Download - BECKHOFF-EtherCAT Beckhoff Course (en)
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Beckhoff EtherCAT Training
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Content
EtherCAT Training
Hardware Function principle
Topology
Advantages and efficiency
In praxis: Driver installation in System
Manager
EtherCAT data exchange
Protocol
Performance
The Fieldbus EtherCAT
Configuration in System Manager
In praxis: Parameterization and
commissioning in System Manager
Sync Units
In praxis: Hot Connect
Diagnosis In praxis: Cable redundancy
XFC eXtreme Fast Control Technology
In praxis: Timestamp terminal
In praxis: Oversampling terminal
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Hardware
EtherCAT Fieldbus master
IPC / Control Panel
Intel chipset based network card
with special TwinCAT real-time
Ethernet driver:
FC9001/9002/9004/9011
Supported network adapter in
Information System(online:http://infosys.beckhoff.com/c
ontent/1033/tcsystemmanager/refer
ence/ethercat/html/ethercat_supnet
workcontroller.htm?id=10257)
Embedded PC / Control Panel
CX90xx CX10xx
CX50xx
etc.15.03.2012 3EtherCAT Training 3
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15.03.2012 4EtherCAT Training 4
Hardware
Overview standard components EL (IP20)
Bus Coupler
EK1100 / EK1101
EL or ES terminal with E-bus
Busen
dcap:EL9011
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15.03.2012 5EtherCAT Training 5
Hardware
Overview standard components KL (IP20)
Bus Coupler
BK1120
KL or KS Terminal with K-bus
En
dterminal:KL9010
(BK1250: EtherCATK-bus)
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15.03.2012 6EtherCAT Training 6
Hardware
Overview standard components EP (IP67)
EP1111 EtherCAT BoxEP1122 EtherCAT 2-port junction
The EtherCAT connection is done via screwable, shielded M8 plug. The
plug shows the link and activity state.
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Hardware
Further EtherCAT components
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EK1501 EK1521 EK1122 EK 1132
EK1110 EL6692
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Functional princ ipleEtherCAT Ultra high-speed for Automation
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Functional principle
Highlights
Ethernet up to the terminal complete continuity
Ethernet process interface scalable from 1 bit to 64 kbyte
First true Ethernet solution for the field level
exact timing and adapted to synchronisation
Different approaches that try to provid real-time capability for classical
Ethernet:
Suspend collision detection (CSMA/CD)
Special switches that distribute Ethernet telegrams in a precisely
controlled timely manner
ProblemEven for very small data quantities a complete Ethernet frame has to
be sent
An underlying bus system adds small delays (e.g. K-bus)
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EtherCAT
Ethernet down to the I/O terminals!
Direct access of EtherCAT slave controller (ESC) to process data inEtherCAT frame
ESC differs by command header between process data and other
commands
Ring bus system with software based ending
Ethernet view: EtherCAT bus is one Ethernet node
Process data e.g. from the PLC are no longer received and
interpreted in devices. Process data is taken from the telegram by
the EtherCAT Slave Controller (ESC) or copied into it.
The EtherCAT frame is delayed [ns] by passing through the
EtherCAT slaves.
The last node in the segment returns the frame to EtherCAT-master.
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15.03.2012 11EtherCAT Training 11
EtherCAT
ESC
EtherCAT Slave Controller (ESC) handles the EtherCATcommunication in an EtherCAT slave.
Each EtherCAT slave has such an ESC to ensure that cyclical and
acyclical process data can be exchanged between mater and slave
via the EtherCAT fieldbus.
This ESC can handle simple functions such as digital inputs and
outputs directly, or it can be connected to a further processor in the
EtherCAT slave via serial/parallel interfaces for handling more
complex tasks such as drive control.
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15.03.2012 12EtherCAT Training 12
EtherCAT
Scheme of EtherCAT slave
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EtherCAT
typical embedding of ESC
From the RJ45 socket electrical signals are transferred to the PHY(PHYsical interface) via the transformer.
It extracts the user data from the coded Ethernet signal and
transfers them to the ESC for processing.
The EtherCAT telegram is then relayed with minimum delay (due todynamic processing) to the next EtherCAT slave via the PHY and
the socket.
The ESC automatically parameterises itself with configuration data
from an EEPROM.when the salve starts up. If a further CPU exists
in the slave, the slave can communicate with it via interfaces.
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TopologyEtherCAT Ultra high-speed for Automation
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Topology
line, tree or star topology
up to 65,535 devices
network size: almost unlimited (> 500 km)
operation with or without switches
cost-effecitve cabling: Industrial-Ethernet- patch cable (CAT5)
twisted pair physical layer
Ethernet 100BASE-TX, up to 100 m between 2 devices
alternative: fibre-optic variants 50 up to 2,000 m
hot connect/disconnect of bus segments
extension to GBit Ethernet possible
Transfer physics is converted in the coupler to the E-bus signalLVDS (Low Voltage Differential Signaling)
If necessary reconversion of the signal at the end of the bus
segment for transfer to the next Anschaltgruppe resp. Coupler.15.03.2012 15EtherCAT Training
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15.03.2012 16EtherCAT Training 16
Topology variant
line: any number of nodes lined up
DVI
IPC
....
up
65,535
nodesCable: standard CAT5 cable
without crossover
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15.03.2012 17EtherCAT Training 17
Topology variant
Daisy Chain
DVI
IPC
....
Cable: standard CAT5 cable
without crossover
Up to
65,535
nodes
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15.03.2012 18EtherCAT Training 18
Topology variant
Daisy Chain + drop lines
DVI
IPC
....
Cable: standard CAT5 cable,
without crossover
Up to
65,535
nodes
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15.03.2012 19EtherCAT Training 19
Topology variant
mixed structures
Cable: standard CAT5 cable
without crossover
DVI
IPC
....
Up to
65,535
nodes
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Advantage and eff iciency
EtherCAT Ultra high-speed for Automation
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Advantage and efficiency
no more network tuning: lower engineering costs
Hard real-time with software master: no plug-in card required
no active infrastructure components (switches, etc.) required
Ethernet cable and connector costs : lower than for traditional
fieldbus
EtherCAT right down to the I/O terminal: no complex Bus Couplers
required
Low interface costs due to the highly integrated EtherCAT Slave
Controller
EtherCAT as alone fieldbus
integration fieldbus in fieldbus to connect further fieldbusses likeCAN, PROFIBUS, ETHERNET, etc.
No further fieldbus master e.g. as PCI card in PC necessary!
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15.03.2012 22EtherCAT Training 22
Advantages and efficiency
EtherCAT instead of PCI
Seamless integration
of exisiting fieldbus devices Process image update-time
via EtherCAT (1500
bytes input and output data):
150s
Until now: Process image update-time
via PCI ( 500 byte input and
output data): 400s
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15.03.2012 23EtherCAT Training 23
Advantage and efficiency
Topology with Ethernet over EtherCAT
Ethernet over EtherCAT (EoE) enables direct connection of
Ethernet devices in EtherCAT fieldbus
Free patency of all Ethernet technologies!
Performance: > 5MBit/s outgoing
Performance: > 2MBit/s incoming
DVI
IPC
....
virtual Ethernet Switch
Functionality
EoE
Switchport
e.g.
connection ofLabel
printer/Scann
er
Programming/
Parameterizationdirectly in I/O
range
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15.03.2012 24EtherCAT Training 24
Advantage and efficiency
Topology with vertical integration
DVI
IPC
....
...via 2. Ethernet Port
+ any Ethernet protocol can be used
+ EtherCAT performance
is not limi ted
+ No switchport terminal necessary
- Requires second Ethernet port (at IPC/controller)
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Driver installation in System Manager
EtherCAT Ultra high-speed for Automation
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In practise
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Real-time Ethernet driver
real-time communication via the network card requires a Y driver
transparent connection in the operating system (conform for theoperating system, at the same time TwinCAT fieldbus card driver)
On the control side an internal prioritization and buffer ensure that
real-time frames alwasy find a free transmission channel
Ethernet frames for the operation system are sent inside the
intervals
At the receiving end, all the Ethernet frames received are examined
by the TwinCAT I/O system, and those with real-time relevance are
filtered out.
all other frames are sent back to the operating system
EtherCAT frames have always the hightest priori ty!
It is recommended to use a separate network card for high-performance data communication from the operating system!
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Real-time Ethernet driver
embedded to operating system
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1 2
Network card operating systemOther
fieldbus
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In praxis
Real-time Ethernet driver
The installation of the real-time Ethernet driver can be done easily
via the TwinCAT System Manager
To use the cable redundancy, the driver has to be istalled on two
network cards
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EtherCAT data exchange
EtherCAT Ultra high-speed for Automation
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EtherCAT data exchange
A range of components are available for implementing direct
synchonous data exchange between two EtherCAT systems.
Depending on the application requirements, the appropriate method
can be selected based on the following criteria.
The characteristic features are:
Synchronous data exchange with predefined data that arespecifiedin the configuration
Asynchronous data exchange
Support for ADS over EtherCAT (AoE)
Support for synchronization of the distributed clocks (DC) in the
two systems
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EtherCAT data exchange
Overview
EL6692 Publisher/
Subscriber
EL6601 FC1100 CX50x0-
B110Maximum
synchronous
Data quantity
480 bytes,
bidirectional
variable 1024 bytes,
bidirectional
(publisher/
subscribermethod)
1024 bytes,
bidirectional
Maximumasynchronous
data quantity
- - Optional -
AoE support Yes Yes - Yes Yes
DC support Yes - - - -
notice - recommended for
synchronization of
EtherCAT systems
- TwinCAT 2.11
required
- use of an
Ethernet port in
both systems as
real-time device
- recommended
for synchronousdata exchange
- transfer of RT
devices into
EtherCAT
terminal
- recommended
for synchronousdata exchange
- Requires free
PCI slot in the
IPC
- TwinCAT 2.11
R2 required
- CX5000 as
subordinate
autonomous
controller with its
own IO is
integrated in thehigher level
system as an
EtherCAT slave
- option B110
required
- TwinCAT 2.11
R2 required15.03.2012 31EtherCAT Training
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EtherCAT data exchange
Topologiy
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TwinCAT
Ec MasterEc Slave
(CX/IPC)
TwinCAT
Ec Master
TwinCAT
Ec Master
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Protocol
EtherCAT Ultra high-speed for Automation
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Protocol
optimised protocol directy within the Ethernet frame
fully hardware-implemented
for routing and socket interface: UDP datagram
processing while passing
distributed clock for accurate synchronisation
Time stamp data types for resolution in nanosecond range
Oversampling data types for hight-resolution measurements
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Protocol in detail
description
The EtherCAT protocol is an Ethernet protocol optimized for process
data. It is sent consistently in one (ore further) Ehternet frames or
via UDP/IP.
The Ethernet frame has a size of 1514 byte. EtherCAT datagramms
(process data, etc.) with a user size of 1486 byte can be sent.
Larger process images are distributed over several Ethernet frames.
With the EtherCAT process data in the Ethernet frame a processimage up to 4 gigabytes can be served.
The data sequence is independent of the physical order of the
EtherCAT slaves in the network, addressing can be in any order.
Device profile according to CANopen (CoE) or Sercos (SoE)
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EtherCAT uses standard frames according to IEEE 802.3
no shortened frames
alternatively via UDP/IP (if IP routing is needed)
Protocol in detail
Structure of frames
MTU: max. 1514 Byte
SourceDestination Header EtherType CRC
16 Bit16 Bit48 Bit48 Bit 32 Bit
Embedded in Standard Ethernet
Frame, EtherType 0x88A4
Ethernet H. IP Header UDP H. Header
Or: via UDP/IP
UDP Port 0x88A4
TypeRes.Length
CRC
1 Bit 4 Bit11 Bit
160 Bit 64 Bit
0 11 12 15
1..n EtherCATtelegrams
MTU=Maximum
Transmission Unit,
in computer
network the
maximum non
fragmented
transferable datavolume.
TCP /IP
UDP /IP
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15.03.2012 37EtherCAT Training 37
EtherCAT Device
Protocol in detail
Continuity for technologies
fully transparent for TCP/IP
all internet technologies available: HTTP, FTP,
Without restricing the real-time capabilities of the bussystem!
Ethernet PHY
EtherCAT MAC / DLL
Process DataMailbox
Ethernet PHY
IP
TCP UDP
Ethernet
Application
Acyclic
Data
Real Time
Application
StandardTCP/IP
Stack
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Performance
EtherCAT Ultra high-speed for Automation
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Performance
256 digital I/Os in 12 s
1,000 digital I/Os in 30 s
200 analog I/Os (16 Bit) in 50 s, that is equivalent to 20 kHz
sampling rate
100 servo axis each 100 s
12,000 digital I/Os in 350 s
The EtherCAT bus system is so fast that between two (PLC) control
cycles internal EhterCAT eradication can be done (compare XFC)
EtherCAT is not limited to 100MBaud
The bus system is no longer the bottle neck of the control!
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Performance
Function pr inciple Ethernet on the Fly
15.03.2012 40EtherCAT Training 40
Wagen
27
Example ICE:
Train (Ethernet Frame) doesnt stop
Somebody who sees the train through a narrow window, sees
the whole train
railway car (Sub telegramms) have variable lengthSingle people (bits) or tour groups (x kbyte) can be removed
and/or inserted.
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Performance
Processing on the fly
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vom Master
to Master
From Master
Data is modified
and/or added while
telegram passes
through
Without buffering,
storing the telegram
minimal
telegram delay
per node
Optimal
performance
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Performance
processing times
Runtimes by the cable length are nearly irrelavant,
100 m Ethernet cable need approx. 550 ns.
Processing time of one or more Ethernet frame through all real
slaves on the foreward path and return path. As order of magnitute
for each slave can be taken:
For an Ethernet device: approx.1 s
For an Ebus device: approx. 300 ns
Processing t ime delayed hub and switches (ISO Layer 2) arenot part of an EtherCAT network. A segementation by router
(ISO layer 3) does not take place.
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Der Feldbus EtherCAT
EtherCAT Ultra high-speed for Automation
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The fieldbus EtherCAT
Mapping of several process images
Traditional fieldbus systemes generate physical process image
This has to be mapped to logical process image(s)
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Control, e.g. IPCFieldbus Scanner/
Master
Logicalprocessimages
PLC Data
Data n
NC Data
DPRAM
node 1
node 2
node 3
node 4
node 1
node 2
node 3
node 4
Mapping
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Der Feldbus EtherCAT
Mapping of process image bisher
The same applies to control systems with just one process image
Resorting of process data (mapping) is required, too.
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Control e.g. PLCFieldbus Scanner/
Master
Logicalprocessimages
Process
Data
DPRAM
node 1
node 2
node 3
node 4
node 1
node 2
node 3
node 4
Mapping
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The fieldbus EtherCAT
Mapping moved into the slave devices
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Logicalprocessimageupto4GByte
0
232 Telegram structu re
Ethernet HDR HDR 1 PLC Data HDR 2 NC Data HDR n Data n CRC
PLC Data
Data n
NC Data
Sub
Telegram 1Sub
Telegram 2
Sub
Telegram n
DVI
IPC
..
..
Control system in unburdened, master becomes
very simple
Data is transmitted according to the application
requirements: extremely fast, flexible and efficient
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Der Feldbus EtherCAT
Direct Memory Access saves time
Fieldbus cards: up to 30% of CPU
time data copying
EtherCAT: NIC is PCI bus master,
is provided by DMA,
directly to PC RAM:
CPU relieved
More performance
15.03.2012 47EtherCAT Training 47
PC RAMPC Control with fieldbus cards
PCI
bus
Scanner card, DP RAM Control task
memcopyCPU
PC RAM
CPU
PC Control with EtherCAT
NIC card, DMA transferControl task
DMA
PCI
bus
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The fieldbus EtherCAT
Reaction time with legacy fieldbus
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Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus CycleBus CycleBus Cycle
Tmpd
TI/O
TI/O
TI/O
TI/O
TI/O
TI/O
TI/O
TI/O
TI/O
TI/O TI/O TI/O TI/O TI/O TI/O
PLC Task OI PLC Task OI PLC TaskOI PLC TaskOI PLC TaskI
Input Output
(Worst case)
best case Reaction Time
Tmpd: Master Processing Delay
TI/O: Local I/O Update Time
(local Extension Bus + Firmware)
worst case Reaction Time
Input
(best case)
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The fieldbus EtherCAT
EtherCAT System
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Tmpd
TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O
PLC task OI PLC task OI PLC task OI PLC task OI PLC taskI
No underlying extension bus any more
No dedicated master device any more
bus cycle bus cycle bus cycle bus cycle bus cyclebus cyclebus cycle
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The fieldbus EtherCAT
Processing between two control cycles
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PLC task OI PLC task OI PLC task OI PLC task OI PLC taskI
TDMA (NIC)
TEtherCAT Cycle
TDMA (Time for data transferfrom/to Ethernet controller via
direct memory access):
neglectible
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The fieldbus EtherCAT
Reaction time with EtherCAT
15.03.2012 51EtherCAT Training 51
PLC task OI PLC task OI PLC task OI PLC task OI PLC taskI
Input(Worst case)
Output
worst case
Reaction Time
Input(best case)
best case
reaction time reduced significantly with the same
controller performance
no underlying local I/O cycles and extension bus delays
any more due to the very simple protocol no dedicated master
systems (e.g. plug in cards) required