EtherCAT as a Master Machine Control Tool

Galil  Mo(on  Control  

Ma-  Klint  Applica(ons  Engineer  Galil  Mo(on  Control  

EtherCAT  as  a  Master  Machine  Control  Tool

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

Moderator Presenter

Miles Budimir Design World

Matt Klint Galil Motion Control

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

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

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

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)

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

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

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

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

•  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  

•  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  

•  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  

•  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  

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

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

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

The  EtherCAT  Slave  Architecture  

Simple  PDO  Example  

Incoming PDO Position Data

Slave Target Position Memory Object

4 x 8 bits

x607A

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 PDO Incoming PDO

EtherCAT  Hardware  Standard  Ethernet  Physical  Layer  components

•  CAT5  cabling •  Network  Interface  Cards

FPGAs  for  fast  command  processing  by   slave  units

EtherCAT  Only  Physical  Layout  EtherCAT  Master  

EtherCAT  Drive  1  

EtherCAT  Drive  2  

EtherCAT  Drive  3  

Motor/  Encoder  

Motor/  Encoder  

Motor/  Encoder  

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

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

DMC  Code  Example  

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

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.

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

Questions? Miles Budimir Design World [email protected] Twitter: @DW_Motion

Matt Klint Galil Motion Control [email protected]

Galil Applications Engineering Team 1 (916) 626-0101 [email protected] www.galil.com

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