EtherCAT as a Master Machine Control Tool
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There is an increasing demand in the automation and motion control industries for a localized motion control solution that can coordinate motion between multiple remote components. Previously, field bus protocols such as Modbus or Ethernet have been implemented to address this demand. Although successful in moving data across automation networks, these protocols lacked the real time performance necessary for a distributed motion control system. The EtherCAT communication protocol provides a high speed, low overhead communication scheme that allows efficient, deterministic communication between motion controller and remote components. Based on Ethernet and streamlined specifically for point to point transmission of real time data, the EtherCAT standard is quickly becoming the preferred choice for centralized control of tightly coupled motion between remote components. This presentation is aimed at designers of automation and motion control systems with a basic understanding of Ethernet communication.
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EtherCAT as a Master Machine Control Tool
- 1. Galil Mo(on Control Ma- Klint Applica(ons Engineer Galil Mo(on Control EtherCAT as a Master Machine Control Tool
- 2. q This webinar will be available afterwards at www.designworldonline.com & email q Q&A at the end of the presentation q Hashtag for this webinar: #DWwebinar Before We Start
- 3. Moderator Presenter Miles Budimir Design World Matt Klint Galil Motion Control
- 4. Agenda • Galil Motion Control • About • Introduction to EtherCAT • Origins • Communication Format • Ethernet vs. EtherCAT • Hardware and Physical Layout • Galil’s DMC-‐‑500x0 EtherCAT Master • Features • Configuration and Setup • Setup Example • Summary • Cost and advantages of an EtherCAT control network • Q&A
- 5. About Galil Established Reputation and long History of Success • Founded in 1983 by Dr. Jacob Tal and Wayne Baron • Introduced the 1st microprocessor based servo controller • Profitable for over 119 consecutive quarters • Over 750,000 motion controllers and PLCs delivered Excellent Engineering Support and Service • Worldwide network of factory trained reps & distributors • Support team with over 100 years combined motion control experience • Online support tools at www.galil.com
- 6. Communica(on Protocols • Standardization allows cross platform integration • Easily attainable infrastructure lowers costs • Modular Design • Modules are easily replaceable • Additional modules can be added as needed • Wide market with dozens of vendors per type • Galil was the first to introduce TCP/IP communication to motion control, since then it has become the most widely used communication protocol in the industry
- 7. EtherCAT Origins Ethernet for Control Automation Technology • Invented by Beckhoff Automation in 2003 • Ethernet based fieldbus, optimized for industrial automation control • Based on CANOpen, a device profile for embedded systems used in automation • Standards defined and maintained by the EtherCAT Technology Group (ECTG)
- 8. EtherCAT and Ethernet • Ethernet • Designed to move large amounts of data through many different nodes • Able to route data to and from billions of separate addresses allowing communication across vast networks • Large overhead involved in encapsulating, routing and formaXing data • Software handles extraction and processing of data • EtherCAT • Uses standard Ethernet hardware, CAT5 cabling and Network Interface Cards (NIC) • Streamlines Ethernet communication at the hardware level • Data processing on slave devices is handled “on the fly” via FPGA or ASIC, minimizing latency • Initial setup and configuration required
- 9. Ethernet Frame An Ethernet frame contains: • Ethernet Header • Destination Address: 6 bytes • Source Address: 6 bytes • EtherType: 2 bytes, 0x0800 specifies IPv4. • Ethernet Data • Payload: 46 – 1500 bytes • CRC (Checksum): 4 bytes Standard Ethernet Frame
- 10. EtherCAT Frame An EtherCAT frame is very similar to an Ethernet frame: • Ethernet Header • EtherType 0x08A4 specifies EtherCAT • EtherCAT Header • Data Length: 11 bits • Reserved: 1 bit • Protocol type: 4 bits (0x01 indicates CoE, CAN over EtherCAT) • EtherCAT Data: 46 – 1496 bytes • Working Counter: 2 bytes • CRC (Checksum): 4 bytes EtherCAT Frame
- 11. EtherCAT Communica(on • Each drive on the network has a unique address, set by hardware • Master/Slave configuration with the EtherCAT Master sending and requesting data from the Slave • Data not addressed to a particular slave are forwarded along to the network • Minimal processing time can provide cycle update rates of up to 32kHz • Network physical layout is limited only by the allowable lengths of CAT5 Ethernet cable, up to 100 m • Increased noise immunity due to reliance on Ethernet physical components
- 12. • Each cubicle is an EtherCAT Slave, containing an engineer • Each engineer is told where to sit by its hardware address (station ID) • The engineer is assigned specific tasks by SDOs • The boss is the EtherCAT Master, sending instructions (PDOs) out to the engineers each morning and picking up their work at the end of the day. EtherCAT Communica(on Analogy
- 13. • Profile Position Master sends position commands to the Slave, slave handles profiling parameters • Profile Velocity Master sends velocity commands to the Slave, slave handles profiling parameters • Profile Torque Master sends torque commands to the Slave, slave handles profiling parameters • Cyclic Position Position is continuously updated by the master, master handles profiling parameters • Cyclic Velocity Speed is continuously updated by the master, master handles profiling parameters • Cyclic Torque Torque is continuously updated by the master, master handles profiling parameters EtherCAT Opera(on Modes
- 14. • Can be any software and or hardware configured to assemble, send and receive EtherCAT datagrams • Requires only standard Ethernet physical layer components for communication • Facilitates coordination between EtherCAT slaves, writing and receiving data from each slave in an EtherCAT frame • In motion control applications, the relevant data sent to the drives are profiling data • The data requested are position and input status EtherCAT Master
- 15. • Reads and processes profiling data • Writes position, input and drive status for return to the master • Can be configured for multiple modes of operation • All slaves contain specific spaces in memory where data can be wriXen • These spaces are called Objects, the entire memory space is called the Object Dictionary • Each object has it’s own address, specified as an index/sub index • Example, operation mode data from the Master is wriXen to the x6060 Object in the slave’s dictionary, position commands are wriXen to the x607A Object EtherCAT Slave
- 16. SDOs and PDOs Data is moved along an EtherCAT network using two protocols, SDOs and PDOs SDO: Service Data Object • SDOs can be sent at any time, before, after or during real time operation of the network but require additional communication overhead • As a result SDO usage is typically only used for network setup commands PDO: Process Data Object • PDOs contain the raw operational data with minimal overhead and thus are used for real time processes, like motion and I/O control • PDO’s can only be used once they have been “mapped” using SDOs • Mapping sets up which byte in each PDO goes to which memory address on the slave
- 17. SDO vs. PDO Summary SDO PDO Transfer confirmation No transfer confirmation Client/server model Peer-‐‑to-‐‑peer model Device Configuration, PDO mapping High priority transfer of small amounts of data Can be sent at any time Can only be used after configuration using SDOs Significant communication overhead No additional protocol overhead
- 18. The EtherCAT Slave State Machine State Allowed Communication Init No User Communication Pre-‐‑Op SDO Communication Only Safe-‐‑Op SDO, PDO Communication Allowed Output PDO info ignored Operational PDO, SDO Communication Allowed
- 19. The EtherCAT Slave Architecture
- 20. Simple PDO Example Incoming PDO Position Data Slave Target Position Memory Object 4 x 8 bits x607A
- 21. PDO Exchange Location Function x607A Target Position x6060 Mode of Operation x6040 Controlword Location Function x6041 Statusword x6062 Position Demand Value X6061 Mode of Operation x6064 Position Actual Value x60FD Digital Input Status Outgoing PDOIncoming PDO
- 22. EtherCAT Hardware Standard Ethernet Physical Layer components • CAT5 cabling • Network Interface Cards FPGAs for fast command processing by slave units
- 23. EtherCAT Only Physical Layout EtherCAT Master EtherCAT Drive 1 EtherCAT Drive 2 EtherCAT Drive 3 Motor/ Encoder Motor/ Encoder Motor/ Encoder
- 24. The DMC-‐500x0 EtherCAT Master • Includes all the features of our flagship DMC-‐‑40x0 series controller with the addition of EtherCAT drive support for up to 8 axes in Cyclic Position Mode* • Only motion controller in the industry with the ability to mix and match local and EtherCAT drives • Easily configurable and designed with compatibility and flexibility in mind • Multiple drive vendors supported • Compatible with Galil’s entire line of internal servo and stepper motor amplifiers *Cyclic Torque mode supported on select models
- 25. The DMC-‐500x0 EtherCAT Master Currently Supported I/O Features • Forward and reverse limit switch inputs • Home sensor input • Hardware latch/touch probe These I/O features allow access to the DMC-‐‑500x0 commands and subroutines specific to these inputs such as: • #LIMSWI automatic subroutine • FI/FE/HM commands • AL/RL commands • #ECATERR automatic subroutine
- 26. DMC Code Example
- 27. DMC-‐500x0 Hardware Layout DMC-‐50070 EtherCAT Drive 1 EtherCAT Drive 2 EtherCAT Drive 3 Servo Motor Servo Motor Servo Motor Analog and Digital I/O Stepper Motor Servo Motor Servo Motor Stepper Motor Stepper Driver Stepper Driver
- 28. Compa(ble EtherCAT Drives Currently Supported Drives • AMC DZEANTU-‐‑020B080 • Copley XenusPLUS XEL-‐‑230-‐‑36 • Panasonic Minas A5B • Sanyo-‐‑Denki SANMOTION RS2A01A0KA4 • Yaskawa Sigma-‐‑5 SGDV-‐‑R90FE1A Galil is actively working to include support for additional vendors and is seeking input from customers. Contact an Applications Engineer to discuss drive support options.
- 29. Summary • The EtherCAT protocol is gaining traction as a robust and efficient solution to demanding, large scale automation applications • Built on the Physical and Data Link layers of Ethernet communication, making the technology more accessible right off the bat • Higher controller/drive cost is offset by the use of pre existing, easily aXainable hardware • Due to the EtherCAT communication protocol, networks are easily expandable, modifiable and simple to maintain
- 30. Questions? Miles Budimir Design World mbudimir@wtwhmedia.com Twitter: @DW_Motion Matt Klint Galil Motion Control mattk@galilmc.com Galil Applications Engineering Team 1 (916) 626-0101 support@galil.com www.galil.com
- 31. Thank You q This webinar will be available at designworldonline.com & email q Tweet with hashtag #DWwebinar q Connect with Design World q Discuss this on EngineeringExchange.com