Ethercat Introduction

Why Ethernet for Automation?

EtherCAT is: • Today at controller level: state-of-the-art -Faster • Advantages for fieldbuses: - Synchronization – lower costs because the use of commodity technology - Industrial Ethernet -Flexible – Ethernet technology is driven by the office sector - Easier to configure – access to internet technology (e.g. webserver) - Cost effective – reduction of interfaces - Easier to implement • But: Common Ethernet does not achieve fieldbus - Well proven requirements as… - Open - Conformance – Low cost, performance, deterministic (real time),… - Safety - Redundancy -Versatile

EtherCAT is: • EtherCAT is real time down to the I/O level -Faster • No underlying sub-systems any more - Synchronization - Industrial Ethernet • No delays in gateways -Flexible • In- and outputs, sensors, actuators, drives, displays: - Easier to configure everything in one system! - Cost effective - Easier to implement - Well proven - Open - Conformance - Safety - Redundancy -Versatile

EtherCAT is: • Transmission Rate: -Faster – 2 x 100 Mbit/s (Fast Ethernet, Full-Duplex) - Synchronization

- Industrial Ethernet -Flexible • Update Times: - Easier to configure – 256 digital I/O in 11 µs - Cost effective – 1000 digital I/O distributed to 100 nodes in 30 µs = 0.03 ms - Easier to implement – 200 analog I/O (16 bit) in 50 µs, 20 kHz Sampling Rate - Well proven - Open – 100 Servo-Axis (each 8 Byte In + Out) in 100 µs = 0.1 ms - Conformance – 12000 digital I/O in 350 µs - Safety - Redundancy -Versatile

EtherCAT is: • Bandwidth Usage of Ethernet for I/O and Drives: -Faster – Ethernet Frame: ≥ 84 Bytes - Synchronization incl. Preamble + IPG (interpacket gap) - Industrial Ethernet

-Flexible Data pay load: - Easier to configure e.g. 2 Bit..6 Byte

- Cost effective 22 Bytes 4 Bytes 12 Bytes - Easier to implement Ethernet Header Data: ≥46 Bytes CRC IPG - Well proven Request with output data Node - Open Master I/O reaction Response with input data time - Conformance - Safety Ethernet Header Data: ≥46 Bytes CRC IPG - Redundancy -Versatile – with 4 Byte input + 4 Byte output per node: • 4,75% application data ratio at 0 µs reaction time/node • 1,9% application data ratio at 10 µs reaction time/node

EtherCAT is: • Bandwidth Usage Comparison: -Faster – At 4 Byte user data per node: - Synchronization • Polling / Timeslicing: ~ 2..5 % - Industrial Ethernet – From 2 Bit user data per node: -Flexible • EtherCAT: ~ 80..97 % (Full Duplex, 2 x 100 MBit/s) - Easier to configure - Cost effective

- Easier to implement 100

- Well proven 90 - Open 80 - Conformance 70 60 - Safety 50 - Redundancy 40 -Versatile 30

0 Polling / EtherCAT Timeslicing

EtherCAT is: -Faster - Synchronization - Industrial Ethernet -Flexible Car - Easier to configure 27 - Cost effective - Easier to implement - Well proven - Open - Conformance • Analogy Fast Train: - Safety - Redundancy – “Train” (Ethernet Frame) does not stop -Versatile – Even when watching “Train” through narrow window one sees the entire “Train” – “Car” (Sub-Telegram) has variable length – One can “extract” or “insert” single “persons” (Bits) or entire “groups” (Bytes) – even multiple groups per train

EtherCAT is: -Faster Slave Device Slave Device - Synchronization - Industrial Ethernet EtherCAT Slave EtherCAT Slave -Flexible Controller Controller - Easier to configure - Cost effective - Easier to implement - Well proven - Open • Process data is extracted and inserted on the fly: - Conformance – Process data size per slave almost unlimited - Safety (1 Bit…60 Kbyte, if needed using several frames) - Redundancy – Compilation of process data can change in each cycle, e.g. -Versatile ultra short cycle time for axis, and longer cycles for I/O update possible – in addition asynchronous, event triggered communication

EtherCAT is: -Faster Master - Synchronization - Industrial Ethernet -Flexible - Easier to configure - Cost effective 2 2 - Easier to implement 1 Ethernet Header ECAT HDR PLC Data NC Data Data n Ethernet HDR HDR HDR - Well proven - Open - Conformance • Minimal protocol overhead via implicit addressing - Safety – Optimized telegram structure for decentralized I/O - Redundancy -Versatile – Communication completely in hardware: maximum (+ predictable!) performance – No switches needed if only EtherCAT devices in the network – Outstanding diagnostic features – Ethernet-compatibility maintained

EtherCAT is: • 40 Axis (each 20 Byte Input- and Output-Data) -Faster • 50 I/O Station with a total of 560 EtherCAT Bus - Synchronization Terminals - Industrial Ethernet -Flexible • 2000 Digital + 200 Analog I/O, Bus Length 500 m - Easier to configure • Performance EtherCAT: Cycle Time = 276 µs - Cost effective at 44 % Bus Load, Telegram Length = 122 µs - Easier to implement - Well proven - Open 276 µs - Conformance Ether CA T in spite of this cycle time still 56% bandwidth remaining, e.g. for TCP/IP - Safety 479 µs SERCOS III - Redundancy 763 µs -Versatile Profinet IRT

2347 µs Pow er link

6355 µs Profinet I/O

0 1000 2000 3000 4000 5000 6000 7000

EtherCAT is: • Reaction time with legacy fieldbus I/O: -Faster - Synchronization - Industrial Ethernet I PLC Task O I PLC Task O I PLC Task O I PLC Task O I PLC Task -Flexible - Easier to configure

- Cost effective Tmpd - Easier to implement - Well proven Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle - Open - Conformance - Safety T T T T T T T T T T T I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O TI/O TI/O TI/O TI/O - Redundancy best case reaction time -Versatile worst case reaction time

Input Input Output (worst case) (best case)

T : Master Processing Delay mpd TI/O: Local I/O Update Time (local Extension Bus + Firmware)

EtherCAT is: • System Architecture with EtherCAT: -Faster - Synchronization - Industrial Ethernet I PLC Task O I PLC Task O I PLC Task O I PLC Task O I PLC Task -Flexible - Easier to configure no dedicated Master Device any more

- Cost effective T mpd - Easier to implement - Well proven Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle - Open - Conformance - Safety T T T T T T T T T T T I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O I/O TI/O TI/O TI/O TI/O - Redundancy on underlying extension bus any more -Versatile

- Open TDMA (NIC) - Conformance TDMA = Time for Data Transfer - Safety from/to Ethernet Controller via - Redundancy T Direct Memory Access: neglectible EtherCAT Cycle -Versatile

EtherCAT is: • Reaction Time with EtherCAT: -Faster - Synchronization - Industrial Ethernet I PLC Task O I PLC Task O I PLC Task O I PLC Task O I PLC Task -Flexible - Easier to configure - Cost effective

- Easier to implement best case worst case - Well proven - Open EtherCAT Input Input Output - Conformance (worst case) (best case) Bus Cycle - Safety

- Redundancy -Versatile – 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

EtherCAT is: • Traditional fieldbus system generate physical process -Faster image - Synchronization • This has to be mapped to logical process image(s) - Industrial Ethernet -Flexible - Easier to configure - Cost effective - Easier to implement Control System, e.g. IPC - Well proven DPRAM Node 1 - Open Fieldbus Scanner/Master - Conformance Node 1 Data n - Safety Node 2 Node 2 - Redundancy PLC Data -Versatile

NC Data Node 3 Node 3

Node 4

logical process images

Node 4 Mapping

EtherCAT is: • The same applies to control system with just one process -Faster image - Synchronization • Resorting of process data (“Mapping”) is required, too - Industrial Ethernet -Flexible - Easier to configure - Cost effective - Easier to implement Control System, e.g. IPC - Well proven DPRAM Node 1 - Open Fieldbus Scanner/Master - Conformance Node 1

- Safety Node 2 Node 2 - Redundancy Process- Data -Versatile

Node 3 Node 3

Node 4

Logical process image process Logical

Node 4 Mapping

EtherCAT is: Master -Faster - Synchronization - Industrial Ethernet -Flexible - Easier to configure

- Cost effective Ethernet Header ECAT HDR PLC Data NC Data Data n Ethernet HDR 2 HDR 2 HDR HDR 1 HDR - Easier to implement - Well proven Data n

- Open PLC Data - Conformance - Safety NC Data Datagram 1 Datagram 2 Datagram n - Redundancy logical process images up to 4 GByte -Versatile • Control System is unburdened, master becomes very simple • Data is transmitted according to the application requirements: extremely fast, flexibly and efficiently

EtherCAT is: • Fieldbus cards: PC Control with Fieldbus cards -Faster up to 30% of CPU PC RAM - Synchronization time for data Scanner card, DP RAM - Industrial Ethernet copying Control task -Flexible PCI - Easier to configure CPU memcopy bus - Cost effective - Easier to implement - Well proven - Open • EtherCAT: PC Control with EtherCAT PC RAM - Conformance MAC is PCI Bus - Safety master, data is CPU - Redundancy provided by DMA Control task -Versatile directly to PC RAM: PCI CPU relieved more MAC DMA bus performance

EtherCAT is: • EtherCAT Node measures time difference between -Faster 3 leaving and returning frame - Synchronization - Industrial Ethernet -Flexible - Easier to configure - Cost effective - Easier to implement EtherCAT Frame - Well proven Processing Direction - Open EtherCAT Frame - Conformance Forwarding Direction - Safety - Redundancy -Versatile

EtherCAT is: • EtherCAT Node measures time difference between -Faster 3 leaving and returning frame - Synchronization - Industrial Ethernet -Flexible - Easier to configure IPC - Cost effective Master - Easier to implement - Well proven - Open - Conformance - Safety - Redundancy -Versatile

EtherCAT is: • Precise Synchronization (<< 1 µs!) by exact adjustment -Faster 3 of Distributed Clocks - Synchronization - Industrial Ethernet -Flexible M - Easier to configure S IPC ∆t - Cost effective Master - Easier to implement - Well proven S S - Open - Conformance

- Safety S S S S - Redundancy -Versatile

EtherCAT is: • Switchport with integrated IEEE 1588 Boundary Clock -Faster 3 - Synchronization IEEE 1588 Grandmaster - Industrial Ethernet -Flexible M Boundary - Easier to configure S Clock - Cost effective Master - Easier to implement - Well proven S S - Open - Conformance

- Safety S S S S - Redundancy -Versatile

EtherCAT is: • Long Term Scope View of two separated devices -Faster 3 • 300 Nodes in between, 120m Cable Length - Synchronization - Industrial Ethernet -Flexible - Easier to configure - Cost effective - Easier to implement - Well proven Simultaneity: ~15 ns - Open - Conformance Jitter: ~ +/-20ns - Safety - Redundancy -Versatile

EtherCAT is: • EtherCAT uses Standard Ethernet Frames: IEEE 802.3 -Faster 3 • Alternatively via UDP/IP (if IP Routing is needed) - Synchronization 3 - Industrial Ethernet • no shortened frames -Flexible - Easier to configure Standard Ethernet Frame - Cost effective

- Easier to implement 0..32 48 Bit 48 Bit 16 Bit 16 Bit 48 -1498 Byte Byte 32 Bit - Well proven DA SA EtherType Header DatagramEthe 1 Darnetta gramDaten 2 … Datagram n Pad. CRC - Open - Conformance Embedded in Standard Ethernet EtherCAT Telegram - Safety Frame, EtherType 0x88A4

- Redundancy 160 Bit 64 Bit 16 Bit 48 -1470 Byte -Versatile Ethernet Header IP Header UDP H. Header EtherCAT Data Pad. CRC

Or: via UDP/IP UDP Port 0x88A4 11 Bit 1 Bit 4 Bit Length Res. Type

EtherCAT is: • fully transparent for TCP/IP -Faster 3 • all Internet technologies (HTTP, FTP, Webserver,…) - Synchronization 3 available without restricting the real time capabilites! - Industrial Ethernet -Flexible • full tool access to devices at real time operation – - Easier to configure with and without TCP/IP - Cost effective - Easier to implement EtherCAT Slave Device - Well proven - Open Ethernet Real Time Standard Application Application - Conformance TCP/IP Stack - Safety TCP UDP Acyclic - Redundancy IP Data -Versatile Mailbox Process Data EtherCAT MAC / DLL

Ethernet PHY Ethernet PHY

EtherCAT is: • Any Ethernet Device can be connected to Switchport -Faster 3 • Access to Webserver with Standard Browser - Synchronization 3 - Industrial Ethernet -Flexible Virtual Ethernet Webserver - Easier to configure Switch Functionality - Cost effective Switchport Master - Easier to implement - Well proven - Open - Conformance - Safety - Redundancy -Versatile

EtherCAT is: • Virtual Ethernet Switch routes any Ethernet Frame -Faster 3 • From inside as well as from outside the segment - Synchronization 3 - Industrial Ethernet -Flexible Virtual Ethernet - Easier to configure Switch - Cost effective Functionality Switchport Master - Easier to implement - Well proven - Open - Conformance - Safety - Redundancy -Versatile

Ethernet Switch

EtherCAT is: • Interface to any Ethernet Device or Network -Faster 3 • Ethernet Frames are inserted into EtherCAT Protocol: - Synchronization 3 – ‘Ethernet over EtherCAT’ - Industrial Ethernet -Flexible - Easier to configure EtherCAT Switchport - Cost effective - Easier to implement Ethernet MAC PHY - Well proven - Open RX1 RX2TXRX RX3 RX4 - Conformance µC - Safety Fragmentation - Redundancy -Versatile Mailbox Process Data PHY EtherCAT MAC / DLL PHY

TX2TX3TX1 TX2TX3TX1

EtherCAT is: • …via Switchport -Faster 3 - Synchronization 3 - Industrial Ethernet Master -Flexible - Easier to configure - Cost effective - Easier to implement - Well proven Switchport - Open - Conformance - Safety • + any Ethernet Protocol can be used - Redundancy • + requires only one Ethernet Port (at IPC/Controller) -Versatile • + EtherCAT performance is not limited

EtherCAT is: • ...via 2. Ethernet Port -Faster 3 - Synchronization 3 - Industrial Ethernet Master -Flexible - Easier to configure - Cost effective - Easier to implement 2nd Ethernet - Well proven Port - Open - Conformance - Safety • + any Ethernet Protocol can be used - Redundancy • + EtherCAT performance is not limited -Versatile • but: requires second Ethernet Port (at IPC/Controller)

EtherCAT is: • …via Switch -Faster 3 - Synchronization 3 - Industrial Ethernet Master -Flexible - Easier to configure - Cost effective - Easier to implement Ethernet - Well proven Switch - Open - Conformance - Safety • + any Ethernet Protocol can be used - Redundancy • + requires only one Ethernet Port (at IPC/Controller) -Versatile • but: performance reduced by switch delay (and generic Ethernet traffic)

EtherCAT is: • Standard Ethernet Topology: Star -Faster 3 - Synchronization 3 - Industrial Ethernet 3 -Flexible - Easier to configure - Cost effective - Easier to implement - Well proven - Open - Conformance - Safety - Redundancy -Versatile

EtherCAT is: • Flexible tree structures – arbitrarily extendable -Faster 3 – Topology variants like Line, Star, Tree, Daisy Chain - Synchronization 3 + Drop Lines possible; can be used in any combination! - Industrial Ethernet 3 – Up to 65.535 nodes for each EtherCAT segment -Flexible - Easier to configure – Standard Ethernet cabling Line - Cost effective - Easier to implement - Well proven - Open Master - Conformance - Safety - Redundancy -Versatile

Drop Line Star/Tree

EtherCAT is: • Ethernet Signal Variants of EtherCAT: -Faster 3 – 100BASE-TX (up to 100 m between 2 nodes) - Synchronization 3 – 100BASE-FX (longer distances between 2 nodes) - Industrial Ethernet 3 -Flexible – LVDS (for modular devices)

- Easier to configure LVDS* - Cost effective 100 m - Easier to implement - Well proven - Open Master - Conformance - Safety - Redundancy Ethernet on Ethernet on 100BASE-TX 100BASE-FX -Versatile up to 100 m (fibre optics) with transformer for longer coupling Ethernet on LVDS* physical layer: distances for modular devices

• Any number of physical layer changes allowed

*LVDS: Low Voltage D ifferential Signaling according to ANSI/T IA/EIA-644, also used in IEEE 802.3ae (10Gigabit Ethernet) © EtherCAT Technology Group, 2009 35

EtherCAT Extra Large System Test

EtherCAT is: -Faster 3 - Synchronization 3 - Industrial Ethernet 3 -Flexible - Easier to configure - Cost effective - Easier to implement - Well proven - Open - Conformance - Safety - Redundancy -Versatile

10.056 EtherCAT Nodes

EtherCAT is: • Protection of your investment -Faster 3 • smooth migration path from legacy fieldbus to EtherCAT - Synchronization 3 • seamless integration of existing fieldbus devices, e.g.: - Industrial Ethernet 3 – AS-Interface -Flexible – CAN, CANopen - Easier to configure – CC-Link - Cost effective – ControlNet - Easier to implement – DeviceNet - Well proven – Ethernet/IP - Open – FIPIO - Conformance – Interbus - Safety – IO-Link - Redundancy – Lightbus -Versatile – LONWorks – Modbus Plus, RTU, TCP – MPI – PROFIBUS – PROFINET IO – … • maximum system expandability with low cost fieldbus gateways © EtherCAT Technology Group, 2009 37 EtherCAT instead of PCI

EtherCAT is: • Update Times (examples): -Faster 3 – Process image update-time - Synchronization 3 via PCI (500 Bytes input and output data each): 400 µs - Industrial Ethernet 3 – Process image update-time -Flexible via EtherCAT (1.500 Bytes input and output data): 150 µs - Easier to configure - Cost effective - Easier to implement - Well proven - Open - Conformance - Safety - Redundancy -Versatile

EtherCAT is: • No Slots in Control System (IPC or PLC) required any -Faster 3 more - Synchronization 3 • Nevertheless maximum expandability - Industrial Ethernet 3 -Flexible - Easier to configure - Cost effective - Easier to implement - Well proven - Open - Conformance - Safety - Redundancy -Versatile

EtherCAT

EtherCAT is: • Addressing -Faster 3 – No manual address setting required - Synchronization 3 – Addresses can be assigned automatically - Industrial Ethernet 3 – Addresses can be kept -Flexible 3 - Easier to configure • no new addressing if nodes are added - Cost effective - Easier to implement - Well proven - Open - Conformance - Safety - Redundancy -Versatile

EtherCAT is: • Topology: -Faster 3 – Automatic topology target/actual comparison - Synchronization 3 - Industrial Ethernet 3 -Flexible 3 • Diagnosis: - Easier to configure – Diagnosis with exact localization - Cost effective - Easier to implement - Well proven • Network planning: - Open – Performance independent of: - Conformance • Slave implementation - Safety • Topology (no Switches/Hubs) - Redundancy

-Versatile

EtherCAT is: • Implementation / Tools: -Faster 3 – Standard Network Monitor Tools, e.g. MS Network Monitor - Synchronization 3 or Wireshark: free of charge - Industrial Ethernet 3 – Parser Software: free of charge -Flexible 3

- Easier to configure 3 - Cost effective • Less effort for Network planning: - Easier to implement – Simplified configuration - Well proven – Default settings will work, no network tuning - Open - Conformance - Safety • Improved Diagnosis: - Redundancy – Faster error handling leads to less downtime -Versatile

• Faster Setup: – No address setting required

EtherCAT is: • Master: -Faster 3 – no dedicated plug in card (co-processor) - Synchronization 3 – on-board Ethernet Port is fine - Industrial Ethernet 3 -Flexible 3 - Easier to configure 3 • Slave: - Cost effective – low cost Slave Controller - Easier to implement • FPGA or ASIC - Well proven 32 Bit – for simple devices: no µC needed µC - Open - Conformance – no powerful µC needed - Safety - Redundancy • Infrastructure: -Versatile – no Switches/Hubs required – Standard Ethernet Cabling + Connectors

EtherCAT is: • Slave Implementation: -Faster 3 – All time critical functions implemented on ASIC or FPGA - Synchronization 3 • ESC handles Real-time Protocol in Hardware - Industrial Ethernet 3 – Integrated Communication State Machine -Flexible 3 – Network Performance independent of - Easier to configure 3 - Cost effective 3 • Slave-µC Performance - Easier to implement • Protocol Stack - Well proven – For usage with or without µC (Host CPU) - Open • Integrated DPRAM (1…8kByte) - Conformance • Integrated Distributed Clock Handling - Safety • Ultra precise interrupts to µC - Redundancy

-Versatile

EtherCAT is: Name ET1100 ET1200 netX5 -Faster 3 Type ASIC ASIC ASIC - Synchronization 3 - Industrial Ethernet 3 Hardware Supplier -Flexible 3 Package BGA128 QFN48 BGA201 - Easier to configure 3 0,8mm Pitch 0,5mm Pitch 0,8mm Pitch

- Cost effective 3 Size 10 x 10 mm 7 x 7 mm 13 x 13 mm - Easier to implement µC Interface serial/parallel serial* serial (SPI), - Well proven (8/16-bit, async)* parallel (8/16/32-bit, async) - Open Digital I/O 32 8-16* 16 - Conformance DPRAM 8 kByte 1 kByte 6 kByte - Safety SyncManager 8 4 8 - Redundancy FMMUs 8 3 8 -Versatile Distributed Clocks Yes Yes Yes No. Of Ports 2-4 (MII/E-bus)* 2-3 (E-bus/max. 2 (MII)

1xMII)* Specials Routable with - Multi Protocol standard PCB Support

* configurable

EtherCAT is: Name netX 100 netX 500 netX50 -Faster 3 Type ASIC ASIC ASIC - Synchronization 3 - Industrial Ethernet 3 Hardware Supplier -Flexible 3 - Easier to configure BGA345 BGA345 PBGA 3 Package 1mm Pitch 1mm Pitch - Cost effective 1mm Pitch 3 Size 22x22 mm 22x22 mm 19x19 mm - Easier to implement µC-Bus µC-Bus µC-Bus - Well proven µC Interface (internal, 32-bit) (internal, 32-bit) (internal, 32-bit) - Open Digital I/O 16 (GPIO) 16 (GPIO) 32 (GPIO) - Conformance 256/400 Byte 256/400 Byte - Safety DPRAM (Mailbox/Process (Mailbox/Process 6 kByte Data) Data) - Redundancy SyncManager 4 4 8 -Versatile FMMUs 3 3 8 Distributed Clocks Yes Yes Yes No. Of Ports 2 (100BASE-TX) 2 (100BASE-TX) 2 (100BASE-TX)

Multi Protocol Multi Protocol Multi Protocol Specials Support, Integrated: Support, Integrated: Support, Integrated: PHYs, ARM-9 µC PHYs, ARM-9 µC PHYs, ARM-9 µC

EtherCAT is: Name ET1810/ET1811/ET1812 ET1815/ET1816/ET1817 -Faster 3 Type FPGA + IP Core FPGA + IP Core - Synchronization 3 - Industrial Ethernet 3 Hardware Supplier -Flexible 3 Cyclone I+II+III, Spartan - Easier to configure 3 Supported Chips Stratix I+II+III+IV+GX+II GX, 3+3E+3A+3AN+3ADSP, - Cost effective 3 Arria GX Virtex II+II Pro+II Pro X+4+5

- Easier to implement Package FPGA dependent FPGA dependent

- Well proven Size FPGA dependent FPGA dependent - Open serial/parallel serial/parallel - Conformance µC Interface (8/16-bit, async) (8/16bit, async) AVALON®* OPB®* - Safety Digital I/O 8-32* 8-32* - Redundancy DPRAM 1...60 kByte* 1...60 kByte* -Versatile SyncManager 0…8* 0…8* FMMUs 0…8* 0…8* Distributed Clocks Yes* Yes* No. Of Ports 2 (MII) 2 (MII)

Several IP Core License Several IP Core License Specials models available models available

* configurable © EtherCAT Technology Group, 2009 47 EtherCAT is easier to implement: Master

EtherCAT is: • Master Implementation: -Faster 3 – e.g. with Master Sample Code (Source) - Synchronization 3 – EtherCAT Configuration Tool - Industrial Ethernet 3 – XML Data format of ESI and ENI -Flexible 3 - Easier to configure 3 - Cost effective 3 - Easier to implement - Well proven - Open - Conformance - Safety - Redundancy -Versatile

EtherCAT is: • Example: Master with just one process image -Faster 3 – typical e.g. for small controllers with one control task - Synchronization 3 – up to 1488 Byte Process data size - Industrial Ethernet 3 – Header for Process Data communication remains constant -Flexible 3

- Easier to configure 3 Ethernet Header ECAT EtherCAT Telegram Ethernet Frame EtherCAT - Cost effective 3 DA SA Type Data Pad. FCS

HDR HDR WKC - Easier to implement 3 6 Bit 6 Bit 2 Bit 2 Bit 10 Bit 0….1486 Byte 2 0…32 4 Byte - Well proven - Open constant header completely sorted Working Padding Bytes and - Conformance (mapped) process data Counter: CRC generated by constant Ethernet Controller

- Safety (MAC) - Redundancy – Master can be implemented with minimal effort -Versatile – No separate communication processor required (e.g. on plug-in card)

– Much simpler that legacy fieldbus systems – Very much simpler than competing Industrial Ethernet approaches…

EtherCAT is: • In series production since 2003 -Faster 3 • Numerous applications - Synchronization 3 • Great product variety of - Industrial Ethernet 3 -Flexible 3 available EtherCAT products - Easier to configure 3 - Cost effective 3 - Easier to implement 3 - Well proven - Open - Conformance - Safety - Redundancy -Versatile

EtherCAT is: EtherCAT Device -Faster 3 - Synchronization 3 File System, HTTP, FTP,… DEVICE Application - Industrial Ethernet 3 Bootloader The SERCOS* The CANopen -Flexible Process Data 3 Standard Standard - Easier to configure 3 - Cost effective 3 TCP UDP IDN Object Dictionary - Easier to implement 3 IP Service Channel SDO - Well proven PDO 3 AT File Access Map- - Open EN 50325-4 MDT IEC 61800-7-204 IEC 61800-7-201 ping Ethernet IEC 61800-7-304 - Conformance IEC 61800-7-301

- Safety FoE EoE SoE CoE CoE/SoE

- Redundancy Mailbox Process Data

-Versatile EtherCAT Slave Controller

Ethernet Physical Layer

*SERCOS interface™ is a trademark by SI e.V.

Typical EtherCAT Device Architecture

EtherCAT is: -Faster 3 EtherCAT Device - Synchronization 3 - Industrial Ethernet HTTP, FTP,… DEVICE Application 3 optional -Flexible 3 DeviceDevice Profile Definitions - Easier to configure Definitions 3 - Cost effective 3 TCP UDP Parameters - Easier to implement 3 Cyclic Synchronous - Well proven 3 IP Asynchronous Communication - Open Communication (Implicit (Explicit Addressing) Ethernet Addressing) - Conformance

- Safety EoE CoE/SoE CoE/SoE - Redundancy Mailbox Process Data -Versatile EtherCAT Slave Controller

Ethernet Physical Layer

EtherCAT is: -Faster 3 EtherCAT Device - Synchronization 3 - Industrial Ethernet HTTP, FTP,… Servodrive Application 3 optional IEC 61800-7- -Flexible 3 204 is the - Easier to configure 3 SERCOS* - Cost effective 3 Drive Profile TCP UDP IDN - Easier to implement 3 Process Data: AT / MDT - Well proven IP Service Channel 3 - Open Servodrive Profile IEC 61800-7-204 - Conformance Ethernet Mapping to EtherCAT: IEC 61800-7-304 - Safety EoE SoE SoE - Redundancy Mailbox Process Data -Versatile EtherCAT Slave Controller

Ethernet Physical Layer

*SERCOS interface™ is a trademark by SI e.V.

EtherCAT is: IEC 61800-7: Generic Interface and use of profiles for power drive systems -Faster 3 - Synchronization 3 IEC 61800-7-1: Interface Definition - Industrial Ethernet 3 Annex A: Annex B: Annex C: Annex D: -Flexible 3 Mapping to Mapping to Mapping to Mapping to - Easier to configure 3 DS402 CIP PROFIdrive SERCOS*

- Cost effective 3 - Easier to implement 3 IEC 61800-7-200: Profile Specifications - Well proven 3 - Open IEC 61800-7-201: IEC 61800-7-202: IEC 61800-7-203: IEC 61800-7-204: Profile Profile Profile Profile - Conformance CiA 402 CIP Motion PROFIdrive SERCOS* - Safety - Redundancy IEC 61800-7-300: Mapping of Profiles to Network Technologies -Versatile

IEC 61800-7-301 IEC 61800-7-304 B C Mapping to Mapping to Mapping to ...... Mapping to Mapping to Mapping to CANopen EPL EtherCAT SERCOS I/II SERCOS III EtherCAT

*SERCOS interface™ is a trademark by SI e.V.

EtherCAT is an open technology

EtherCAT is: -Faster 3 - Synchronization 3 - Industrial Ethernet 3 -Flexible 3 • Foundation: November 2003 - Easier to configure 3 • Tasks: Support, Advancement and Promotion of - Cost effective 3 EtherCAT - Easier to implement 3 • The worlds largest organization dedicated to Industrial - Well proven 3 - Open Ethernet - Conformance • more than 940* member companies from - Safety 45 countries in 6 continents: - Redundancy – Device Manufacturers -Versatile – End Users – Technology Providers • Membership is open to everybody

*as of Feb 2009 © EtherCAT Technology Group, 2009 55 EtherCAT is an open technology

EtherCAT is: • Protocol is disclosed completely: -Faster 3 – EtherCAT is IEC, ISO and SEMI Standard - Synchronization 3 (IEC 61158, IEC 61784, ISO 15745, SEMI E54.20) - Industrial Ethernet 3 -Flexible 3 - Easier to configure 3 - Cost effective 3 - Easier to implement 3 • Slave Controller from several sources available - Well proven 3 - Open • Slave Controller provides interoperability - Conformance • ETG organizes Interoperabilitly Testing („Plug Fests“), - Safety Workshops and Seminars - Redundancy -Versatile • Conformance Testing + Certificates

EtherCAT is: • Master Stacks for various RTOS available*, including Open / Shared Source! -Faster 3 – eCos - Synchronization 3 – Intime - Industrial Ethernet 3 – Linux with RT-Preempt

-Flexible 3 – MICROWARE OS-9

- Easier to configure 3 – On Time RTOS-32

- Cost effective 3 – PikeOS

- Easier to implement – Proconos OS 3 – Real-Time Java - Well proven 3 – RMOS - Open – RT Kernel - Conformance – RT-Linux - Safety – RTXC Quadros

- Redundancy – RTAI Linux

-Versatile – QNX

– VxWin + CeWin

– VxWorks

– Windows CE

– Windows XP/XPE with CoDeSys SP RTE

– Windows XP/XPE with TwinCAT RT-Extension

EtherCAT is: • Management Board of IEC has approved Liaison of -Faster 3 EtherCAT Technology Group with IEC SC65C WG - Synchronization 3 11/12/13 + JWG10 (SC65C: Digital Communication) - Industrial Ethernet 3 -Flexible 3 - Easier to configure 3 - Cost effective 3 - Easier to implement 3 • Thus ETG is official IEC Standardization Partner - Well proven 3 - Open - Conformance - Safety - Redundancy -Versatile

EtherCAT is: -Faster 3 - Synchronization 3 - Industrial Ethernet 3 -Flexible 3 - Easier to configure 3 - Cost effective 3 - Easier to implement 3 - Well proven 3 - Open - Conformance - Safety

- Redundancy ETG Office Japan -Versatile ETG Headquarters ETG Office Tokyo Germany ETG Office North America ETG Office Nuremberg China Austin, TX Korea Beijing Seoul

EtherCAT is: • As of April 2009: 1000 Members -Faster 3 - Synchronization 3 1000 1000 - Industrial Ethernet 3 940 -Flexible 3 881 900 820 - Easier to configure 800 3 766 - Cost effective 3 696 700 - Easier to implement 3 634 600 - Well proven 575 3 515 - Open 458 500 404 - Conformance 357 400 321 - Safety 285 240 214 300 188 - Redundancy 169 117136 200 -Versatile 59 89 33 100

0 Nov-03 May-04 Nov-04 May-05 Nov-05 May-06 Nov-06 May-07 Nov-07 May-08 Nov-08 May-09

EtherCAT is: -Faster 3 Australia Austria Belarus Belgium Bosnia and Brazil Canada China - Synchronization 3 Herzegovina - Industrial Ethernet 3 -Flexible 3 - Easier to configure 3 Croatia Czech Rep Denmark Finland France Germany Greece - Cost effective 3 - Easier to implement 3 - Well proven 3 Hungary India Israel Italy Japan Korea Liechtenstein Lithuania - Open - Conformance

- Safety Mexico Netherlands New Zealand Norway Poland Portugal Romania Russia - Redundancy -Versatile

Serbia Singapore Slovakia Slovenia South Africa Spain Sweden

Switzerland Taiwan Thailand Turkey Ukraine United Kingdom USA

EtherCAT is: • Much more important than membership figures: How -Faster 3 many are active, how many implement the technology? - Synchronization 3 • Dec 2008: More than 690 Implementation Kits sold to - Industrial Ethernet 3 ETG Members (25% Master, 75% Slaves), plus there are -Flexible 3 Open + Shared Source masters! - Easier to configure 3 • SPS/IPC/Drives 2008: 60 Vendors with over 180 different - Cost effective 3 EtherCAT Devices at ETG booth: - Easier to implement 3 – 25 different drives from - Well proven 3 16 manufacturers jointly

- Open operating in one network

- Conformance – 15 different functional - Safety Masters in one setup,

- Redundancy using 10 different -Versatile operating systems – Safety devices (master + slave devices) from 2

manufacturers operating

in one system

– Master to Master and redundancy live demo

EtherCAT is: I/O, Controller, HMI, Servo Drives, Variable Speed Drives Sensors, Slave + Master Development Kits -Faster 3 - Synchronization 3 Control Panels, Hydraulic Valves - Industrial Ethernet 3 and Pneumatic Valves, -Flexible 3 … - Easier to configure 3 - Cost effective 3 - Easier to implement 3 - Well proven 3 - Open - Conformance - Safety - Redundancy -Versatile

EtherCAT is: -Faster 3 - Synchronization 3 - Industrial Ethernet 3 -Flexible 3 • Conformance and interoperability are very important - Easier to configure 3 factors for the success of a communication technology - Cost effective 3 – Conformity to the specification is an obligation to all users of - Easier to implement 3 the EtherCAT technology - Well proven 3 – Therefore the EtherCAT Conformance Test Tool (CTT) is - Open 3 used - Conformance - Safety – Test Cases for the CTT are provided by the Working Group - Redundancy „Conformance“ within the ETG community -Versatile – The EtherCAT Conformance Test proves conformance officially with issuing a certificate after passing the test at an offical EtherCAT Test Center (ETC)

EtherCAT is: -Faster 3 - Synchronization 3 - Industrial Ethernet 3 -Flexible 3 • Safety over EtherCAT (FSoE) defines a safety - Easier to configure 3 communication layer for the transportation of safety - Cost effective 3 process data between Safety over EtherCAT devices. - Easier to implement 3 • FSoE is an open technology within the EtherCAT - Well proven 3 Technology Group (ETG). - Open 3 - Conformance 3 • The protocol is developed according to IEC 61508 - Safety – It meets the Safety Integrity Level (SIL) 3 - Redundancy – Residual Error Probability R(p) < 10-9 -Versatile • The protocol is approved by an independent Notified Body (TÜV)

EtherCAT is: -Faster 3 - Synchronization 3 - Industrial Ethernet 3 -Flexible 3 • FSoE Frame is mapped in the cyclic PDOs - Easier to configure 3 – Minimum FSoE Frame-Length: 6 Byte - Cost effective 3 – Maximum FSoE Frame-Length: depending on the number of - Easier to implement 3 safe process data of the Slave Device - Well proven 3 – Therefore the protocol is suitable for safe I/O as well as for - Open 3 functional safe motion control - Conformance 3 - Safety • Confirmed transfer from the FSoE Master to the FSoE - Redundancy Slave and vice versa. -Versatile • Safe Device Parameter can be downloaded from the Master to the Slave at Boot-Up of a FSoE Connection • Certified products with Safety over EtherCAT are available since 2005.

EtherCAT is: -Faster 3 - Synchronization 3 - Industrial Ethernet 3 -Flexible 3 • The FSoE specification has no restrictions according to: - Easier to configure 3 – Communication layer and interface - Cost effective 3 The communication layer is not part of the safety measures: - Easier to implement 3 black channel - Well proven -2 3 (assumed unsolved bit error rate: p = 10 ) - Open 3 – Transmission speed - Conformance 3 Length of safe process data - Safety – (lenght of safe process data is arbitrary) - Redundancy -Versatile • Routing via unsafe gateways, fieldbus systems or backbones is possible

EtherCAT is: -Faster 3 - Synchronization 3 - Industrial Ethernet 3 -Flexible 3 • Can be routed via non-safe gateways - Easier to configure 3 • Can be routed via fieldbus systems - Cost effective 3 • One Safety technology for (almost) all bus systems - Easier to implement 3 - Well proven 3 - Open 3 - Conformance 3 - Safety - Redundancy -Versatile

EtherCAT is: • Black channel approach -Faster 3 – with safety and non-safety data on the same bus - Synchronization 3 - Industrial Ethernet 3 Device 1 Device 2 -Flexible 3 - Easier to configure 3 Safety Safety - Cost effective 3 Application Application - Easier to implement 3 - Well proven 3 Standard Standard Application Application - Open 3 - Conformance 3 Safety over Safety over Safety - Safety EtherCAT EtherCAT over Protocol Protocol EtherCAT - Redundancy

-Versatile EtherCAT EtherCAT EtherCAT Communication Interface Communication Interface DLL and AL

EtherCAT Telegram

Safety data container (FSoE Frame)

EtherCAT is: • One channel communication system -Faster 3 – Model A according to IEC 61784-3 Annex A - Synchronization 3 - Industrial Ethernet 3 Device 1 Device 2 -Flexible 3 - Easier to configure 3 Controller A Controller B Controller B Controller A Safety Safety Safety Safety - Cost effective 3 Protocol Protocol Protocol Protocol Controller A Controller B Controller A Controller B - Easier to implement 3 Safety Safety Safety Safety - Well proven 3 Protocol Protocol Protocol Protocol - Open 3 EtherCAT EtherCAT Slave Controller Slave Controller - Conformance 3 - Safety PHY PHY PHY PHY - Redundancy -Versatile Magnetics Magnetics Magnetics Magnetics

RJ45 RJ45 RJ45 RJ45

EtherCAT is: • Ethernet telegram -Faster 3 Ethernet EtherCAT - Synchronization 3 1. Datagram 2. Datagram FSC Header Header - Industrial Ethernet 3 -Flexible 3 - Easier to configure 3 - Cost effective 3 Safety over EtherCAT frame - Easier to implement 3 - Well proven 3 - Open 3 CMD SafeData CRC_0 SafeData CRC_1 Conn ID - Conformance 3 - Safety - Redundancy – Safety over EtherCAT frame -Versatile • The FSoE Frame is a data container mapped in the process data of the devices

• A new FSoE Frame is recognized if at least one bit has changed according to the last frame

• For every 2 Byte SafeData a 2 Byte CRC is calculated • Up to n Byte SafeData can be transmitted

EtherCAT is: Measure Sequence Connection CRC Watchdog -Faster 3 Error Number ID Calculation - Synchronization 3 Unintended repetition - Industrial Ethernet 3 Loss -Flexible 3 - Easier to configure 3 Insertion - Cost effective 3 Incorrect sequence - Easier to implement 3 Corruption - Well proven 3 - Open 3 Unacceptable delay - Conformance 3 Masquerade - Safety Repeating memory errors - Redundancy in Switches -Versatile Incorrect forwarding between segments

EtherCAT is: • Decentralized Safety-Logic -Faster 3 • Standard PLC routes the safety messages - Synchronization 3

- Industrial Ethernet 3 Standard Safety Inputs -Flexible 3 PLC - Easier to configure 3 - Cost effective 3 - Easier to implement 3 - Well proven 3 Safety Outputs - Open 3 - Conformance 3 - Safety - Redundancy -Versatile S

S Safety Drives Safety Logic S

EtherCAT is: • Fully integrated solution: -Faster 3 – safe and standard communication in one channel - Synchronization 3 • Reduction of fieldbuses and interfaces - Industrial Ethernet 3 -Flexible 3 • Central configuration, diagnosis and maintenance for - Easier to configure 3 safe and ‚unsafe‘ I/O in one tool - Cost effective 3 • Safety application makes full use of EtherCAT - Easier to implement 3 advantages: - Well proven 3 – Short reaction times - Open 3 - Conformance 3 – Almost unlimited number of nodes - Safety – Large network extensions - Redundancy – Cable redundancy options -Versatile – High Flexibility with Hot Connect

EtherCAT is: • Cabling redundancy -Faster 3 – 2nd Ethernet port needed on master side only - Synchronization 3 • Hot Swap of devices - Industrial Ethernet 3 -Flexible 3 • Hot Connect of network segments Hot Connect - Easier to configure 3 • Master Redundancy with Hot Swap Group - Cost effective 3 - Easier to implement 3 Master - Well proven 3 - Open 3 - Conformance 3 - Safety 3 - Redundancy -Versatile

EtherCAT is: -Faster 3 EtherCAT Master - Synchronization 3 - Industrial Ethernet 3 RX Unit TX Unit -Flexible 3 RX TX - Easier to configure 3 - Cost effective 3 MAC 1 - Easier to implement 3 RX TX - Well proven 3 - Open 3 - Conformance 3 - Safety 3 - Redundancy -Versatile ☺ ☺ ☺ Slave 1 Slave 2 Slave N RX TX RX TX RX TX ...... TX RX TX RX TX RX

RX TX RX TX RX TX RX TX ...... TX RX TX RX TX RX TX RX

RX TX RX TX RX TX RX TX RX TX ...... TX RX TX RX TX RX TX RX TX RX

EtherCAT is: -Faster 3 EtherCAT Master - Synchronization 3 - Industrial Ethernet 3 RX Unit TX Unit Only 2nd Ethernet -Flexible Port required – 3 RX TX no special - Easier to configure 3 Interface Card - Cost effective 3 MAC 1 MAC 2 - Easier to implement 3 RX TX RX TX - Well proven 3 - Open 3 - Conformance 3 - Safety 3 - Redundancy -Versatile ☺ ☺ ☺ Slave 1 Slave 2 Slave N RX TX RX TX RX TX ...... TX RX TX RX TX RX

EtherCAT is: -Faster 3 EtherCAT Master - Synchronization 3 - Industrial Ethernet 3 RX Unit TX Unit -Flexible 3 RX TX - Easier to configure 3 - Cost effective 3 MAC 1 MAC 2 - Easier to implement 3 RX TX RX TX - Well proven 3 - Open 3 - Conformance 3 - Safety 3 - Redundancy -Versatile ☺ ☺ ☺ ☺ Slave 1 Slave 2 Slave N-1 Slave N RX TX RX TX RX TX RX TX ...... TX RX TX RX TX RX TX RX

EtherCAT is: -Faster 3 EtherCAT Master - Synchronization 3 - Industrial Ethernet 3 RX Unit TX Unit -Flexible 3 RX TX - Easier to configure 3 - Cost effective 3 MAC 1 MAC 2 - Easier to implement 3 RX TX RX TX - Well proven 3 - Open 3 - Conformance 3 - Safety 3 - Redundancy -Versatile ☺ ☺ ☺ ☺ Slave 1 Slave 2 Slave N-2 Slave N-1 Slave N RX TX RX TX RX TX RX TX RX TX ...... TX RX TX RX TX RX TX RX TX RX

EtherCAT is: • Master to Slave -Faster 3 • Slave to Slave - Synchronization 3 • Master to Master - Industrial Ethernet 3

-Flexible 3 M2S - Easier to configure 3 - Cost effective 3 Switchport - Easier to implement 3 - Well proven 3 Master - Open 3 M2M - Conformance 3 - Safety 3 Switch Gateways - Redundancy 3 -Versatile M2S Master S2S

EtherCAT is: • Wireless Devices can be connected via Switchport -Faster 3 • Wireless segment does not slow down EtherCAT - Synchronization 3 communication - Industrial Ethernet 3 • Protocol: EtherCAT Automation Protocol -Flexible 3 – Pushed and/or Polled Process Data Exchange - Easier to configure 3 • Wireless Segment transparent for Master Device - Cost effective 3 - Easier to implement 3 Master Switchport - Well proven 3 l co - Open 3 oto Pr on - Conformance ati 3 tom Au - Safety AT 3 erC Eth - Redundancy 3 -Versatile

e.g. RFID Reader

EtherCAT is: • High Performance -Faster 3 – EtherCAT is the fastest Industrial Ethernet technology - Synchronization 3 • Flexible Topology - Industrial Ethernet 3 -Flexible 3 – Benefit not only for widely distributed applications - Easier to configure 3 • Ease of Use - Cost effective 3 – Easy configuration and maintenance - Easier to implement 3 • Low Cost - Well proven 3 - Open 3 – Inexpensive implementation & infrastructure - Conformance 3 • Functional Safety - Safety 3 – Safety communication integrated - Redundancy 3 -Versatile • Product Variety – Great variety of available EtherCAT products

EtherCAT is: • Fast applications, e.g.: -Faster 3 – packaging machines - Synchronization 3 – high speed presses - Industrial Ethernet 3 – injection molding machines -Flexible 3 - Easier to configure 3 – woodworking machines - Cost effective 3 – machine tooling (CNC) - Easier to implement 3 – test beds - Well proven 3 – robotics - Open 3 – … - Conformance 3 - Safety 3 - Redundancy 3 • Widely distributed applications, e.g.: -Versatile – materials handling – logistics – data acquisition – …

EtherCAT is: • Due to low cost master and simple wiring as well: -Faster 3 – Small Embedded Controller - Synchronization 3 – Small PLCs - Industrial Ethernet 3 – Any PC based Control Application -Flexible 3 • with or without real time requirements - Easier to configure 3 - Cost effective 3 - Easier to implement 3 • EtherCAT allows one to apply fieldbus technology where - Well proven 3 cost issues require direct wiring today - Open 3 - Conformance 3 - Safety 3 - Redundancy 3 -Versatile

EtherCAT is: Please visit -Faster 3 www.ethercat.org - Synchronization 3 for more information - Industrial Ethernet 3

-Flexible 3 - Easier to configure 3 - Cost effective 3 - Easier to implement 3 - Well proven 3 - Open 3 - Conformance 3 - Safety 3 - Redundancy 3 -Versatile 3 EtherCAT Technology Group ETG Headquarters Ostendstr. 196 90482 Nuremberg, Germany Phone: +49 911 54056 20 [email protected] © EtherCAT Technology Group, 2009 87