EtherCAT –

The Automation Backbone

Made by Beckhoff

Dr. Guido Beckmann

Technology Marketing

Bus System and Control Architecture

Super Fast Controls (such as PC based Controls)

require a super fast bus technology!

Brutus: WW1 Aircraft Engine with

47 l (!) Displacement and

740 h.p. (550 kW) Power,

Brutus: Experimental Vehicle with WW1 BMW Aircraft engine, built by Auto & Technik Museum Sinsheim, Germany

but inadequate tires….

The Ethernet Fieldbus.

Minimum Ethernet Frame: 84 Bytes!

For Industrial Automation:

usually only a few Bytes per device are needed

@ 4 Bytes Process Data: Only 4,75% Application Data Ratio

2 Frames per device Controller Device: Output data

Device Controller: Input data

Industrial Ethernet | Bandwidth utilization

Ethernet Frame Payload: min. 46 BytesEthernet HDRFCS

CRC

Interpacket

GapProcess

Data

Industrial

Ethernet

Process data is extracted and inserted on the fly

One frame for all Slaves

Minimal protocol overhead via logical addressing

Assigned automatically by the master during boot-up

Process data size individual per slave: 1 bit…60 kByte

Communication completely in hardware: maximum

(+ predictable!) performance

EtherCAT Functional Principle: Processing on the Fly

Master

Ethernet Frame Payload: Up to 1500 ByteEthernet HDRFCS

CRC

Interpacket

GapPLC Data NC Data PLC 2 Data

ECAT

Hdr

Process data is extracted and inserted on the fly

One frame for all Slaves

Minimal protocol overhead via logical addressing

Assigned automatically by the master during boot-up

Process data size individual per slave: 1 bit…60 kByte

Communication completely in hardware: maximum

(+ predictable!) performance

EtherCAT Functional Principle: Processing on the Fly

Master

Ethernet Frame Payload: min. 46 BytesEthernet HDRFCS

CRC

Interpacket

GapPLC Data NC Data PLC 2 Data

ECAT

Hdr

Switches are commonly used for Ethernet

Almost all Switches use „Store & Forward“

Line Topology means cascaded Switches

Example: Full frame, 20 nodes in line topology: 2,5 ms!

EtherCAT with Processing on the fly: Delay ~20µs@20 nodes

Industrial Ethernet | Switch Delays

Internal Switches

Internal

SwitchSwitchSwitch

Internal

Switch

Industrial

Ethernet

Switches are commonly used for Ethernet

Almost all Switches use „Store & Forward“

Line Topology means cascaded Switches

Example: Full frame, 20 nodes in line topology: 2,5 ms!

EtherCAT with Processing on the fly: Delay ~20µs

Industrial Ethernet | Switch Delays

Internal Switches

Internal

SwitchSwitchSwitch

Internal

Switch

Industrial

Ethernet

Ethernet uses addressing by MAC on Layer 2

(-) Device Replacement

or TCP/IP on Layer 3 / 4

(-) IP-Address management

(-) Software Stacks involved

Industrial Ethernet | Addressing

192.168.100.5

192.168.100.6

192.168.100.7

192.168.100.8 192.168.100.10 192.168.100.20

34-7A-56-32-88-34

72-45-7d-bc-32-aa

bd-34-64-8b-ff-97

52-4c-5a-bd-cf-95 95-63-5f-2d-ac-bd 78-95-5f-2d-ac-fd

Logical Addressing0x10000

?? ??

0x10004 0x10008 0x1000B 0x20000 0x20020

0x20001

0x20003

0x20004

0x20005

0x20007

0x20008

0x2000A

0x2000C

0x20021

0x20023

0x20024

0x20025

0x20027

Each individual slice can

be an EtherCAT slave!

Industrial

Ethernet

564 pages!

Design and Implementation

Guide for Plantwide

EtherNet/IP Networks

Ethernet uses addressing by MAC on Layer 2

(-) Device Replacement

or TCP/IP on Layer 3 / 4

(-) IP-Address management

(-) Software Stacks involved

Industrial Ethernet | Addressing

192.168.100.5

192.168.100.6

192.168.100.7

192.168.100.8 192.168.100.10 192.168.100.20

34-7A-56-32-88-34

72-45-7d-bc-32-aa

bd-34-64-8b-ff-97

52-4c-5a-bd-cf-95 95-63-5f-2d-ac-bd 78-95-5f-2d-ac-fd

Logical Addressing0x10000

?? ??

0x10004 0x10008 0x1000B 0x20000 0x20020

0x20001

0x20003

0x20004

0x20005

0x20007

0x20008

0x2000A

0x2000C

0x20021

0x20023

0x20024

0x20025

0x20027

Each individual slice can

be an EtherCAT slave!

Industrial

Ethernet

I/O Ports

EtherCAT

Slave

Controller

µC

Application

e.g. CiA402 Drive Profile

SDO

Object Dictionary

PDO

PDO Mapping

Industrial Ethernet

Protocol Stacks are

BIG

Processing them needs

TIME

Industrial Ethernet | Stack Delays

Ethernet

MAC

I/O Ports

I/O Ports

EtherCAT

Slave

Controller

µC

IP

TCP UDP

Encapsulation

CIP Message

Encapsulation

Implicit

Msg

Explicit

Msg

CIP

Network & Transport

Device Profile

Application Objects

(e.g. I/O)

O

I

Out In

I/O Ports

EtherCAT

Slave

Controller

µC

Application

e.g. CiA402 Drive Profile

SDO

Object Dictionary

PDO

PDO Mapping

Industrial Ethernet

Protocol Stacks are

BIG

Processing them needs

TIME

Industrial Ethernet | Stack Delays

Ethernet

MAC

I/O Ports

I/O Ports

EtherCAT

Slave

Controller

µC

IP

TCP UDP

Encapsulation

CIP Message

Encapsulation

Implicit

Msg

Explicit

Msg

CIP

Network & Transport

Device Profile

Application Objects

(e.g. I/O)

O

I

Out In

EtherCAT: Performance Breakthrough

EtherCAT Technology Group (ETG)

is worlds largest Fieldbus organization

3770 members (June 2016)

Outstanding adoption rate

© h

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ino

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oto

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© EtherCAT Technology Group

Outstanding Adoption RateJune 2016

EtherCAT – Made by Beckhoff

EtherCAT Terminals Embedded PC

Servo Drives EtherCAT Plug-in Modules

EtherCAT Box

Industrial PC

System overview – Flexible Topology

Flexible topology

IPC

Ethernet TCP/IP

Automation suite,

EtherCAT master

Bus/

line100 m

Fibre optic

(100BASE-FX)

up to 20,000 m (singlemode)

100BASE-FX

Tree/

star

E-bus K-bus

BK1250

Industrial Ethernet cable

(100BASE-TX)

EtherCAT down to the IO level

High bandwidth utilization allows integration of underlying

fieldbus technologies into the EtherCAT process image

Fieldbus master or slave

Migration path for machine builder

Small Embedded PC solutions with maximum flexibility

Integration of legacy fieldbus systems

Fieldbus integration

IEEE 1588

eXtreme Fast Control Technology

for higher production efficiency

EtherCAT – Distributed clocks

Time synchronization integrated in slave hardware

EtherCAT Slave Controller

Shifting accuracy to the I/O level

Distributed absolute

system synchronization

CPU

I/O

drive devices

Resolution: 10 ns

Accuracy: < 100 ns

XFC technologies

EtherCAT – Backbone for eXtreme Fast Control XFC

eXtreme Fast I/O eXtreme Fast Communication

eXtreme Fast Controller (IPC) eXtreme Fast Runtime

XFC in practice

Printer position control

Linear path control Part tracking

Glue application

Digital cam

Closed-loop control

EtherCAT – Backbone for Scientific Automation

Measurement technology

Condition Monitoring

The Beckhoff servo terminal

Robotics

EtherCAT – The Automation Backbone

Made by Beckhoff