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.

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
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