for yourself about Real-time Ethernet Date Location 10/11/2011 (Tues) Boston 10/12/2011 (Wed) Chicago 10/13/2011 (Thurs) Milwaukee 10/18/2011 (Tues) San Diego Phoenix – Is it in the interconnection? 10/19/2011 (Wed) – Is it in the network? 10/20/2011 (Thurs) Denver – – Come to EtherCAT Technology Group Roadshow – 6 U.S. locations • Evaluate your machine control platform for bottlenecks 36 © Omron
  37. 37. Questions Bill Faber, Commercial Marketing Manager – Motion, Drives, Vision Omron Industrial Automation, Dennis Hydock, President – High-end Motion/Robot/Vision Integration Integrated Industrial Technologies, Keith Grey, Strategic Account Manager – Automotive Omron Industrial Automation, 37 © Omron