ethercat as a master machine control tool galil webinar

Galil Motion Control

Matt Klint Applications Engineer Galil Motion Control

EtherCAT as a Master Machine Control Tool

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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



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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 110 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



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Communication 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



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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)



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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 formatting 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



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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



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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



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EtherCAT Communication

• 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 Layout size 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



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Each cubicle is an EtherCAT Slave, each engineer is told where to sit by an SDO The boss is the EtherCAT Master, sending instructions (PDOs) out to the engineers each morning and picking up their work at quitting time.

EtherCAT Communication Analogy



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Object Dictionary: x6060 • 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 Operation Modes



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Master • 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



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• Slave • Reads and processes profiling data • Writes position, input and drive status for return to the master • Can be configured in for multiple modes of operation • All slaves contain specific spaces in memory where data can be

written • 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 written to the

x6060 Object in the slave’s dictionary

EtherCAT Slave



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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 are “mapped” using SDOs

• Mapping sets up which byte in each PDO goes to which memory address on

the slave



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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 ELECTROMATE

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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 ELECTROMATE

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The EtherCAT Slave Architecture



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PDO Processing

Incoming PDO Position Data

Slave Target Position Memory Object

4 x 8 bits

x607A



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Master/Slave Communication



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EtherCAT Communication Timing

EtherCAT Master EtherCAT Slave

CAT5 Ethernet Cable

t = 0

t = 1 ms



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EtherCAT Hardware

Standard Ethernet Physical Layer components • CAT5 cabling • Network Interface Cards

FPGAs for fast command processing by slave units



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EtherCAT Only Physical Layout

EtherCAT Master

EtherCAT Drive 1

EtherCAT Drive 2

EtherCAT Drive 3

Motor/ Encoder

Motor/ Encoder

Motor/ Encoder



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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



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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



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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



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Compatible 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.



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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 attainable

hardware

• Due to the EtherCAT communication protocol, networks are easily expandable,

modifiable and simple to maintain



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Please submit your questions regarding any part of this presentation or about

EtherCAT in general at this time

Additionally, please contact Galil’s dedicated Applications Engineering team anytime

with additional questions or comments:

Q & A

1 800 377 6329 [email protected]

In Canada contact: Electromate 1 877 737 8698 [email protected]



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