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December 2013 B 25361 CAN Newsletter Hardware + Software + Tools + Engineering

Encoders make mobile elevating work platforms ﬂexible

Electric servo drives prove themselves in outdoor use

Motion Motion control Walking excavator uses J1939-linked hydraulics www.can-newsletter.org Adding Connectivity to Your Design

Microchip offers support for a variety of wired and wireless communication BEFORE YOUR NEXT WIRED protocols, including peripheral devices and solutions that are integrated with a PIC® Microcontroller (MCU) or dsPIC® Digital Signal Controller (DSC). OR WIRELESS DESIGN: 1. Download free software libraries Microchip’s Solutions include: 2. Find a low-cost development tool USB Wi-Fi® 3. Order samples 8-, 16- and 32-bit USB MCUs for basic, Innovative wireless chips and modules low-cost applications to complex and highly allowing a wide range of devices to connect www.microchip.com/usb integrated systems along with free license to the Internet. Embedded IEEE Std 802.11 www.microchip.com/ethernet software libraries including support for USB Wi-Fi transceiver modules and free TCP/IP www.microchip.com/can device, host, and On-The-Go. stacks. www.microchip.com/lin Ethernet ZigBee® www.microchip.com/wireless PIC MCUs with integrated 10/100 Ethernet Certified ZigBee Compliant Platform (ZCP) for MAC, standalone Ethernet controllers and EUI the ZigBee PRO, ZigBee RF4CE and ZigBee - 48™/EUI - 64™ enabled MAC address chips. 2006 protocol stacks. Microchip’s solutions CAN consist of transceiver products, PIC18, PIC24 8-, 16- and 32-bit MCUs and 16-bit DSCs with and PIC32 MCU and dsPIC DSC families, and integrated CAN, stand alone CAN controllers, certified firmware protocol stacks. CAN I/O expanders and CAN transceivers. MiWiTM LIN MiWi and MiWi P2P are free proprietary protocol stacks developed by Microchip for LIN Bus Master Nodes as well as LIN Bus Slave short-range wireless networking applications Nodes for 8-, 16- and 32-bit PIC MCUs and based on the IEEE 802.15.4™ WPAN 16-bit dsPIC DSCs. The physical layer specification. Wi-Fi G Demo Board connection is supported by CAN and LIN (DV102412) transceivers.

he CiA 402 profile for CANopen-specific due to the Tdrives and motion con- SRDO immanent restrictions trollers is already quite ma- to an 8-byte payload. The fol- ture. Introduced in 1996, it lowing safety functions are still has its benefits and its supported: weaknesses. Nevertheless, Safe acceleration range it is one of the most imple- Safe brake control mented motion profiles — Safe cam not just for CANopen com- Safe direction negative munication. The interna- Safe direction positive tionally standardized profile Safely-limited increment (IEC 61800-7-201) has also Safely-limited position Additional building blocks for the CiA 402 CANopen been mapped to Ether- Safely-limited speed motion profile are under development: Safe motion cat and Powerlink (IEC Safely-limited torque function (CiA 402-4) and PDO mapping for devices 61800-7-301). In the next Safe maximum controlling asynchronous and synchronous motors revision of this internation- acceleration (CiA 402-5) al standard, mappings to Safe maximum speed CC-Link IE and EPA will Safe operating stop mapping is not suitable, be- Abstract be launched as well. Of Safe stop 1 cause the system design- The CiA 402 CANopen Microchip offers support for a variety of wired and wireless communication course, IEC 61800-7-301 Safe stop 2 er needs to assign COB-IDs profile for drives and BEFORE YOUR NEXT WIRED protocols, including peripheral devices and solutions that are integrated also contains CANopen Safe speed monitor to the PDOs. Only the first motion controllers will with a PIC® Microcontroller (MCU) or dsPIC® Digital Signal Controller (DSC). OR WIRELESS DESIGN: mapping. CiA will withdraw Safe speed range four have pre-defined COB- be enhanced in the part 1 to part 3 of the CiA Safe torque-off IDs. Type specific PDO map- direction of drives. 1. Download free software libraries Microchip’s Solutions include: 402 specification, in order The safety functions pings for servos and stepper Additionally, there is 2. Find a low-cost development tool to avoid double-specifica- comply with the correspond- motors, respectively for fre- a new PDO mapping USB Wi-Fi® 3. Order samples tions and the risk of incon- ing IEC standards. The safe- quency inverters overcome under development for 8-, 16- and 32-bit USB MCUs for basic, Innovative wireless chips and modules www.microchip.com/usb sistent descriptions. Never- ty control-words and safety this problem, but do not sup- devices that can handle low-cost applications to complex and highly allowing a wide range of devices to connect theless, the CANopen SIG status-words are highly de- port both kinds of motors si- asynchronous and integrated systems along with free license to the Internet. Embedded IEEE Std 802.11 www.microchip.com/ethernet motion control will continue vice-specific depending on multaneously. The proposed synchronous motors software libraries including support for USB Wi-Fi transceiver modules and free TCP/IP www.microchip.com/can to enhance the profile. New the supported safety func- additional PDO mapping will using the same motion device, host, and On-The-Go. stacks. www.microchip.com/lin building blocks will be spec- tions. Therefore, the profile be specified in CiA 402-5, controller. Ethernet ZigBee® www.microchip.com/wireless ified in additional parts of provides a mapping function another building block of the CiA 402 specifications. for command bits and status the CiA 402 series of spec- Link PIC MCUs with integrated 10/100 Ethernet Certified ZigBee Compliant Platform (ZCP) for MAC, standalone Ethernet controllers and EUI The modular approach en- bits. Also, SRDO mapping is ifications. It is intended that www.can-cia.org the ZigBee PRO, ZigBee RF4CE and ZigBee ables motion control manu- highly device-specific. The three TPDOs and three RP- - 48™/EUI - 64™ enabled MAC address chips. 2006 protocol stacks. Microchip’s solutions facturers to implement opti- CiA 402-4 specification pre- DOs will be pre-defined. The consist of transceiver products, PIC18, PIC24 CAN mized functionality in their defines merely the mapping fourths will be used manufac- and PIC32 MCU and dsPIC DSC families, and 8-, 16- and 32-bit MCUs and 16-bit DSCs with products. of the safety control-word and turer-specific. The standard- certified firmware protocol stacks. integrated CAN, stand alone CAN controllers, One of the most im- the safety status-word into ized PDOs contain the status CAN I/O expanders and CAN transceivers. MiWiTM portant extensions is the SRDOs. Additional safety word, respectively the con- LIN MiWi and MiWi P2P are free proprietary support of safety func- target values and safety ac- trol word. Additionally, they protocol stacks developed by Microchip for tions. The SIG will adopt tual values may be mapped contain the values for vl ve- LIN Bus Master Nodes as well as LIN Bus Slave short-range wireless networking applications the motion safety profile by the system-designer. locity (first instance), position Nodes for 8-, 16- and 32-bit PIC MCUs and based on the IEEE 802.15.4™ WPAN originally developed by (second instance), and ve- 16-bit dsPIC DSCs. The physical layer specification. Wi-Fi G Demo Board the ETG (Ethercat Tech- Special PDO mapping locity (third instance). “With connection is supported by CAN and LIN (DV102412) nology Group). The map- this mapping we use the very transceivers. ping to CANopen will be Besides safety, there is a same EDS for power derive similar as to Ethercat in re- trend to control asynchro- systems irrespective of if they spect to the object diction- nous and synchronous mo- control asynchronous or syn- ary (index and sub-indexes tors with the very same de- chronous motors,” said Gün- control Motion will be the same). However, vice. This requires additional ther Wenzel from Schneider the mapping to SRDOs is PDO mapping. Generic PDO Electric. Holger Zeltwanger

The Microchip name and logo, the Microchip logo, dsPIC, MPLAB and PIC are registered trademarks of Microchip Technology Incorporated in the U.S.A. and other countries. All other trademarks are the property of their registered owners. CAN Newsletter 4/2013 3 ©2012 Microchip Technology Inc. All rights reserved. ME1023BEng/05.13 The WAGO-I/O-SYSTEM 750 – Cover story One System for All Applications! The future of CiA 402 – Building blocks for safe motions 3 The CiA 402 CANopen profile for drives and motion CAN be connected to any fieldbus controllers will be enhanced with mappings to CC-Link IE and EPA in its next revision. There is also a new PDO

Table of contents of Table mapping being developed, for devices that control synchronous and asynchronous motors.

Imprint Motion control Publisher Walking excavator uses J1939-linked hydraulics 8 CAN in Automation GmbH Kontumazgarten 3 Encoders make mobile elevating work DE-90429 Nuremberg platforms flexible 26 Electric servo drives prove themselves [email protected] in outdoor use 38 www.can-cia.org www.can-newsletter.org Motor selection: Optimizing belt drives 48

Tel.: +49-911-928819-0 Fax: +49-911-928819-79 Hardware

CEO Holger Zeltwanger "We open our systems to facilitate simple CAN AG Nürnberg 24338 integration of third-party products" 22 Systeme Helmholz: 25-year anniversary 28 Printed in Germany Hard copies: 3000 Control panels use off-the-shelf Soft copies: 3000 CANopen components 40 2nd generation safety controller for mobile application 44 Editors ([email protected]) Annegret Emerich Tool Cindy Weißmüller Holger Zeltwanger Easy diagnostics with an app 6 (responsible according to the press law) Layout Engineering Nickel Plankermann 750-337 750-338 750-347 750-348 750-837 767-2501 750-658 V-model development of safe application 12 Advertising manager CANopen device configuration editors 30 Gisela Scheib (responsible according CAN and Ethernet – similar but different 34 750-658 CAN Gateway: to the press law) CANopen for Chinese product quality 36 t Gateway for all CAN protocols Distribution manager From motor control to system monitoring 46 Julia Adolf t CAN 2.0A, CAN 2.0B © Copyright t Supports all CAN baud rates and autobaud CAN in Automation GmbH on this edition, we were also busy finishing a Special Edition in Chinese as well as one on t Operating modes: sniffer, transparent, mapped I/O CANopen Lift and of course we are always writing for the CAN Newsletter Online as well. If you are looking for more regular updates from the world of CAN then this magazine and the CAN Newsletter Online is the place to go. For your convenience, we also send out a weekly email that keeps you up to date with the articles we publish each week, called CiA's Weekly www.wago.com Telegraph. We would be happy to add you to our growing list of subscribers.

4 CAN Newsletter 4/2013 The WAGO-I/O-SYSTEM 750 – One System for All Applications!

CAN be connected to any fieldbus CAN

750-337 750-338 750-347 750-348 750-837 767-2501 750-658

750-658 CAN Gateway: t Gateway for all CAN protocols t CAN 2.0A, CAN 2.0B t Supports all CAN baud rates and autobaud t Operating modes: sniffer, transparent, mapped I/O

www.wago.com Easy diagnostics with

Tool an app

Andreas Schneider, Burkhard Schranz

Introduction n English taxi company High complexity, high Awith several hundred costs, low storage Ford vehicles got the ball capacity - automotive rolling: “The taxi business supplier Getrag Ford always challenges the gear- Transmissions GmbH box extremely: The engine has been confronted is constantly turned on and with these data logging off, there are high temper- issues in the past atures and the vehicle is while trying to acquire mostly used for short dis- measured data on the tances,” explained Andreas condition of its dual- Schneider, responsible for clutch gearbox during the measuring technolo- operation. Optimeas gy at Getrag Ford Trans- developed an intelligent missions GmbH (GFT), Co- Figure 1: SmartCANLog and cost-effective logne. “Therefore we are data logging solution highly interested in con- - is based on a highperfor- based on their smart ducting customer measure- cal to Schneider. Therefore mance ARM platform and platform for the gearbox ments at dual-clutch gear- he started to search for a is equipped with an isolat- specialist, which can boxes of the power shift data logger with more stored and ISO 11898-conform save data of 120 days. type series to gather infor- age volume, which was at CAN connection. It current- mation on the gearbox con- the same time reasonably ly supports log files such dition during permanent priced and easy to handle. as RAW CAN and Multiplex operation.” Sensors con- “Data logger in the high-end CAN. The latter is used by nected to the gearbox con- sector are often very com- the control unit of the gear- trol unit help to collect data plex and require a high ef- box. The device is equipped on shifting travels, hydraulic fort of programming and with a micro SD slot, which pressure, rotational speed parameter setting, which al- can be operated by the or torque values - including ways requires a technician. gearbox specialist in combi- potential error codes. We wanted to avoid this, as nation with 64 GiB memory However, data loggers far as possible - and hence cards. available in the company provide our customers, i.e. were only able to store in- the OEMs, with the possi- formation of 20 hours. Then bility to just use the logger,” the vehicle had to be brought explained Schneider. to the garage to retrieve the The company found GFT records 140 channels data - or a technician had to the suitable solution in in total using the multiplex drive to the customer. Both procedure, which means that the data logger collects a maximum of 200 MiB per hour. They are compressed by a factor of 10, which results in 0,5 GiB per day. This allows the user to save the data of approximately 120 days on the smartCAN- Log. Schneider comment- ed: “Compared to the previous solution, which only provided data storage for one day, this system offers an enormous advantage to Figure 2: Different housing options of the smartCANLog us - in particular the easy

6 CAN Newsletter 4/2013 Due to its high stor- Authors age volume and low complexity, the logger is also a good solution for drive tests - no matter where in the world they are conduct- ed. At the end of the drive test only the storage card is pulled out - and the measured data can be read. Climate conditions are ir- Burkhard Schranz relevant, because in case Optimeas Measurement of fleet use the logger is and Automation Systems installed in a splash-proof GmbH automotive housing. The Am Houiller Platz 4/B Figure 3: Employment of the device in the car device, which measures DE-61381 Friedrichsdorf 13 cm x 7,5 cm x 3 cm, Tel.: +49-6172-9977120 parameter setting.” Con- the card into the logger. is usually installed in Fax: +49-6172-99771289 necting the micro SD card The logger recognizes ex- [email protected] to a computer or laptop en- changed or new SD cards compartment. ables the user to install two automatically, closes run- “The smartCANLog ful- software files: a DBC data- ning data collections, con- fills our requirements per- base file and a configura- figures the measurement fectly. And based on its tion file. The DBC file con- based on the DBC file in- functional range it is also tains information about data formation and starts col- very attractive in terms sent by the gearbox. The lecting data automati- of price,” said Schneider. configuration file defines, cally. The logger reads “Traditional solutions usu- among other things, the the existing DBC file and ally provide extended func- size of the data blocks and with it decodes received tionalities, which we mostly whether or not data should CAN messages complete- Andreas Schneider be compressed. ly and channel by chan- functions, the more com- Getrag Ford Hence, the function of nel. All data is marked with plicate programming, pa- Transmissions GmbH the logger is determined a time stamp and mutual- rameter setting and fault Scarletallee 2 by the software. In order ly stored in a data file on tracing become.” There- DE-50735 Köln to keep the usage as easy the SD card. The resulting fore GFT decided in favor Tel.: +49-221-58970 as possible, Optimeas de- data format can be com- of the data logger of Op- getrag.info.koeln@ velops software specifi- pared to a video recording, timeas. Not least because getrag.com cally according to the re- which means that all data the functionality of the log- quirements of the individu- up to the latest data point ger can be, despite its slim Links al customer as well as the is readable even in case of design, flexibly extend- www.optimeas.de application. This basically an abrupt stop of the mea- ed. Schneider mentioned means that an app is run- surement. measuring, for instance ning on the smartCANLog, external data such as tem- which can be flexibly ad- for us lies in the dramati- peratures, voltage or cur- justed. It is also possible to cally reduced effort,” said rents. For that purpose initiate pre-evaluations of Schneider. “Whereas be- Optimeas will extend its measurement results on the fore we had to continuous- system by analog inputs. logger - or the connection ly send technicians to the Alternatively it is also pos- of an ODB2 diagnostics in- customer, with the logger sible to wire CAN mea- terface in case a direct con- that is only necessary dur- surement modules with www.getrag.com nection to the control unit ing the first start-up in or- the CAN knot to be able is not possible. Even test- der to do the wiring and to record this data with the ing benches can be flexi- to show local employees logger: “With the CAN net- bly expanded. Furthermore, what they need to consider work you are able to set up, software updates can be when installing the logger depending on the measur- implemented within min- in another vehicle. After- ing task, an extensive mea- utes. Customers can install wards data measuring runs surement system based on

Tool their own software on the automatically and support the smartCANLog.“ data logger with the help of is not required.” Today, an app loader. GFT monitors the prop- er recording of the device via an acoustic monitoring system. Optimeas will upgrade the next device generation of the smart- After the installation the CANLog with a visual mon- user only needs to insert itoring system.

CAN Newsletter 4/2013 7 Walking excavator uses J1939-linked hydraulics

Motion control Motion

Company Linde Hydraulics Grossostheimer Str. 198 DE-63741 Aschaffenburg Tel.: +49-6021-150142-0 [email protected]

Abstract The Swiss excavator manufacturer Menzi Muck has unveiled the first model of its next generation walking excavator series at the Bauma trade fair in Munich (Germany). The hydraulics in these construction machines are configured as a complete system of Linde Hydraulics components, including the electronic control unit alking excavators — dimensions, ensuring that in streams. An appear- ECU. A J1939 network Walso known as spi- the machines remain high- ance on German TV show links the control system der excavators — are con- ly flexible and can be adapt- "Wetten, dass..?" in 2006 devices. struction machines that ed to the surrounding con- showed how flexible these move forwards on four ditions, both in drive mode machines can be. The im- wheels, which are connect- and work mode, when the pressive video is still avail- ed to the undercarriage by stabilizers on the legs are able on YouTube and shows legs. These legs can also extended. This means that a walking excavator from be used to adjust the track they are ideally suited for Menzi Muck climbing over width and the height of the working in locations such a 5-m concrete block - us- vehicle over a wide range of as very steep slopes or ing the bucket as additional support - and proving just how appropriate the name "spider excavator" is.

At the Bauma 2013, Linde Hydraulics revealed - almost 30 years after intro- ducing load sensing with the Linde Syn- chron Control system – the latest devel- During the development of opment of the LSC system for mobile its walking excavator series machines. The LSC+ combines the char- the machine builder worked acteristics of the tried-and-tested control in close collaboration with system with the additional advantages of Linde Hydraulics and Girtec, electronic control. The electronics identi- The hydraulic monoblock valve system the Linde Hydraulics sys- fy the operator's intentions and set pump with electric piloting tem partner based in Swit- and valves to the highly dynamic or fine zerland. Together, the control range, depending on the require- works. A monoblock valve system, which companies developed a hy- ment. The supplier offers the LSC+ as a was developed especially for the LSC draulic system that utiliz- complete system, including the electronic system, takes on the hydraulic control es the benefits of the Linde control connectable to J1939-based net- functions. Synchron Control (LSC) and not only meets the

8 CAN Newsletter 4/2013 Anz. CANnews_Janztec_2013_1rot:AS Katalog_2013 26.07.2013 15:24 Uhr Seite 1

Industrial Computing Architects

30 years of experience in industrial computer systems Janz Tec AG, has been one of the leading the case of distributed systems. For this manufacturers of electronic assemblies reason, Janz Tec AG also places great and complete industrial computer systems value on innovative and sophisticated since 1982. The company describes itself technology in the industrial communication as Industrial Computing Architects business sector. The InCom products and develops embedded PCs, industrial developed in-house enable the control computers and industrial communication systems for your machines, plan and according to customer requirements. systems to be kept at the highest level.

Good communication is very important With 30 years of experience in the market, nowadays – not just in real life, but also Janz Tec AG is capable of meeting in machines, plant and complex industrial individual customer requirements at any applications from a wide range of inds- time – this starts as early as the concept tries. This applies especially if error-free phase, continues through the develop- transmission of data is required due to ment and production of the components more and more compact construction and up to series delivery. the necessity for more performance in

Janz Tec AG · Industrial Computing Architects · Im Doerener Feld 8 · 33100 Paderborn · Fon: +49.52 51.15 50-0 · www.janztec.com demanding requirements of The special features of operates in a particularly the movements of a walking the LSC system include its energy-efficient manner. The excavator, but also enables "social load sensing" capa- joystick, which the operator additional functions to be bility. This is a special kind uses to operate the hydrau- implemented. The J1939- of volume flow regulation lic functions, comes from based in-vehicle network for superimposed move- Girtec. That means that connects all electronic de- ments, which are frequently virtually the entire hydrau- vices. required for walking excava- lic system, including the tors. The relevant functions control electronics and man- are supplied as required machine interface, comes Motion control Motion depending on how the from a single source. driver moves the joy- At the core of the hydraulic stick, even if the request- system is a tandem pump ed flow volume exceeds unit. A load-sensing reg- the maximum possible www.linde-hydraulics.com ulating pump of the HPR pump flow rate. In this 105-02 E1L type for the open case, the available flow circuit supplies the working volume is divided amongst hydraulics with hydraulic flu- the actuators depending on id, while an HPV 75-02 E2 their requirements. variable displacement pump for the closed circuit drives the traction motors. The open circuit is The ECU for the walking controlled via a LSC mono- www.menzimuck.com block, in which three direc- comes from the Linde Hy- tional control valves are draulics modular system. integrated in a single cast It maps the complete trac- housing. The pressure relief tion- and working hydrau- function is also integrated in lics of the machine. The the monoblock, and special software developers at functions can be implement- Linde have implemented ed using an intermediate some additional functions plate. The valves have a in the ECU, including the flow-optimized design and option to select pre-config- Video of "Wetten feature integrated pressure ured drive programs, such dass...?" appearance compensators and pressure as an "eco mode" where copiers. the walking excavator

The Linc series of electronic control units for mobile machines provides safety functions up to performance level d (ISO 13849-1). The product by Linde Hy- Linc 2 draulics is CAN-connectable and sup- safety ports the J1939 application profile. controller Core parts of the product are a featuring function controller and a safety control- CAN ler. Due to the redundant design, the connectivity unit can provide safety functions and thus is able to meet global legal stan- Single parameters can be config- dards for on-road machinery. The devic- ured via the LinDiag diagnosis software. es are used individually or combined, for The Linc 1 controller for electric drives hydraulic and electric drives, as well as and closed loop hydraulic propel drives combinations of both. Additionally to the features 10 digital inputs (4 pull-up, 6 drive components and the combustion pull-down), 6 analog inputs (0 V to 5 V), engine, components such as sensors, 4 current inputs, 3 frequency inputs, 4 joysticks and pedals can be integrated in digital outputs, and 7 PWM outputs. The the CAN-based control system. Linc 2 unit provides 24 digital inputs (12 Upon delivery, the control is pull-up, 12 pull-down), 20 analog inputs, preconfigured with the desired functions, 9 frequency inputs, 8 low-side digital machine characteristics and vehicle outputs, and 32 PWM outputs with cur- data. rent feedback.

10 CAN Newsletter 4/2013 NEW PRODUCT

PCIe USB PCI-104 CAN Interface CAN Interface CAN Interface

PCI PC-104 Ethernet CAN Interface CAN Interface CAN Interface CAN Interfaces for Your Requirements • Economical solutions for series applications www.ems-wuensche.com • Optimized for industrial applications • Solutions for stationary and mobile use Sonnenhang 3 D-85304 Ilmmünster • Software support for bus-analysis, Tel. +49-8441-490260 measurement and control Fax. +49-8441-81860

Bosch oﬀ ers a broad portfolio of Automotive Electronics IP modules for automotive and Smart and innovative IP solutions industrial application. Our certiﬁ ed IP modules are ready for integration, for embedded systems making the perfect adaption of micro- controllers to your needs easy.

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safe clean & economical V-model development of safety application

Engineering

Christoph Filser, Tobias Heilig, Rolf Jung

Authors to move in any curve or rotation around a freely defined middle point. The concept for the transitional movement is depicted in Figure 2. The OmniMove vehicles are built for internal logistics and can lift loads up to 100 metric tons. There are ten different vehicle models with numerous customer specific options Christoph Filser Figure 1: The OmniMove wheel with vaulted rollers on the to meet any requirement. Tobias Heilig periphery Anywhere from 4 to 20 drive Rolf Jung wheels as well as numerous oving extremely heavy to conventionally steered additional load wheels can Company Mloads with radio remote wheels the logistics area re- be configured in order to fa- Sensor-Technik control in areas with per- quired can be reduced by cilitate the transport of large, Wiedemann GmbH sonnel traffic always has up to 50 % and the produc- unwieldy components. Am Bärenwald 6 a risk associated with it. tion area correspondingly Kuka needed to find a DE-87600 Kaufbeuren There are numerous ways increased. control system that would Tel.: +49-8341-9505-0 to reduce the risk through The OmniMove wheel operate with many types of [email protected] safety systems and addi- has a special rim with vault- vehicles and fulfill customer tional peripheral equipment. ed rollers mounted on the specific requirements. For The companies Kuka and periphery. Positioned at a many years Sensor-Tech- Links STW have jointly developed 45 ° angle, when the wheel nik Wiedemann (STW) has www.sensor-technik.de a new type of monitoring is driven, two power compo- offered fast and flexible for a floor conveyer without nents result, which are par- control solutions in mobile a driver cabin. In this arti- allel and perpendicular to applications with its ESX cle a method is described, the drive axis. family of controllers. STW that illustrates how safety is Through diverse turn- has continued this series achieved through a certified ing directions of the wheels, with the ESX-3XL 32-bit safety application in a free- some of the power compo- controller. The controller ly programmable controller nents compensate each was conceived to provide a intended for safety relevant other over the chassis high level of flexibility. With applications. while others combine to de- up to six internal expansion www.kuka.com Kuka OmniMove is termine the motion of the boards, 84 of the 162 pos- the designation for an ag- vehicle. sible connector pins can ile type of drive for a floor Thus, in addition to be configured with distinct conveyer. With its electric straight, sideways, and diag- functions, from simple I/O to drives, the OmniMove pro- onal travel, it is also possible encoders, special I/O, data vides unlimited maneuver- ability in all directions as well as rotation in place. Through its omni-direction- al drive wheels the vehicle may be freely navigated and steered in all directions by remote control, even in the narrowest spaces, with a positional accuracy of up to ±1 mm. Compared Figure 2: Concept of the transitional movement

12 CAN Newsletter 4/2013 CAN/CAN Isolating Gateway CAN Repeater

Ethernet/CAN NEW Gateway EtherCAN CI-ARM9/RMD CAN/Ethernet Gateway embedded Linux Kernel 3.5.0 ARM9 CPU / 454MHz 2GByte EMMC Flash Optical Physical 128 MByte RAM Fibre Transceiver Layer Analyser CAN Network Technology Successfully applied in www.ems-wuensche.com Machine automation Building automation Sonnenhang 3 D-85304 Ilmmünster Transportation systems Tel. +49-8441-490260 Telecommunication systems Fax. +49-8441-81860 storage and communication safety must be defined be- software according to DIN interfaces. The mainboard fore certification can take EN ISO 13849-1 apply. The of the ESX-3XL also offers place. Which safety stan- safety architecture is con- software configurable I/O dards should be applied? ceptualized based on Cat- functions. The 28 available The standards are mostly egory 2 of the standard. inputs are all 12-bit multi- defined by the application. The control unit consists functional inputs (MFI), i.e. The application described of a freely programmable the application program- here is a floor conveyer, main controller and an in- mer can define their func- which can transport loads dependent system super-

Engineering tion. Initialization functions of up to 100 metric tons. visor (SSV). The SSV is allow the programmer to Figure 3: Controller Therefore this vehicle must also a programmable con- specify each input as an an- ESX-3XL with expansion meet special safety require- troller that monitors the alogue current or voltage in- boards ments for industrial trucks main controller by assum- put (measurement range: with respect to braking dis- ing watchdog functionality, 5 V, 10 V or 40 V) or as dig- serious accidents in appli- tance and subsequently the monitoring system voltages, ital/RPM (frequency) input. cations that include func- maximum allowable vehicle testing logical events and Furthermore, the 3XL soft- tions relevant to the safety speed. thereby allowing the utili- ware library allows an ap- of people and things in the The risk analysis of zation of the controller in plication specific function environment. This assumes this application resulted safety critical applications. to be called when the input that the criteria for function- in performance level PL-c The main controller has di- signal changes (callback al safety are correctly ful- from the guidelines for ma- agnostic routines that con- function). The RPM signal filled. “Safe” is defined here chine safety DIN EN ISO tinuously check the entire covers frequencies from as a situation where the risk 13849-1 as being appli- system in hardware and 0,6 Hz to 20 kHz. Filtering is smaller than the general- cable for the OmniMove. software and place the may be applied to the MFI ly accepted risk limit. An ac- STW developed the safety system into a safe condi- signal through software, ceptable risk level is defined requirements and a safety tion in the event of a failure. with configurable debounce for the application. This risk plan for the OmniMove and The safe condition in this times and low pass filters. is determined by a combi- the Institute for Work Safe- application is emergency All outputs can pro- nation of the probability of ty IFA in Sankt Augustin ap- stop. duce PWM signals, are pro- occurrence and the severi- proved the requirements. As a result of their detected against short circuit ty of the damage. In the current project sign the OmniMove vehi- and are controllable via 12- Functional safety is a these conditions are imple- cles can reach speeds up bit current measurement part of the overall safety of mented with a safety orient- to 6 km/h. The risk analy- and status feedback for a system that depends on ed software module on the sis however produced sig- complete diagnosis. electronic systems, other ESX-3XL electronic control- nificantly lower allowed The core of the con- safety technologies, and ler. For that software mod- maximum speeds. Two controller is a 150 MHz Tricore external risk factors. The re- ule the requirements for ditions for maximum speed processor with 4-MiB RAM, quirements on the functional safety relevant application limits are described. a 6-MiB flash memory and a 32-KiB EEPROM parame- deployment System Context Diagram ter memory. The mainboard has four CAN interfaces Control module

and a serial (EIA-232) port. notes Additional communication The already existing interfaces (including Ether- speed controller of KUKA. net and USB) may be added by means of the expansion

boards. * Callback function for emergency stop cause Emergency stop cause * Start of OM3S * Initialization of the CAN message objects

Recent experience with nu- «system» merous applications has OM3S shown that the customer requirements for functional safety are growing. With in-

creased integration of con- * Parameters and CRC checksum from EEPROM troller and memory compo- * Frequencies and directions of 4 encoders * Value (low or high) to 5 digital outputs * Values (low or high) of 3 digital inputs * Value (low or high) to external system supervisor nents, safety requirements * Data via CAN field bus may be fulfilled in an eco- nomically viable manner, alongside the normal func- ECU HAL tionality. Where does the need for functional safety oriented electronic controls originate? These controllers reduce the risk of Figure 4: Overview of the OM3S system

14 CAN Newsletter 4/2013 A STEP AHEAD Our new products and services CANlink WLAN 2103

Wireless CAN-data telemetry data in real time extended range transmission up to 400 meter range: CAN- link WLAN connects CAN-networks and turns smartphone into remote controlls.

high data frequency

CANview GPS

Position, elevation or inexpensive no additional compass direction: gateway- ﬁ rmware components CANview GPS pro- programming necessary vides cost-efﬁ cient tracing and displays on local CAN-bus interface.

easy and ﬂ exible conﬁ guration CANlogger GPS

Record CAN-mess- up to two GPS ages and GPS-data conﬁ gurable CAN-channels using only one device: CANlogger GPS provi- analog and digital I/Os des easy handling and unlimited use.

power management

RM Displays Series 3100

Enlarged displays for optional extended ports optimal representation touch screen and simple conﬁ gu- version ration: four designs compliment the range of products provided.

illuminated keys easy conﬁ guration

Find out more about our services and products at www.rmcan.com RMsys Dashboard

The Dashboard desk- top application displays CAN message bar graphs gauges data in real-time. The surface representation is individually conﬁ gurable.

display values diagrams

RM MICHAELIDES RM MICHAELIDES DE US SOFTWARE & ELEKTRONIK GMBH SOFTWARE & ELECTRONIC CORP. Headquarters US Subsidiary

Donaustr. 14 711 E. Monument Ave., Suite 310 36043 Fulda, Germany Dayton, Ohio 45402-1490, USA V-CARD Phone +49 661 9490 - 0 Phone +1 937 558 - 2211 Fax +49 661 9490 - 333 Fax +1 937 641 - 8787 Toll-Free +1 877 RMCAN-US

[email protected] www.rmcan.com ing has the tasks “Identifica- to meet the requirements tion of the currently allowed of a safety software with maximum speed” and “Cal- performance level PL-c ac- culation of the actual speed cording to DIN EN ISO of the vehicle from available 13849-1 the following quali- signals from three wheels ty attributes must be fulfilled: (the fourth wheel provides The parameters loaded a redundancy in the speed in non-volatile mem- measurement)”. ory (EEPROM) must If the actual speed is be verified with CRC too high or any other er- checksums, ror is sensed, an emergen- The integrity of the main cy stop must be initiated memory (RAM) must be immediately. ensured through suitable The name of the devel- means, oped system is OmniMove Program flow control Figure 6: OmniMove, an extremely agile type of drive for a Speed Surveillance Sys- must be monitored floor conveyer tem (OM3S). It has the fol- with a system lowing core tasks (functional supervisor with watch- The first condition is for spaces. To guarantee safety requirements): dog functionality to the load condition. For an under these conditions the Reliable recognition of guarantee the correct empty vehicle the maximum maximum allowed speed is the load condition of the program processing. allowed speed is 3 km/h, reduced to 0,1 km/h. vehicle by redundant Among the overall re- which is the normal walk- The maximum allowed load sensors, quirements for OM3S is the ing speed of a pedestrian speeds are specified based Reliable recognition of prerequisite that it must be (for example, the opera- on defined stopping distanc- the status of the laser implemented on the PL-d tor with the remote con- es during an emergency scanner protective field certified safety ESX-3XL trol unit). For a loaded stop. The OmniMove vehi- (active or disabled by controller with integrated vehicle the maximum al- cles are intended for many the override button) hardware diagnostics. The lowed speed drops to different tasks, meaning a by redundant signal - 1 km/h. large number of design vari- paths, nostics is divided into two The second condition ants and operational situ- Determination of the cur- parts: pertains to vehicles that are ations. The risk evaluation rently allowed maximum Start-up diagnostics that outfitted with laser scan- can therefore also differ sig- speed based on load are executed when the ners that create a protection nificantly, and the maximum condition and override controller is switched on zone around the vehicle. speed must be adjusted ac- information, and test all of the basic Laser scanners can bring cordingly. The maximum Reliable reading of the functions, for example a vehicle to a stop as soon speed is set individually for encoder signal from the the safety relay; these as they sense an obstacle each vehicle type through individual drive wheels tests cannot be repeated (e.g. personnel) in the path. software parameterization. of the vehicle through at a later time because There are situations where redundant sensors with they would affect the op- the laser scanner must be analogue and/or digital eration of the vehicle, switched off (override con- outputs, Periodic tests of memory ditions), for example driving The safety oriented software Calculation of the ac- and CPU for the through narrow warehouse module for speed monitor- tual speed of the vehi- integrity of content and cle from the drive wheel function, which run in encoders (this can be the background, parallel accomplished by a math- to the application ematical model with the software. x/y coordinates and the In this project Kuka al- instantaneous rotational ready uses the controller to Frequent and early reviews prevent the development velocity of the three drive effort of going in the wrong direction or into a dead wheels), software. The OM3S will Fault recognition through also run on this controller design to another person, shortcomings in design plausibility check. with interfaces to: will become evident. It will be clear whether the Every recognized fault The vehicle control soft- underlying considerations are logical and complete. or a speed in excess of the ware from Kuka, and, Reviews also uncover misunderstandings, presently allowed maximum The Hardware Abstrac- differences in interpretation or incompleteness of the speed must result in an emer- tion Layer (HAL) of the requirements. Reviews during the design process gency stop for the vehicle controller. should be done to explain the solution, why it was (the safe state). The monitor- done this way, what alternatives there were, and why ing software must be suitable

Engineering they were not chosen. In this way the work of the for all conceivable config- architect can be reproduced and either confirmed or urations (geometry, size, corrected. The review is an important test that can number of driven and auxil- The specifications of this prevent errors from being propagated. iary wheels, etc.) of the ve- project are processed exclu- hicle. In order for the system sively in database oriented

CAN Newsletter 4/2013 19 requirements management of the actual vehicle speed.

software. This promotes the Requirements Acceptance testing (Installed) Multiple drive tests, exten- atomic capture of individual management system sive technical discussions

requirements (individual en- System System testing with safety experts and System tities) that are referenced by speci!cation eventually modifications to number and can be individ- the OM3S specification were Architectural Integration testing Subsystems design ually tested. This leads to Inspection/ necessary to find a tech- testable requirements and review/ nically and commercially static analysis Component Unit testing Components traceability of the individ- design viable solution and deliver a ual requirements through successful, safe product. Implementation Motion control Motion the life cycle of the application and back to their or- igin or source. The individu- Analytical measures al requirements go through Constructive measures The software application ful- formal reviews by various filled all aspects of function- working groups based on al safety, while maintaining the following criteria, and Figure 5: The development process of safety software both the availability of the the results are documented follows the V-model system and the flexibility in so that they can be incorpo- terms of the large number rated into subsequent ver- System tests will then The software testers of vehicle variants. Param- sions of the specification: be defined for testable re- also have the task of man- eterization of the software unambiguity, completeness quirements in a system test aging defects. The de- is a necessary part of the and testability. specification. A configura- fects must be entered into safety considerations, and The system archi- tion manager is assigned a ticket system. Once en- ensures the flexibility to tecture must be designed to administer the system tered, the processing of accommodate future cus- before the design of the in- configuration and to main- the defects will be sys- tomer requirements, and the dividual software compo- tain an overview of which tematically tracked, with inherent changes to the risk nents. A second software versions of the individual their status (e.g. Developer situation. architect from outside the development components Analyzing, Tester Con- project must review the ar- (specifications, architec- firmed Resolution, etc.) chitecture and then it can tural designs, system test Once a first version of the be refined. specifications, implemen- specification is complet- There must be a unit tation, test protocol) go ed and released, work can test written for each func- together. The importance begin on the software ar- tion that is implemented in a of the software tests is chitecture and system test software component. Thus, emphasized with iden- specification. In practice, each software change can tification of a test man- work can begin earlier when be tested completely and ager. The test manager a stable set of requirements preferably automatically. will be assigned this role have been identified. After This ensures that all by the project manage- this, desired changes can previous functions still work ment. He produces a test only be introduced through error-free after the change. management plan, or- a change management sys- After the requirements are ganizes the tests and tem. Each change request put in the specification, they coordinates the activities is entered into the ticket sys- are evaluated for testability. of the software testers. tem and must go through a series of different status conditions before it is finally ap- proved and implemented. With the conditions for (SCD) functional safety fulfilled, the OmniMove should oper- A System Context Diagram (SCD) depicts all external ate without unnecessary in- entities and can then interact with the system. terruption. The availability of The SCD depicts the system to be built as a black the machine is a very impor- box. tant benchmark for the cus- It graphically depicts its interactions with external tomers. Initial tests showed entities. that the availability was too It determines the flow of information and control restricted. In order to im- between the system and the external entities. prove the availability, the A context diagram should depict in a simple manner safety application was modi- what kind of relationship the system has with the fied to compensate for unex- surrounding participants. It should not attempt to pected effects from vibration represent the architecture of the system. In this in the vehicle and the effect overall view the system is handled as a black box. on the wheel speed mea- The emphasis lies on how the system relates to its surement. Filtering of the environment, not on its architecture or decomposition. wheel sensors was required to ensure a stable evaluation

20 CAN Newsletter 4/2013 Projekt1 30.04.2013 11:00 Uhr Seite 1 “We open our systems to

Hardware facilitate simple integration of third-party products”

Company ince April 2013, Chris- Jetter AG with nowadays Stian Benz has been about 250 employees leading the technology was founded in 1980 and sales staff in the Jet- by Martin Jetter, who ter AG. At the beginning of had it listed at the next year, he will assume stock exchange in the chairman position of the 1999. The company Management Board. “CAN has subsidiaries in was, is, and will be one of China, Great Britain, our network technologies Switzerland, and the which we believe in,” said USA. In 1999, the Christian Benz. “The Jetter JetWeb Industrial AG was the first company Ethernet approach was which introduced Ethernet presented at Hanover into industrial automation. Fair. In the course of “However, for applications time, the company that do not require high acquired Ebelt (2000), bandwidth we have been Futronic (2005) and using CAN and CANopen Control Developments for many years,” explained (2008). Benz. The company is com- In 2006, the JX3-I/O mitted to support open stan- system was introduced, dards such as CANopen which includes the and Ethercat. “We will make JX3-BN-CAN bridge some announcement during module. the SPS IPC Drives exhibi- tion in Nuremberg,” he add- Link ed. Nevertheless, the com- www.jetter.de pany does not intend to become a device supplier, it will remain mainly a turnkey system provider. However, the integration of third-party products with CANopen and Ethercat interfaces as Figure 1: “For mobile machines we have developed a well as additional commu- modular control unit, which can be used in different kinds nication technologies into of vehicles,” said Christian Benz, the director of technology Related articles Jetter control systems will and sales Electric servo drives be simplified. prove themselves in The company head- In the mobile automa- Glass (Switzerland) belong- outdoor use – page 38 quartered in Ludwigs- tion business, the compa- ing to Bucher Industries burg (Germany) has two ny provides CANopen and (Switzerland). business areas: industrial Isobus (ISO 11783) prod- Emhart Glass is a lead- automation and mobile au- ucts as well as CAN-related ing supplier of equipment, tomation. In industrial con- solutions with proprietary controls and parts to glass trol systems, CANopen higher-layer protocols. “In- container industry. With ex- is used as the preferred dustrial automation is our pertise in glass container network only for digital main business,” explained forming, glass condition- and analog I/O mod- Benz. “Some 80 % of the in- ing, gob forming, ware han- ules. Drives and mo- come is generated from in- dling, cold end inspection, tion controllers use the dustrial control systems.” refractory parts and quality The most important indus- assurance, the company's network solution. trial customer is Emhart machines and systems are

22 CAN Newsletter 4/2013

is why we are flexible and the CAN network from the designed for both day and can provide a high quality.” ECU to the (ISO) terminal. night use due to the back- In mobile automation, Jetsym, the programming lit keys and the light sensor, the company has several tool with the Jetsym STX which automatically adapts key customers. Rosenbau- plain text high-level lan- the illumination of the dis- er (Austria) makes fire- guage, is continuously adap- play to the brightness of the fighting trucks, Grimme ted to meet market and surroundings. The HMI is

Hardware (Germany) produces potato customer requirements. Ac- equipped with four function harvesters, and Bucher Mu- cordingly, the latest version keys and is available with nicipals (Switzerland) man- can run under Windows 8 an optional Digipot. The op- ufactures municipal vehicles. and contains functions that erating temperature rang- The two electric drives used make programming, diag- es from -20 °C to +65 °C. by Grimme in a prototype nostics and commissioning Thus, it can be used for out- vehicle improve its har- more efficient. For example, door applications. The HMI Figure 2: The JVM-104 vesting performance. Op- recordings in the integrat- runs Windows CE as its op- human machine interface eration even in wet fields ed oscilloscope can also erating system. Peripheral designed for outdoor under harsh environmental be made via CAN networks. devices can be controlled applications is IP65-rated conditions is possible. Previously, this was only via CAN interface. Two Additionally, Jetter has possible via Ethernet or se- multi-purpose inputs and sold worldwide. The control developed a version of the rial interface. four PWM outputs are systems designed by Jetter Jetviewsoft development tool At the Bauma exhi- available as options. The use CANopen networks for specifically for the Isobus bition in Munich (Germa- device can be equipped “slow” I/Os clocked in mil- market, called ISO-De- ny), the JVM-104 human with an optional USB and liseconds. The company signer. The ISO-Designer machine interface (HMI) Ethernet port. Typical ap- invests about 20 % of the is a high level tool to de- has been introduced. Its plications include auto- turnover in research and sign screen masks for HMIs 3,5-inch TFT display with mated construction and development. “We have a on agricultural machines. LED backlight is installed agricultural machinery, but high vertical integration,” These masks are distributed in a rugged plastic en- also traditional industrial said Christian Benz, “which via the Isobus protocol on closure. This product is automation.

Bucher Industries (Switzerland) offered via one of its subsidiaries a price of EUR 7 (about 150 percent of the market price) to shareholders. The Swiss group has held a stake in Jetter since 2005, which most recently amounts to about 30 %. Bucher Industries is planning to strengthen the competence of the Jetter company in the area of automation solutions and to expand its market share. The aim of the takeover offer is to acquire all of the shares in Jetter AG. The Supervisory Board and the Management Board of Jetter supported the takeover offer. Since 2002, Jetter has been an important partner of Bucher The old and the new chairman of the Management Board (Martin Jetter on Industries, not only developing and the right, Christian Benz in the middle), and CFO (chief financial officer) manufacturing electronic control Günter Eckert (on the left), who is responsible for finance and production systems for Emhart Glass, but also supplying the electronics for The founder of the company, Benz will succeed him as chairman. municipal vehicles manufactured by Martin Jetter, will continue to be He said, “Our goal must be not Bucher Municipal. In the past two responsible for the development. only for the company to be seen financial years, Jetter generated Nevertheless, he intends to resign as the supplier of technology to on average around 50 % of its from his position as member and the Bucher Group, but also for it to turnover with the Bucher Group, with chairman of the Management Board continue securing market share in the majority of that turnover being of Jetter AG at the end of the year, the industrial and mobile automation accounted for by the Emhart Glass and to subsequently take a seat on segment through highly active market division. the Supervisory Board. Christian cultivation.”

24 CAN Newsletter 4/2013 C M Y CM MY CY CMY K

Figure 3: “We see great potential in China, both in industrial and in mobile automation, and are convinced that our innovative products will quickly find their buyers here,” stated Bruno Dörig, manager of the subsidiary in China

At Bauma, the com- Jetter has had a pres- pany also launched the ence in China with its own JXM-TX5 controller for branch office since the mid- hydrostatic drives, which dle of 2012. Bruno Dörig was designed for outdoor has been managing the of- use. Among other things, it fice for the first few years. meets all requirements for As an application engineer, use in harsh environments, he had already been sup- such as vibration and shock porting various customers resistance. It comes in an in the Far East for a num- IP68-rated enclosure. The ber of years. Dörig is there- operating temperature rang- fore familiar with the culture es from -40 °C to +85 °C. and characteristics of coun- The product communicates tries in that part of the world. via two CAN interfaces using Before leaving for China, CANopen and SAE J1939 he headed up the Product protocols. A permanent Eco Management department mode reduces exhaust in Germany. The Chinese emissions and fuel con- branch office provides sumption. The controller customer advice, sales and is configurable and can be order processing, as well parameterized. This makes as technical support locally. it possible to start on an in- “Closeness to the custom- cline, or drive in mountain- er is very important in this ous conditions with full-load fast-growing market. This is or idle, without the driving why we also want to offer all wheels locking up. An ABS these services locally,” said control unit can also be con- Dörig. nected to the controller. The software of the control unit enables jerk-free acceleration and deceleration. Trips at a constant diesel engine speed, as well as the speed-dependent adjust- ment of the hydro-pump and engine are also possible. The built-in load limit control function prevents the diesel engine from stall- ing. A typical application is the hydrostatic drivetrain, which can be found in most municipal vehicles, or agricultural and construction machinery. Encoders make mobile elevating work platforms ﬂexible

Motion control Motion

Company The first approach to TWK Elektronik make elevating work plat- Heinrichstr. 85 forms smarter was using DE-40041 Düsseldorf standard electro-optical en- Tel.: +49-211-96117-0 coders with SSI interface. Fax: +49-211-6377-05 They were of singleturn type [email protected] measuring 360 ° with 12 bit resolution. They allowed for Links continuous rotation and start- www.twk.de ed from zero again after a complete round. As the slewing ring of the tracked chassis and the pinion of the measuring device form a gear the measuring device needed to be of multiturn type. The multiturn types have an internal gear box that can measure up to 4096 rotations. www.teupen.com The multiturn types were mounted to the tracked chassis of the platform measuring the angle of rotation. A similar application can be found in all mobile cranes, bucket excavators and mo- torized concrete pumps. Standard optical encoders were doing well for the technical requirements but safety regulations required Introduction Figure 1: The LEO platform with stabilizer additional effort. Construction and maintenance work on o reach areas in build- enough to dynamic move- buildings and houses Tings that are difficult to ments and loads. Impor- used to be done with access, the elevating work tant test points are within expensive scaffolds. platforms needed to be- the tracked chassis mov- In the 70s of the last come more flexible. Now ing the complete platform. century mobile elevating encoders are required to Further measurements are work platforms came on give set-points and values done in all joints and at the to the market reducing for rotation and inclination. basket. the effort and costs The control takes care of The inclinometers of for the work at places the stability and the balance the series NBX65 are based difficult to access. The to prevent falling of the plat- on MEMS technology (mi- first platforms had a form. The speed of moving cro electro mechanical height of 10 m to 20 and the load of the platform system). They detect the in- m. This range is now are also considered. clination within a range of increased to 100 m. The company Teupen 10° to 180° with an accu- But not only the height developed a specific control racy of 0,5°. The resolution was important. The total for a large variety of their is 0,01°. They measure one operation distance was elevating platforms. This or two axis and generate a Figure 2: Elevating platform also of interest. (See control is based on fuzzy CANopen, analogue or SSI LEO for exceptional height Figure 1) control logic to react fast output signal. and distances

26 CAN Newsletter 4/2013 The singleturn type As the electronic TBE with SSI interface is chamber does not contain also electro-magnetic. The moving parts it can be pot- sensing elements are based ted. The protection class is on hall effect. The encod- IP69K. The encoders can be ers are built in two-chamber used in harsh environment. technique so the electron- TWK offers a range of ic chamber can be potted. encoders and inclinometers The extended temperature with CANopen safety and range of -40 °C to +85 °C, PROFIsafe interface in re- which in former times used dundant technique certified to be an expensive option by German TÜV. on the electro-optical devices, is now the standard range. The redundant SSI Figure 3: T-series encoder in two-chamber technique output and the redundant supply voltage are connected with two separate plugs. Even if one connection fails, the application can continue working correctly. The control can detect the failure and take measures to drive the application into a safe position according to the safety regulations. The housings of the encoders are made of alu- minum or of stainless steel. The thickness of the wall is 5 mm to 10 mm. The shaft is made of 12 mm stainless steel and can take a load of 250 N axial and radial. A Figure 4: TRN64 encoder for slewing ring and gearwheel sealing ring around the shaft free from backlash (ZRS) prevents water from entering the encoder at the mechanic The measurements free from backlash (ZRS). chamber. needed to be carried out This gear wheel is also a redundantly to make sure development from TWK. that in case of failure of any The gearwheel is made component incl. sensors of high-grade synthetic. nobody gets injured. This It is solid and has a well- is in accordance to SIL2 defined flexibility at the (safety integrated level 2). contact points. Standard To avoid two encoders on gearwheels for backlash a ll measuring points TWK free operation consist of developed encoders with several components includ- duplicates of all compo- ing a spring. Standard gear- nents that are susceptible to wheels are not applicable failures. The electro-mag- in safety relevant applica- netic encoders of the T-se- tion as their components ries give the possibility to have a limited lifetime. An- duplicate all relevant com- other feature of that spe- ponents inside the device. cial encoder is that it will So the mean time to failure never have an “overflow”. (MTBF) was increased. As the circumferences of The development of a slew ring and gearwheel special encoder for slewing are known the micro con- ring applications was the troller inside the encoder consequent result of that calculates the position requirement. The electro- correctly even when the in- magnetic encoder TRN64 ternal number of 4096 ro- is equipped with redun- tations is exceeded. The dant sensing and trans- TRN64 has a CANopen control Motion mission components. It is safety interface and is SIL2 Figure 5: TRN64 encoder for slewing ring and gearwheel to be mounted to a gearwheel certified. free from backlash (ZRS)

CAN Newsletter 4/2013 27 Systeme Helmholz:

Hardware 25-year anniversary

Links www.helmholz.com

Milestones of the company 1988: Foundation of the Helmholz engineering office 1990: First S5 products 1998: S7-300 I/O product family 1999: First distributor overseas 2001: Profibus connector 2003: Netlink gateway 2006: Office in China Figure 1: Manfred Helmholz (right) is still the CEO, but daily business is done by Carsten 2007: Helmholz daughter Bokholt (left) and Karsten Eichmüller (middle) in Spain 2008: Own building in wenty-five years ago, “Nevertheless, CAN prod- connectors, and a CAN Großenseebach TManfred Helmholz es- ucts are important,” stated bridge device. The company 2009: REX 300 Ethernet tablished an engineering Bokholt, who is responsi- sells more than 10000 CAN router company for software and ble for research and devel- products annually. Carsten 2009: Helmholz daughter plant commissioning with opment. “In particular, the Bokholt did not want to an- in France two employees in Erlangen Profibus DP to CANopen swer questions about a CAN 2011: Helmholz daughter (Germany). Just two years coupler and the CAN 300 1500 interface module: “This in Benelux later, he launched the first PRO interface module are can currently be neither con- 2012: TB20 modular Siemens S5 product. Today, our sales drivers in the firmed nor denied.” I/O system the 85-employees company CAN business.” In addition, The CAN devices serves its worldwide cus- the company offers CAN are used in many different tomers through a network of sales offices and distribu- tors from its headquarters in Großenseebach, just a few kilometers away from the today the building is not rent- ed, it is owned by the company. “And we need more space,” said Carsten Bok- holt, looking out of the window. “We plan to double the size of the current building; the land is already bought.” CAN-related business accounts for 10 percent Figure 2: The young Manfred Helmholz in 1988 at his desk

28 CAN Newsletter 4/2013 ® PRODUCTS $"/PQFO)BSEXBSF 4PGUXBSFBOE5PPMT

t4ZTUFNPO.PEVMFT Figure 3: The TB20 modular I/O system comes optionally with a CANopen bus-coupler t$"/PQFO1SPUPDPM4UBDLT machines, including extrud- The TB20 business t$"/*OUFSGBDFT er downstream devices com- has not taken-off yet. “The pliant with CiA 420 profiles. design-in phase of most ap- They are also used in ship plications is longer than a t"VUPNBUJPO$PNQPOFOUT automation systems and year,” explained Bokholt. in automotive test stands. “But we have already won Recently, the company a lot of contracts. It is just a introduced a ProfinetIO-to- matter of time until the TB20 learn more about our sales will increase. It is one $"/BOE$"/PQFOQSPEVDUT implement the CiA 309-4 of our key-products for the specification,” said Bokholt. future.” “It is transparent to the Pro- finetIO master, which makes commitment to “Made in configuration much easier.” Germany” will be contin- Consulting All hardware and software ued in the future. “Our cus- Design developments are done in tomers expect high product Germany. Even end-assem- quality,” stated Bokholt, “and Prototyping bly and testing of the boards we want to satisfy them with Volume products developed and Production headquarters. manufactured in Germany, The company has de- the home of quality.” The veloped the TB20 modular products are tested in-house I/O system, which was and by external indepen- Bringing your idea to life. already pre-announced in dent laboratories (e.g. EMC 2010. The available CAN- tests). Mobile Off-Road Machinery open bus-coupler complies Functional Safety with CiA 301 and partly with CiA 401 (PDOs and process Railway data). The extension module series comprises digital and analog I/O functionality as well as dedicated functions (e.g. counters). The configuration of them is proprietary - dardized CiA 401 parame- ® SERVICES ters. The ergonomic design has overcome disadvantag- $VTUPN&MFDUSPOJD%FTJHOBOE.BOVGBDUVSJOH4FSWJDFT es of some “early birds” from competitors. t$POTVMUJOHBOE t"TTFNCMZBOE Energy measurement is a hot topic. The company Training Volume Production will provide related TB20 I/O t1SPKFDU4QFDJmDBUJPO t1SPUPUZQJOH modules in the near future, which will measure for ex- t)BSEXBSFBOE t0&.*OUFHSBUJPO ample the consumed power. Software Development Services CiA has currently released the corresponding CiA 458 CANopen profile for measuring energy consumption. www.systec-electronic.com phone: +49 3765 38600-0 ı [email protected] CANopen device conﬁguration editors

Engineering

Dr. Heikki Saha

Author n modern, distributed con- Itrol systems re-use of functions expects the use of a limited number of components in as many instanc- es as possible. Each component instance requires unique settings assigned during the system design. A common misunderstanding Dr. Heikki Saha is that CANopen is only a se- TK Engineering rial communication protocol P.O. Box 810 and therefore parameteriza- FI-65101 Vaasa tion is considered a part of Tel.: +358-6-35763-00 software development. Such Fax: +358-6-35763-20 an approach easily leads into [email protected] system configuration incon- Figure 2: Launching the device editor of the system design sistencies, because system tool Links level configuration manage- www.tke.fi ment is missing. Standard havior. Control and system DCF files are used for stor- designers are not necessar- ing the settings of CANopen ily able to fluently edit the devices. The simplest ap- raw files or assign the cor- Instead of only communi- proach is to manually con- rect raw values. Typical re- cation protocols, CANopen figure each device for a pro- sults have been incorrect specifications include a thor- totype system and store the or even missing parameter ough layered description settings of each device into values, because the neces- of communication servic- corresponding DCF file. Af- sary parameters with their es, system design process Introduction ter storing the settings, they descriptions are described [3] [10], configuration files This article presents the can be used for manufactur- only in text documents. In [10] [11] [12] and integration main principles of device ing of the systems with equal addition, product specif- mechanism between various configuration editors as settings. Further challeng- ic commissioning tools with design tools [11]. CANopen two case examples. The es can appear during the as- dedicated bus access are device profiles provide an ef- editor in the first example signment of device parame- available for some products ficient approach to the re-use is targeted at CANopen ters. Raw configuration files [2], which will lead to a need of common measurement encoders. It was with raw parameter values for too many different bus in- and drive functions in sys- possible to implement a are typically accessed by terfaces. Functional safety tems. It has been proved ear- generic editor because software developers, who do requirements are tightening lier, that using CANopen to the encoders share a not necessarily have a de- up and setting requirements coordinate the development uniform logical structure tailed understanding of sen- for well defined and docu- of distributed systems signif- [14]. The second example sor, drive and system be- mented processes [8] [9]. icantly improves both quality presents an editor for Main targets are to get man- and efficiency of the software general purpose I/O 01 [Tools] aged structural descriptions development [3] [5]. devices. Because of 02 Items=2 for the systems, to help with CANopen also helps the generality, device or 03 [Tool1] the selection of correct com- to manage a system's com- device family specific 04 Name=Device Settings ponents, and to use them plexity and tolerate differ- 05 Command=encwiz.exe $DCF editors are required [13]. according the specifications ences between components 06 Wait=1 Both device profiles are 07 Make=0 and with correctly set pa- and a sytem's life-cycle. [4]. supported by a large : : rameter values. Following Following the design process number of devices, standardized processes re- efficiently expects the use which helped to find out Figure 1: Example [Tools] sults in understandable de- of appropriate tools. Multi- the main commonalities section in an encoder signs, including design doc- ple system design tools have and differences. EDS file umentation. been on the market for years.

30 CAN Newsletter 4/2013 The possibility of link- the same basic structure ing device specific tools with measurement direc- to the system design tools tion control, scaling and [11] has not become wide- preset. Advanced features, ly known, because prod- such as speed computing uct specific commissioning and CAMs, are not included tools [2] have common- in the examples of this ar- ly been used. The roles of ticle, because they are not the tools are clear – system supported by the majority structure and all communi- of the encoders. The type cations are designed with information is available in system design tools and the higher word of the de- product specific add-ons vice type object [14]. En- can be used for adjusting coder class information is Figure 3: Parameters of a class C1 absolute linear encoder the device behavior. not available and thus sup- The clear distinction ported options need to be between the parameter determined based on the groups improves the pro- objects supported by the cess [4]. Device configura- encoders. Supported warn- tion plugins provide a safe ings and alarms are clearly access for control and sys- indicated in the object dic- tem experts to the device tionary, which helps with parameters. The approach troubleshooting. Only the follows the standardized support of commissioning CANopen design process diagnostics control cannot and moves the focus from be determined unambigu- editing the raw values in a ously from the object dic- set of files to adjusting the tionary. Figure 4: Parameters of a class C2 absolute multiturn system behavior. In addi- The measurement unit encoder tion to system design, stan- of an encoder is the most dard tools can also be used essential information from under configuration. Figure for system troubleshooting, the system point of view, 3 presents an example view based on system configura- because it directly affects for a class C1 linear encod- tion stored as a CANopen control software [6]. En- er without preset function Generic I/O-devices are the project. coder configuration wizards and with scaling disabled. most typical CANopen de- The use of a CANopen can automatically compute Measurement direction and vices on the market. The tool integration interface the measuring step size for scaling selections are pre- device profile is versa- provides vendor and ver- both signal and parameter sented in human readable tile, which introduces spe- sion independence be- objects, based on current form and fields for unused cial challenges to the gen- tween the tools. The tools scaling parameter values. and unsupported parame- eral purpose configuration in the example figures are Currently it is possible to ters are hidden to keep the editors. The basics are just examples – the pre- determine the output signal user interface as simple as straightforward – there are sented concepts are not unit by combining informa- possible. The step size has dedicated object areas for limited to the example tools. tion from various objects. been computed based on digital and analog inputs Figure 1 presents how links But it is not possible to as- the linear encoder measur- and outputs [13]. There are to the external tools can be sign measurement unit in- ing step settings. also well defined optional defined in EDS files, where formation directly to the Another example is control blocks for input and the links are automatically signal and parameter ob- shown in Figure 4, where output signals organized so copied into DCF files during jects, because such an a class C2 multiturn abso- that the sub-indexes match the system design. System entry is not supported by lute encoder with scaling with corresponding signal design tool passes a path of DCF file format. XDC files and preset support is un- objects. Supported input the corresponding DCF file supporting unit informa- der configuration. Direc- and output types are indi- as a command line option. tion can be used in the fu- tion enumeration has been cated in the higher word of The command in an exam- ture, e.g. when tool support changed according to the the device type. ple system design tool is has been included [12]. The rotary encoders and sup- A problem can arise in highlighted in Figure 2. use of XDC files instead of ported optional fields are the digital inputs and out- DCF files enables exporting included. The step size has puts, which are organized more complete signal spe- been computed based on as groups of eight signals. cific meta information into the assigned single turn With EDS and DCF files it The structure of CANopen the CANopen abstraction resolution and the number is possible to identify the encoders is clearly de- layers of application proof distinguishable revolu- number of supported digi- fined and thoroughly orga- grammable devices [5]. tions. Preset value is typi- tal channels in multiples of nized [14]. Main differenc- The user interface of cally adjusted only by the eight signals, not one by one Engineering es are the most common the encoder configuration control system. Position [1] [10]. If the minimum and encoder types – linear, sin- wizard can be made scal- and offset fields are target- maximum value of a byte gle- and multiturn absolute able according to the fea- ed mainly for troubleshoot- object is defined, the low- encoders. All types share tures supported by a device ing purposes. est and highest supported

CAN Newsletter 4/2013 31 bits can be determined, but – configuration errors and possibly unsupported bits inconsistencies, causing between cannot be exactly dozens of hours of trouble- indicated. shooting and repair in as- Many devices sup- sembly and service, can be port multiple analog signal avoided. All improvements types and ranges, which apply to each revision cycle are controlled by manufac- of a project. turer-specific objects.

Engineering The objects can be linked to the standardized signal objects by using ob- The concepts presented in ject links [10] to enable this article are based on generic tools to create com- EDS and DCF files, which plete groups of objects for will be replaced with im- each channel organized proved XDD and XDC files. to screen in a logical or- Using the presented con- der. The second problem cepts with the new file for- is exposed, when channel Figure 5: Parameters of a valve driver mats makes no sense, un- specific physical scaling is til at least tool integration needed [6]. There are stan- into the configuration wiz- Thus, all errors caused by and emergency error code dardized objects for the de- ard. In the example devic- informal parameter modifi- decoding support are add- scription of the physical es, operational mode is a cation requests, invalid raw ed to the file format. Tool units, but the effect of scal- complex parameter, which values and violated file for- integration support is vital, ing objects into the units is is divided into three fields mats can be avoided. because it enables all in- not completely defined. The – actuator index, control Overall performance formation transfers to and device specific parameter mode and direction. De- will be improved in many from CANopen projects in- editor could provide such signers will be confused ways. Setting parameters dependently of the tools. services, but it expects the by such complex raw val- becomes much faster and Emergency error code de- support of corresponding, ues without using an editor less prone to errors, sav- coding improves diagnos- object specific meta infor- hiding the complexity. The ing time-consuming trou- tics efficiency significantly mation entry in configura- device specific tool also en- bleshooting and correction because the use of multiple tion files. If signal types are ables an improved screen of the numerous parame- languages is already sup- selected by physical con- layout. The block diagram ter values. Designers need ported [12]. nections, e.g. by using type has been adopted from the to spend less time reading Multiple pictures can specific pins, systemat- corresponding device pro- the device manuals again be linked to each XDD and ics cannot be provided by file with additional device and again to find out the XDC file [12]. Several fig- CANopen. specific blocks. Despite on correct raw values. Espe- ures are needed for each Object links can also the parameter organiza- cially with simpler devices, device, e.g. background im- be used to define feedback tion in the object dictionary, knowing the device profile ages of device configura- inputs of the outputs. The block specific behavior can is often enough. Utilization tion editors and component third problem can be rec- be clearly visualized. Albe- of the CANopen tool inte- figures as icons for system ognized if an output can it the configuration wizard gration minimizes the addi- design and configuration be either digital or analog. is device specific, it does tional effort caused by the download tools. Standardized signal objects not increase overall com- configuration wizard. When More detailed meta in- can be used and they can plexity because of the stan- they have been installed, formation is available for be assigned together with dardized tool integration after passing the accep- signals and parameters object links but a method mechanism. tance test, extra work is not [12]. In addition to the mini- for describing which one required. When only one mum, maximum and default is active is missing. Corre- system tool has network values, value enumera- sponding objects can be in- access, only one interface tions [7], derived types cluded into the same group adapter and device driver and units [12] are support- by object links, but depen- Based on a few years of are needed. ed. More detailed data type dencies of the object val- testing in various projects, The average speed- definitions enable the gen- ues cannot be described the most significant bene- up of the parameter assign- eration of more complete in EDS and DCF [10]. The fit of CANopen device edi- ment phase seems to be abstraction layer for appli- same problem also applies tors is that the main focus as high as 60x, even with cation programmable de- to XDD and XDC files [12]. can be on the management very simple devices. Abso- vices. Unit and scaling of CANopen valve drivers of system behavior instead lute time saving in a design signal and parameters may contain all listed character- of the raw values and file of system with 15 relative- be managed based on DCF istics causing problems for formats. One consequence ly simple devices may be files [6], but device edi- a generic configuration wiz- is that instead of program- over 2 hours. Half of the tors may improve the unit ard. Therefore the example ming experts, control and speed-up comes from tool and scaling management wizard presented in Figure system experts – who have integration and another half 5 is device specific. The the best system level knowl- comes from intuitive user based in the device profile approach enables includ- edge – can take control interfaces. The most sig- specific knowledge. De- ing device specific details over the system behavior. nificant result is indirect vice editors may also use

32 CAN Newsletter 4/2013 IO Modules for device specific knowledge, Parameter grouping ® ® especially for generic I/O works similarly with EDS CANopen and EtherCAT devices. It is impractical to and DCF files. The main include such functionality in difference is that in XDD generic conversion or code and XDC each signal and generation tools. Therefore, parameter has its own - unique identifier, based ly supporting object units on which the linking works should be completed. [7] [12]. The identifiers can Parameter grouping be utilized by device con- support provides solutions figuration editors for e.g. for two problems that are improving an automat- encountered with generic screen layout manage- ic I/O devices. First, bool- ment. However, description ean signals can be defined of parameter dependencies as individual signals and cannot be included without mapped into the object dic- extensions. tionary as groups of eight signals. As a consequence, device editors can detect the exact number of supported digital inputs and outputs, and boolean signals can be provided in the generated abstractions as booleans instead of raw bytes [5]. Second, complex parameters can be defined and mapped into objects as groups of signals with complete enumeration, reducing the need for device specific editors. For CAN, CANopen® and EtherCAT® References 1] Decker B. M., Improving and testing CiA 401 for the next generation of I/O devices, Proceedings of the 11th iCC, CiA, 2006, pp. 01-01 – 01-05 Quick and cost e! ective connection [2] Lelkes A., Compact drives with CAN interface for industry applications, Proceedings of 13:th iCC, CiA, 2012, pp. 11-08 – of analog and digital IO signals 11-13 [3] Saha H., Wikman M., Nylund P., CANopen network design and IEC 61131-3 software design, CAN-Newsletter 3/2009, CiA, Up to 16 digital and analog (12 2009, pp. 52–58 [4] Saha H., Benefits of intelligent sensors and actuators bit resolution) inputs and outputs, throughout the systems life cycle, The Twelfth Scandinavian International Conference on Fluid Power, May 18-20, 2011, depending on device version Tampere, Finland, ISBN-978-952-15-2517-9, pp. 169–181 [5] Saha H., Improving development efficiency and quality of distributed IEC 61131-3 applications with CANopen system Ready to use pre-conﬁ gured or design, Proceedings of 13:th iCC, CiA, 2012, pp. 10-15 – 10-21 [6] Saha H., Unit and scaling management in CANopen projects, easy conﬁ guration via free tools or CAN-Newsletter 3/1013, CiA, 20013 pp. 8-14 [7] Gedenk T., Use cases and advantages of the new XML device system controller descriptions for CANopen devices, Proceedings of 12:th iCC, CiA, 2008, pp. 06-01 – 06-07 [8] Safety of machinery. Safety-related parts of control systems. Part 1: General principles for design, IEC 13849-1, IEC, 2008, For industrial and automotive usage 182 p. [9] Safety of machinery. Functional safety of safety-related electrical, electronic and programmable electronic control systems, IEC EN 62061, IEC, 2005, 201 p. [10] CANopen Electronic datasheet – Part 1: General definitions and electronic data sheet specification, CiA-306-1, CiA The IXXAT IO Modules are also [11] CANopen Electronic datasheet – Part 3: Network variable available as board level product handling and tool integration, CiA-306-3, CiA or customized OEM design for [12] CANopen device description – XML schema definition, CiA- 311, CiA easy integration into customer [13] CANopen device profile for generic I/O modules, CiA-401, CiA products [14] CANopen device profile for encoders, CiA-406, CiA

IXXAT Automation GmbH Leibnizstr. 15 · 88250 Weingarten Tel.: +49 751 56146-0 Member of the HMS group Internet: www.ixxat.de

cia_anzeigen.indd 2 18.10.2013 14:00:01 CAN and Ethernet – similar but different

Engineering

Christian Bornschein

Author AN and Ethernet have Christian Bornschein Cthe need for commu- Port GmbH nication in common. Other Regensburger Straße 7b characteristics are different, DE-06132 Halle an der for example the kind of de- Saale vices the networks are used Tel.: +49-345-777550 for. From the very beginning Fax: +49-345-7775520 CAN was intended to transfer small packets of con- Link trol data in hard real time, www.port.de while Ethernet was created to move large amount of data. For Ethernet, being de- terministic or real-time was not part of the plan. Common is also their creation as bus- Figure 1: Delay caused by a Hub ses. CAN is still a bus, Ether- net not anymore. The switch to twisted pair and star topology as well as the use of mul- Introduction tiport bridges made Ethernet Ethernet is significantly even more of a “data lorry”. older than CAN. While At first Ethernet shared Ethernet was invented with CAN the idea of a bus: in 1973 but published in All nodes were “listening on 1976, CAN was created the same wire”, the Yellow in 1983 and published Cable or the RG58, the in 1987. Both networks Cheapernet. This topolo- had the reason for their gy was limited to 10 Mbit/s. invention in common: Only Half Duplex communi- The need for various cation was possible. Upon devices to communicate. transition to 100 Mbit/s the This article outlines the common basics of CAN and Figure 2: Delay introduced by a Switch (best case) differences between CAN Ethernet vanished com- and Industrial Ethernet pletely when the Ethernet typical delay of a hub. The something goes wrong. A and shows some of the topology changed to point significant effect is that in switched Ethernet network challenges of Industrial to point topology with Twist- a Half Duplex network only with its highway-like infra- Ethernet with some ed Pair cables. The Full-Du- one node can communi- structure provides a perfect technical background. plex Mode, introduced by the cate, while all other nodes base for the Ethernet “data Furthermore it raises the Ethernet Multi Port Bridges, are quiet. Every node on the lorries”. question: Why switching which was called “Switches”, network sees all valid data to Ethernet at all? took over and the Half Du- packets, which is good for plex Mode, used by the re- Real-Time Control such as peaters, also called “Hubs”, it is used in CAN networks, Connecting CAN to the bus disappeared. but bad for a “data lorry” takes little effort: Take a CPU In the Half Duplex Mode network, since other nodes or MCU with on-board CAN every network message was could be communicating dur- controller, some optional op- seen everywhere in the net- ing this time. tical isolators, a CAN trans- work. On the face of it this Full Duplex uses Eth- ceiver, and a connector. For seems to be an advantage, ernet Switches, and Switch- software connectivity (e.g. especially considering that es cause delays by storing CANopen) a protocol library Hubs cause a very small packets and sending them is needed, in a perfect world delay. Figure 1 shows the out randomly – or not, if coming with a GUI Design

34 CAN Newsletter 4/2013 canAnalyser Tool to ease up and speed up messages with a dynamic the development process. answer in hardware, roughly New Version 3.0 Connecting Office Eth- - ernet is not significantly more mote Transmission Request. complicated than CAN. The These components are usu- components are similar: ally carried by a FPGA. Only Take a PHY (equivalent to in very rare and very spe- the transceiver), an Ethernet cific use cases, standard transformer (equivalent to the Ethernet components are optical isolator) and a RJ45 suitable. Powerlink claims connector. full management of the net- Connecting to Industri- work and only grants access al Ethernet is not that simple to “regular” (TCP/IP) network since many aspects need to traffic in the ASND cycle. be taken into consideration. The components are basically the same; however Indus- trial proof equipment needs Ethercat comes with a com- to be used. A protocol library pletely modified Layer 2, al- with corresponding Design ways needing an Ethercat Tools is needed for the soft- Slave Controller (ESC) – the ware here as well – in a per- physical layer component of fect world the libraries would Ethercat. These ESCs are be compatible with other pro- available by Beckhoff as IP- tocol libraries. Cores for FPGA or ASIC component. Some semiconductor manufacturers have integrated ESCs in their Different than CAN, Ethernet CPU/ MCU designs. Ethercat is connected in star struc- claims full access to the net- ture: One single Ethernet work as well and allows for port is connected to an Eth- “regular“ (TCP/IP) network ernet Switch. For obvious traffic with the EoE (Ethernet over EtherCAT) mailbox pro- make sense in Industrial Eth- tocol. ernet applications. To accom- Powerful analyzing, stimulation, plish a line structure an Eth- recording and data interpretation ernet Switch or Ethernet Hub needs to be built into the unit. functionality Since nothing is easy Different than Ethercat and when it comes to Industrial Powerlink, Profinet and Eth- Ethernet, specific line struc- ernet/IP work with standard For CAN, CANopen, DeviceNet ture components need to be components only except for incorporated – e.g. a Man- Profinet IRT. Both protocols and SAE J1939 based systems aged Switch, an extremely can be integrated in stan- low latency Ethernet Hub for dard network environments Powerlink, an Ethercat slave and are able to use existing New: Multi-board feature controller for Ethercat, or a network stacks (e.g. TCP/IP supports multiple CAN interfaces managed Ethernet switch for Stacks). While Ethernet/IP Profinet and Ethernet/IP. uses only regular UDP/TCP simultaneous communication, Profinet uses a proprietary scheme for real time data. Both protocols rep- New: Improved database concept Powerlink was among the first resent the most significant Industrial Ethernet networks. market share. and graphic display of signals and It adopted the CAN in Automa- statistic data tion communication scheme as well as profiles and was considered the CANopen on Application requirements can New: Data transmission and Ethernet for quite some time. sway the decision in favor of It needs specialized hardware Ethernet or CAN. While CAN reception based on signal level to take advantage of Ether- is designed for Industrial Au- - tomation, Ethernet is made taining industrial suitability. ready for Industrial Automa- This hardware is an extreme- tion. Both work fine, howev- ly low latency Hub and a spe- er they are based on different cial MAC, which can reply to paradigms. IXXAT Automation GmbH Leibnizstr. 15 · 88250 Weingarten Tel.: +49 751 56146-0 Member of the HMS group Internet: www.ixxat.de

cia_anzeigen.indd 3 18.10.2013 14:00:02 CANopen for Chinese product quality

Engineering

Longfeng Gong

Author ore and more system It works as a CANopen communication protocols, Mdesigners and system master and features two PDO, SDO, NMT, SYNC, integrators in China focus CAN ports for a CANopen etc. The layer transforms on CANopen. High reliabil- interface. The CANopen the CAN signal of the ity, real-time capability, low- source code used in the mo- master controller into a cost, fault-tolerance and tion controller card and in CANopen protocol. The compatibility are key com- the testing platform is mod- third layer is the CCM lay- ponents of CANopen. To ular. The testing platform er, which achieves the extend CANopen concepts is based on a TI AM335x CCM main function. It pro- and support more efficient ARM Cortex-A8 running an vides the function interface Longfeng Gong CANopen systems in China, RTLinux operating system. of CANopen read/write, the Hongke Technology makes The CANopen source packaging of API, and pre- Hongke Technology Co., Ltd every effort to help Chinese code implements the com- defines the object dictionary National Science & system designers integrate plete functionality ac- of application object param- Technology Park, their own CANopen appli- cording with the CiA 301 eters. The fourth layer is the South China University cations. Because they can specification and it sup- application layer. The servo of Technology, take advantage of a ma- ports the standard compli- drive responses to the call 510640 Guangzhou, ture and reliable CANopen ant design of fully-featured of the CCM main functions China source code, developers CANopen master or slave and implements the servo Tel.: +86-20-3874-4528 can save time and money. devices. The structure is motion project according to Fax: +86-20-3874-3233 By using the CANopen Pro- scalable and portable. Writ- different testing scenarios. [email protected] tocol Stack Source Code ten entirely in Ansi-C, the The key point of this by the German company source code allows custom project is an integrated de- Links Sys Tec Electronic, Hongke tailoring of the stack to ev- velopment process. It can www.hkaco.com Technology helps spread- ery application. The con- be integrated successfully ing CANopen in the Chi- tinuous modularization of thanks to the experience of nese market. functionalities and imple- Sys Tec Electronic in hard- In China, Hongke mentation in Ansi-C makes ware system integration Technology has managed porting to different target with Linux. The well-defined to help engineers in de- systems possible. Great im- API allows for an easy use veloping servo drives and portance was set on scal- of the CANopen services controllers, motion control- ability and performance. without diving into details ler cards, medical equip- Sys Tec Electronic provides of the implementation. Ad- ment, sensors, encoders, a most convenient environ- ditionally, the example pro- www.systec-electronic.com door control systems, laser ment for development, in- grams target specific demo systems, mining control- tegration and testing of projects, and the compre- lers, HVAC control systems CANopen applications. hensive documentation as- and more - all based on With the benefit of sists the complete project CANopen communication. the modular, scalable and step-by-step. A lot of these prod- portable structure of the Currently, many simi- ucts are already available CANopen source code, the lar CANopen development off the shelf. For complicat- motion controller card builds projects can be found in ed tasks, the company also a modular structure with China, which not only brings provides an OEM porting four layers. The first layer is the German state-of-the- service. The motion con- the Development Environ- art CANopen technology to troller card serves the pro- ment CAN driver software, China but also allows devel- duction quality inspection of provided by the AM335x opers to constantly absorb newly manufactured motors ARM Cortex-A8. The sec- the essence of advanced in testing different operating ond layer is the CANopen technology. Thanks to this functions. protocol stack layer, based cooperation, new CANopen The controller takes on the CANopen source applications will bring vital- charge of managing and code framework, includ- ity to the potential Chinese testing eight servo drives. ing CANopen standard market.

36 CAN Newsletter 4/2013 LINUX device driver You CAN get it... available Hardware & software for CAN bus applications…

PCAN-PC/104-Plus Quad PCAN-miniPCIe Four-channel CAN CAN interface for PCI interface with galvanic Express Mini slots. Single- isolation for PC/104-Plus or dual-channel versions systems. with isolation available.

PCAN-Gateways The PCAN-Gateways allow the connection of different CAN busses over LAN or WLAN networks. 2 High-speed CAN channels with bit rates up to 1 Mbit/s Galvanic isolation of the CAN channels up to 500 V Linux operating system (version 2.6.31) message forwarding through a web interface Plastic casing for mounting on a DIN rail PCAN-Router DR PCAN-Diag 2 Extended operating temperature range (-40 to 85 °C) CAN router in DIN rail Handheld device for CAN PCAN-Wireless Gateway DR: WLAN connection via plastic casing with 2 CAN bus diagnostics with 2.4 GHz dipole antenna (WLAN IEEE 802.11 b/g) channels, selectable bit oscilloscope, trace, and PCAN-Ethernet Gateway DR: LAN connection via rate, and galvanic isolation. measurement functions. RJ-45 connector (10/100 Mbit/s bit rate)

PCAN-USB Pro PCAN-PCI/104-Express High-speed USB 2.0 CAN interface for PCI/104- interface with galvanic Express systems. Available isolation for connecting up as 1-channel, 2-channel, to 2 CAN and 2 LIN busses. and opto-isolated version.

PCAN-Explorer 5 The universal tool for developing and monitoring CAN networks. Extensive user interface improvements: File manage- property editor, and window arrangement using tabs Simultaneous connections with multiple networks / CAN interfaces of the same hardware type Data logging with tracers and the 4-channel Line Writer PCAN-PCI Express PCAN-Repeater DR VBScript interface for the creation of macros CAN interface for PCI Repeater for the galvanic Functionality upgrades with add-ins (e.g. Plotter, J1939, Express slots. 1, 2, and isolation of 2 CAN bus CANdb Import, or Instruments Panel add-in) 4-channel versions with segments, bus status dis- User interface language in English or German galvanic isolation available. play, switchable termination.

International Sales www.peak-system.com

Scan the QR code or enter this URL in your browser Otto-Roehm-Str. 69, 64293 Darmstadt, Germany to have a look at our international sales partners: Phone: + 49 6151 8173-20 – Fax: + 49 6151 8173-29 www.peak-system.com/quick/CiA E-mail: [email protected] Motion control Motion

Electric servo drives prove themselves in outdoor use

Ewald Küpfer, Andreas Leu

Authors here are many cost-ef- power ratings from 5 kW to distribution. For example, if Ewald Küpfer Tfective ways of using 80 kW and is used as a kinetic energy is recuperat- Andreas Leu electric drive technology in wheel or ancillary drive. ed, the energy management agricultural and construction It is stackable - i.e. the system ensures that this en- Company machinery. Thanks to this inverters can be installed ergy is stored or used else- Jetter AG technology, process control one above the other, be- where in the machine. In this Gräterstr. 2 and thus productivity are in- cause all power, control and way, the load and speed of DE-71642 Ludwigsburg creased due to greater ef- water connections are locat- the combustion engine is Tel.: +49-7141-2550-0 ficiency of the electric drive ed on one side. kept constant and energy is Fax: +49-7141-2550-425 technology. Recuperation of The JMM-5000 was saved. kinetic energy and mechan- used in the field for the first This stored energy can Link ical speed decoupling of the time in the middle of 2012 be used for boosting, i.e. www.jetter.de combustion engine enables and has therefore already at times of peak loads, so fuel to be saved, which in proven its suitability for use that the combustion engine return protects the environ- in harsh environments. is held at its optimum con- ment. With its double invert- The efficiency of elec- sumption point. er JMM-5000, Jetter has ex- tric drive systems is, along- The swivel drive on tended its product range for side numerous other factors, an excavator is an exam- the automation and electri- heavily dependent upon how ple. The excavator fills fication of agricultural and long the machine is used. its shovel in the loading construction machinery. The If the machine is not used process, swivels it towards Related articles company's more than thirty for very long, the process the dumper or truck and tips “We open our systems years of experience in indus- improvement must predom- the contents out in the un- to facilitate simple trial applications also bene- inate in order to justify elec- loading process. integration of third-party fits mobile automation. trification. Improved process In doing so, the struc- products” – page 22 The double invert- control means fewer down- ture must be accelerated er, which is designed as a times, optimal filling of the and then decelerated after four-quadrant inverter, can machine, exact feed length approx. imately 90°. This be integrated into the over- that is optimal for fodder use braking energy is recuper- all system. It can be pow- (e.g. for biogas plants, as ated/stored in the process ered with an AC or DC fodder, etc.), low-loss har- and used for acceleration. supply. For self-propelling vesting of the fodder, etc. This reduces the energy harvesting or construction The speed decoupler allows required by the swivel drive machinery, the double invert- each drive to run indepen- by about 50 %. er can also be provided with dently of the speed of the a DC/DC output, so that combustion engine, enabling the vehicle can be supplied it to be operated and held at with 12 VDC or 24 VDC and its most fuel-efficient point. up to 400 A straight from An energy manage- In this application, the en- the vehicle battery. The ment system tailored to the ergy is generated by a PTO inverter is available with machine ensures energy (power take-off) and passed

38 CAN Newsletter 4/2013 Summary Electric drive technology has established itself in industrial automation. Mobile automation to controlled drives for mobile machines, this industry used to rely on hydraulic systems. There is a great number of mobile implements and vehicles though for which the application of electric drive technology is a good idea. Jetter AG now brings the double inverter JMM-5000 Figure 1: Example configuration of JMM-5000 with a DC supply (JetMove Mobile 5000) to the market, especially to the implement via a spe- motor is monitored by ther- different film types used for for such applications. cially designed connector. mocouples. Thanks to its round bales. It fulfills the particularly The PTO is driven via the high power density, the 30 kg This can be done more high requirements front PTO shaft of the tractor. motor delivers 27,5 kW to easily with electric drives, for outdoor use with The VDC generated by the each wheel. The implement which can be more finely regard to temperature, PTO is stored in the DC link is therefore driven via both controlled, than with hydrau- seal, vibration, dirt and of the double inverter and wheels with 55 kW. The lic drives. In electric drives, moisture protection. passed to two permanently planetary gear unit used the torque is detected via excited synchronous motors. has a transmission ratio of the current that flows to the It was specially designed for 1:65 and can be switched motor and is set and moni- this application by Jetter and off while moving the imple- tored to prevent the film from has a high power density. ment from one site to another. tearing. If the torque changes, the baler can be brought to an immediate stop within 450 milliseconds, avoid- ing any tears in the film. This saves valuable downtime. “Saving energy has to go hand in hand with in- creasing efficiency”, which all companies have realized by now. In the field of drive technology in particular, a high amount of potential exists in this direction. Experiences from the area of industrial automation will only continue to help in Figure 2: Example configuration of JMM-5000 with an the area of mobile automa- AC supply tion to a limited extent, as the conditions for outdoor The software imple- use are mostly completely mented in the double invert- different. er controls the speed, so that the implement runs syn- Just like in the potato chronously with the tractor. It harvester, the electrical also monitors the power and energy is generated with torque to avoid the creation a PTO. Important for the of any extended overloads potato harvester is the im- (the double inverter can provement in the energy be overloaded to 150 % for balance. In the winder ap- short periods) and prevents plication, on the other hand, the wheels from "slipping" in the focus is on improving poor surface conditions. the process, because the A resolver is used to viscosity of the film chang- control Motion monitor the motor speed. es depending on different The temperature of the weather conditions and the Figure 3: Schematic of a winding unit on a round bale press

CAN Newsletter 4/2013 39 Control panels use off-the-shelf

Hardware CANopen components

Introduction ince control panels are Switches from Schlegel Sused in a wide range of Elektrokontakt are used applications for various pur- in all kinds of machines, poses, they must fulfill differ- in lifts, ships, and ent requirements concerning special-purpose vehicles. form factor, integrated con- Additionally, the company trol units, and interfaces to configures control panels connect them to controllers. according to customer By adopting a modular ap- requirements. For control proach for all operating solu- panels connected via tions, Schlegel provides and a CANopen interface designes panels that fit into or other industrial their surroundings even in communication small quantities. Thus, cus- protocols, Schlegel tomers can choose the ma- uses Deutschmann terial, shape, and size of the panel, and can also have Figure 1: Control panel from Schlegel install Unigate IC bus them labeled and engraved nodes. in their corporate design. The used when a large number of carrier board is populated At its headquarters company equips the control control and signaling devices with contactors for the con- in Dürmentingen, panels with standard contact must be connected with mini- trol units and physical inter- Germany, Schlegel has elements or with Industrial mal wiring effort. Schlegel of- faces for the desired network. been developing and Ethernet or serial bus system fers modular control panels If required, the manufacturer manufacturing control communication interfaces as and keypads with CANopen also adds I/O interfaces, al- units, signal lamps, required. interfaces and other industri- lowing for peripheral sensors and terminal blocks for al communication systems. to be connected to the net- more than 60 years. A carrier board is config- work or the controller via the Membrane and short ured according to the cus- control panel. Moreover, the stroke keyboards, tomer-specific design of the carrier board contains a enclosures, limit Operating solutions with a se- complete solution, located socket to connect the net- switches, control panels, rial bus system or Industrial behind the front panel, which work module, which organiz- and function blocks Ethernet interface are mainly houses the control units. The es all data traffic between the have also been part of the product portfolio for a long time. The products are primarily used in machine tools, test rigs, instrument With the ready-to-install, all-in-one Uni- CANopen gateways from the CX series panels for lifts, ships gate IC CANopen network nodes, the Uni- connect all types of automation networks and special-purpose gate CL CANopen protocol converters, and with CANopen networks. With their modu- vehicles. However, the Unigate CX modules that are interop- lar design based on two CL units, the DIN they are not limited to erable with CANopen, Deutschmann pro- rail devices are available for all serial bus industrial applications: vides gateway solutions for applications. systems and Ethernet variants with CL de- They allow users to equip new units with vices. In all Unigate series, a script con- ensure reliable switching CANopen interfaces and to connect ex- verts the protocol of the terminal device or in any location, e.g. isting devices without a suitable interface. the network protocol, thus enabling adap- in control panels of In order to connect AS-i devices and net- tation to CANopen requirements. By de- public swimming pools, works in CANopen environments, the com- fault, the devices are delivered with scripts department stores, or pany also offers the Unigate AS-i module, for transparent data transfer. The free-of- office buildings. which features an AS-i master board with charge PC tool, which requires no special the M-4 profile and fulfills the AS-Interface programming or CANopen knowledge, can Power24V specification. be used to create customer-specific scripts.

40 CAN Newsletter 4/2013 CONTROLS | NEW PRODUCT !"#$ DC!""" Dialog Controller Powerful CODESYS V! Display-Controller with Multi-Axis-Function

Basic system features CAN Bus and EtherCAT

The DC2000: An extremely strong CODESYS V3.5 display controller. The powerful 800 MHz ARM controller allows multi axis motion applications controlled by a CODESYS Visit us in hall & | stand ()# So"Motion library. Advanced interfaces, Ethernet and EtherCAT are just some highlights of the controller. CAN Bus combines proven and a#ordable technique with the latest technologies.

More features: → realtime controller with minmal cycle times Berghof Automationstechnik GmbH → multi-axis controller with CODESYS So"Motion Harretstrasse # &!'"" Eningen | Germany → 4,3 inch touch display | 7 inch glass display with capacitive touch [email protected] → communication: Ethernet, EtherCAT, PROFINET, CANopen, RS 485, RS232 www.berghof.com Hardware

Companies Deutschmann Automation GmbH & Co. KG Carl-Zeiss-Str. 8 DE-65520 Bad Camberg Tel.: +49-6434-9433-0 Fax: +49-6434-9433-40 [email protected]

Georg Schlegel GmbH & Co. KG Figure 2: Unigate IC standardized pin assignment Kapellenweg 4 DE-88525 Dürmentingen control panel and the con- our customers with mature Tel.: +49-7371-502-0 troller through the CANopen products within a very short Fax: +49-7371-502-49 protocol. For these network time and at an attractive [email protected] modules, Schlegel uses price. Thanks to the interfac- Featuring hardware and es, we can present the pro- software interfaces with the Links ready-to-install Unigate IC totype of an operating solu- same standardized function- www.deutschmann.de network nodes. tion merely three days after alities, Unigate ICs enable receiving an order.” the implementation of multi- The fact that Schlegel protocol solutions. Manufac- no longer needs staff to turers merely need to inte- “Primarily, we are a manufac- maintain and update the grate the adaptation board, turer of control units, terminal network module software is which holds a socket for the blocks, and signal lamps”, ex- another advantage of the nodes or implement a socket plained Georg Selig, Project cooperation with Deutsch- directly on the device board. Manager at Schlegel. “De- mann: since Deutsch- Thereby, Schlegel can, for veloping serial bus system mann constantly adapts the instance, offer an operat- www.schlegel.biz components is a separate nodes to current networking solution for various pro- field that requires specific specific standards and re- tocol types. They are based know-how and considerable solu- on a carrier plate design, e.g. additional efforts for main- tions automatically remain adapting a carrier plate with tenance, documentation, up to date. Ethernet connections for a and certifications.” There- fore, Schlegel chose an ec- onomically viable solution, cooperating with an exter- Unigate IC nal network module specialist who has relevant experi- Unigate ICs are complete, ready-to-install network ence and know-how. “Using nodes that combine a microcontroller, Flash, RAM, and a network controller on a 45 mm x 25 mm foot- interfaces, we are no longer print in a 32 DIL housing. The miniature interfaces faced with the costly efforts handle the complete communication on the network of proprietary developments”, side, thus significantly relieving the application's mi- said Selig. "Especially small croprocessor. The devices are connected to the to medium quantities, which host processor via a UART interface. In addition to we often deal with when pro- CANopen, the series also covers all standard serial ducing customer-specific bus systems, Industrial Ethernet protocols and build- operating solutions, bene- ing automation systems such as LonWorks and BAC- fit from using Deutschmann net/IP. Deutschmann also offers variants with EIA- products compared with 232 or EIA-485 interfaces for RS-based protocols like developing our own solu- Modbus RTU and Modbus ASCII. tion. This way, we can supply

42 CAN Newsletter 4/2013 Pioneering new technologies Pioneering new technologies

® -3XL 32 bit electronic control unit ESX

Figure 3: The ready-to-install network nodes are available for all standard Industrial Ethernet variants and serial bus systems

® -3XL ESX

B32 bit controller with max. 136 I/Os and 4 × CAN BFreely programmable in „C“ and CODESYS BCertiﬁ ed for safety applications (SIL2, PLd) BIncluding Memory Protection

Pressurethin-film transmitter measuring element with

Figure 4: The Unigate CANopen range includes AS-i-CANopen, CX, the integrated IC CANopen type (front), and CL CANopen (from left to right) different Ethernet standard by data. The script also allows simply exchanging the net- for the integration of custom- work module for another er-specific commands, for M01-CAN model. linking actions with time and event-based triggers, and for displaying all data and status- B pressure ranges from 0 ... 10 bar to 0 ... 2000 bar es within the network. Since (Overall accuracy in the temperature compensated range: 1%) the compiled code com- Schlegel chose this network prises only a small amount B max. media temperature 150°C / max. ambient temperature 125°C node for a variety of reasons. of data and Unigate ICs B wetted parts and case in stainless-steel “In the end, the key factor for feature a large script mem- B CAN-Bus interface our decision was that Unigate ory, even extensive scripts ICs can be easily adapted to can be stored. The Proto- the protocol of our devices col Developer tool features via a script. We therefore no functions for debugging of longer need to make labori- large-scale scripts, such as Exhibitions ous changes to our firmware”, breakpoint, single-step, dis- Agritechnica, Hanover SPS/IPC/DRIVES, Nuremberg said Selig. The concise, C++- play of variables and their 10. – 16.11.2013 26. – 28.11.2013 based script language, which values as well as error dis- Hall 17, Both A34 Hall 7, Both 7-169 can be programmed by play. Since the series fea- means of the free-of-charge tures standardized hardware Protocol Developer Windows interfaces, generated scripts Sensor-Technik Wiedemann GmbH tool, enables users to emu- can be used for all serial bus Am Bärenwald 6 · 87600 Kaufbeuren late applications as well as systems and Ethernet-based Germany buffer and further process models of the series. Telephone +49 (0) 83 41-95 05-0

www.sensor-technik.de

Anzeige_CAN-Newsletter_04-2013 - ESX, M01-CAN - 100x297.indd 1 22.10.2013 15:59:08 2nd generation safety controller

Hardware for mobile applications

Alexander Holler, Hans-Dieter Kaiser

Introduction he processing power of The safety requirements Ta safety PLC is not only defined in EN ISO 13849 are getting more speed but also by its archi- and more relevant in tecture. To address the safe- the mobile machinery ty requirements in controller market. When comparing architectures two principles the requirements in are usual: Figure 2: Safety controller digsy fusion S dedicated C-level Firstly, the architecture standards for different could be realized as a cat- 3 system on the one hand mobile machines, egory 2 system according side and to take advantage it appears that to IEC 13849; the logic unit of the higher performance of Performance Level d (main processor) in that case the two main processors, the Even if a safety controller has (PL-d) is mainly is supervised by a test unit safety controller digsy fusion an internal category 3 archi- demanded for controllers (companion). This category S is based on a dual core tecture, it may also be inte- to achieve sufficient 2 architecture demands sig- safety processor as shown grated in category 2 machine functional safety. Not nificant processor resources in Figure 1. The dual core control systems. The digsy all C-level standards for self-test and thus limits safety processor integrates fusion S safety controller for demand to meet the the capacity available for the the two logics and is there- example is able to commu- safety requirements functionality itself. Further- fore able to manage the dis- nicate with safety sensors in set forth in the EN more specific C-level stan- tribution of the application two ways: either as a redun- ISO 13849 today. But dards like the EN 280 do program on the two cores dant or as a single channel when developing a not permit dedicated safety internally. The processing connection, depending on new machine with a life functions in category 2. of the application program the required safety level and cycle of 5 to 10 years, Secondly, category 3 is done on both processors the design of the sensor. Due the consideration of architectures are built with in parallel step by step. A to the still limited number of functional safety is two discrete main proces- step in this connection is the safety sensors available on inevitable. Beyond the sors. This offers higher smallest possible proces- the market it is useful to have performance level, performance but at higher sor operation, consisting of the opportunity to choose be- additional features costs than category 2 sys- reading and processing data tween both options – provid- of a safety controller tems. In addition, two ap- and writing results. Final- ed the required safety lev- help increase the plication programs, one for ly, the results of both cores el can be achieved in both sustainability and each logic (main processor), are compared. As the opera- ways. Controllers do not in- flexibility of the are required, which impos- tion of both cores is locked herently provide the option to es a higher work load on the together, this procedure is connect safety sensors with system. programmer. called lock step mode. just one channel. To support To avoid the inconve- For demanding appli- this single channel connec- nient handling of two applica- cations it might be neces- tion, the input of the control- tion programs as well as the sary to perform complex ler needs to have internal costs of a discrete category operations like trigonometric diagnosis to assure the de- calculations. In this case manded diagnostic cover- age. If this is available, safety are the appropriate pro- sensors could be connect- Input 1 Logic 1 Output 1 cessing platform to as- ed with a single channel con- sure reasonable calculation nection as shown in Figure 2. time. While the supervision Alternatively, redundant sen- of FPU operations in cate- sors or two sensors provid- gory 2 architectures is not ing redundant signals could Input 2 Logic 2 Output 2 feasible, dual core proces- be connected to the same sors provide the means to safety controller as shown in meet safety requirements Figure 3. without overload of internal This solution is typi- Figure 1: Category 3 architecture / integrated self-tests. cally implemented when the

44 CAN Newsletter 4/2013 relevant safety standards de- Safe communication is mand it or if category 2 sen- achieved through Safety Re- Sensor I1 Logic 1 sors are not available. As the lated Data Objects (SRDO). Q1 safety controller supports SRDOs have to be trans- Q connecting category 2 and mitted periodically within a Test unit S category 3 sensors, it pro- Safeguard Cycle Time (SCT). UB vides the flexibility to select A SRDO consists of two Figure 3: Single channel connection, typical for category the sensor by its performance CAN communication objects 2 architectures and not by its interface. (COB) CAN1 and CAN2 that have to be transmitted within the Safety Related Valida- Sensor I1 Logic 1 Q1 tion Time (SRVT). The two COBs differ in COB-Identifier QS In terms of field busses CAN (COB-ID) – min. 2 bit – and in Sensor Logic 2 is the standard protocol in normal (CAN1), respectively UB mobile machinery. The digsy bitwise inverted (CAN2) pay- Figure 4: Redundant connection, typical for category fusion S offers four CAN in- load. If a receiving node de- 3 architectures terfaces. Each provides dif- tects expired SCT or SRVT ferent protocols, as they are cycles or differences after possible to change the stan- Authors CANopen and J1939. Layer comparing the payloads of dard project without an ad- 2 programming serves as a CAN1 and CAN2, it will enter ditional safety analysis. The way to achieve any other de- safe state. Thus, a safe com- safety controller utilizes Cod- sired protocol. CANopen is munication is guaranteed that esys 3.5 SIL2 for running the widely used in mobile auto- meets the requirements of the safe and the standard project, mation. Many components, EN 61784-3 standard regard- thus it is ensured that just one i. e. sensors and actors, are ing message corruption, un- consistent programming envi- available on the market, us- intended repetition, incorrect ronment is necessary. ing this standard and meeting sequence, message loss, Alexander Holler the requirements for industri- message insertion, masquer- al and mobile applications. ade and addressing. CANopen offers all basic pro- Monitoring the machines tocol functionalities as a de- functionality regarding dan- fined system start up, network gerous conditions is one of management, system data the core tasks of a safety exchange, process data ex- The long life cycle of mo- controller. Once a dangerous change, synchronization and bile machines often requires condition is detected the ma- emergency messaging. The adapting their functionality chine is set in failsafe state required configuration of to changing market require- by the safety controller. This Hans-Dieter Kaiser CANopen communication ments. Digsy fusion S sup- is done by activating a sec- is performed using the stan- ports this through the abili- ond cut off path which de-en- Inter Control dard programming tool of the ty of running two projects in ergizes the outputs. Depen- Hermann Köhler Elektrik safety controller. If functional parallel. The first project (safe ding on the kind of failure GmbH & Co.KG safe communication via CAN project) is responsible for causing the dangerous con- Schafhofstraße 30 is required, CANopen Safe- safe machine functions, while dition it may be necessary DE-90411 Nürnberg ty standard (EN 50325-5) is the second project (standard to shut down the complete Tel.: +49-911-9522-851 recommended. It is a proto- project) takes care of all non- machine. But not all failures Fax: +49-911-9522-857 col extension of CANopen safety related functions like must cause a complete shut- and provides a safe commu- comfort functions. As the down. A safety analysis may Link nication between two or more standard project can not inter- lead to the result that a fail- www.intercontrol.de CAN network members. fere with the safe project, it is ure in one function does not have to automatically result in a shutdown of other machine functions. In this case it is useful to keep the functions unrelated to the failure alive to allow e.g. the recov- ering of the machine or complete the last maneuver. For Resumee Figure 5: CANopen Safety – Safeguard Cycle Time this reason the safety con- Performance, functionality troller provides four groups and conformity with the

of second cut off paths. This relevant safety standards Hardware enables the user to just shut do not exclude each down the outputs that are re- other. 2nd generation lated to the dangerous condi- safety controllers that tion. Other functions can be achieve PL-d according to kept alive even in case of a EN ISO 13849 provide the Figure 6: CANopen Safety – Safety Related Validation Time failsafe. necessary features.

CAN Newsletter 4/2013 45 From motor control to system monitoring

Engineering

Christof Hunger

Author he “Formula Student” is Tan international car racing competition where student teams compete with self-developed vehicles. In this competition, the success of a team does not only de- pend on the performance of the vehicle itself, but also on criteria, such as engineering, marketability and production Christof Hunger costs. Hilscher Gesellschaft für The Speeding Scientists Systemautomation mbH Siegen is one of these racing Rheinstr. 15 teams. After successful par- DE-65795 Hattersheim ticipation with convention- Tel.: +49-6190-9907-44 al vehicles during the 2009 Fax: +49-6190-9907-50 and 2010 race season, the [email protected] team developed for the first Figure 1: During a practice run time an electrically power car Links to participate in the Formula Primary function of the sen- www.hilscher.com Student Electric for the 2011 sor control system is to re- season. System automation ceive the analog information specialist Hilscher from Hat- provided by the various sen- A suitable interface card tersheim, Germany, accom- sors of the vehicle and trans- was required to transmit panied the team during the form it in a digital format in the telegrams of the sensor development of the racing real-time. This includes the system via the CAN network car and contributed interface exclusion of illogical values to the engine control system. cards for its electronic control as well as the detection of de- Hilscher provided the team Introduction system. fective sensors. with its CIFX 104 CANopen Perfectly tuned power Data communication master interface. It comes transmission is one between the sensor system in the form factor of an of the key factors in and the engine control sys- interface card and is avail- modern day racing tem takes place via the CAN able with a variety of inter- sports. A racing team at One vital factor for the abili- network (version 2.0A in lay- faces. The CANopen mod- the university of Siegen, ty of a racing car to transfer er 2 mode), which is the stan- ule of this card is able to also Germany has developed the energy of its engine to dard data network in the process layer 2 communica- a new electric racing the street is an efficient drive automotive field. tion. car. With a CANopen control system. However, master interface from such a system depends on gas pedal brake pedal steer angle wheel speed Hilscher they connected comprehensive information, the various sensors of which is provided by numer- metrology the vehicle to the engine ous sensors and transferred control system. to the engine control system CAN 2.0A in a form ready for processing. CIFX 104-COM For this purpose, the industry PC racing car Se-12e designed engine control by the Speeding Scientists real-time network Siegen features an engine frequency engine left engine right control system communicat- converter ing with a high-performance sensor control system. Figure 2: The system's architecture

46 CAN Newsletter 4/2013 SENSORS FOR MOBILE MACHINES

Figure 3: On the speedway

Figure 4: The S3-12e

One special advan- and the Speeding Scien- Absolute Rotary Encoders tage of the interface card tists Siegen also proved to for the race car S3-12e, was be successful. and Inclinometers the fact that its drivers al- At the Formula Stu- lowed seamless integration dent Germany 2011, which Reliable Measurement under of the data stream into the took place at the Hocken- engine control software run- heim race track in Germany, Harsh Conditions ning on a standard industry the team was able to reach PC. Additional advantages in the 17th place. Unfortu- were the highly robust de- nately, due to a technical High Protection Class: IP69K sign of the interface card defect of the break sys- as well as its high resis- tem, this position could not Fieldbus and Analog Interfaces tance against electromag- be topped anymore during netic interferences. After the season. But the team all, the car was based upon used the test runs for Safety and ATEX – Ex-Proof a low-weight design, which further optimization of the Versions Available required to exchange the vehicle. standard metal enclosure of As a result, the S3-12e the interface card by an es- was able to reach the 4th Successfully Integrated in pecially designed ultra low position at the Formula Concrete Pumps, Drilling Machines, weight enclosure made of Student Spain, which took carbon fiber. place at the Circuit de Cata- Working Platforms, Cranes, Wheel Loaders, lunya in Barcelona. This Leader Masts and More was the best position the Speeding Scientists Sie- Thanks to the CANopen gen had ever reached since master interface, the racing their participation in the team was able to realize Formula Student. seamless interaction be- After all, success is www.posital.com tween the sensor system usually the result of ex- and the drive control system perts getting together and of its race car. The coop- the right people forming a eration between Hilscher team.

POSITAL Germany, Singapore and USA www.posital.com, [email protected] Motor selection: Optimizing belt drives

Benno Wimmer

Motion control Motion

Author onveyor systems with CCAN network are be- coming ever more popular. The reason is the flexibility and simple controllabili- ty of several drives, which the network system provides. It is expected that the systems can be flexibly adapted to a certain extent, Benno Wimmer whether in terms of speed Nanotec Electronic or the loads that are to be GmbH & Co. KG transported. This also ap- Kapellenstr. 6 plies to the choice of drive. DE-85622 Feldkirchen, In conveyors for si- Figure 1: Comparison table of AC motor and Munich multaneous inspections or plug-and-drive stepper motor Tel.: +49-89-9006860 pick-and-place applica- [email protected] tions, for instance, it must be approx. 191 rpm, a drive and the encoder integrated possible to exactly move with a torque rating of 2,8 in the housing. This makes Links to precise positions. Only Nm is required. Here 0,8 them especially compact, www.nanotec.com a drive that knows its pre- Nm is factored in for an ac- and easy to install and concise position can be con- celeration speed of 0,7 s. trol. Only the power supply sidered for this purpose. A suitable asynchro- and the network still need Flexible speeds are anoth- nous motor (AC motor) to be connected. Plug- er point that appears on the would need a capacity of and-drive motors therefore wish list from time to time in at least 60 W in this case. correspond to the funda- terms of a flexible construc- With a construction volume mental CAN notion of a tion design. of 90 mm in diameter and simple, decentralized de- The selection of pos- 185 mm in length, including sign. They can be inte- sible drives is equally di- spur gearing of 7,5:1, this grated in conveyor rolls or verse: AC motors, BLDC motor would have a total rollers to form highly inte- motors or stepper motors weight of 4,3 kg. AC motors grated transport units and operated in closed loop require constant speeds. If can also be used as switch- configurations that behave a different speed is required ing points in conveyor sys- like multipole servo mo- due to the process flow, ei- tems. At a nominal speed tors – all of them are worth ther a new drive unit must or half speed, tests with a considering. The crucial be installed or, at best, the belt conveyor demonstrate factors in the choice of a gear replaced. If flexible an efficiency of 60 % or 45 suitable motor type are the processes are called for, % compared to 52 %, re- speeds required, the de- the situation might not be spectively 30 % with an mand for networking and so fortunate. AC motor. For smaller con- the desired flexibility of the Plug-and-drive motors veyor belts with a load of process. based on stepper motors 2 kg to 3 kg, the size of the We take a look at a are more flexible. With a AC motor normally needs classic example, where a size of 60 mm x 122 mm to be 60 mm (weight 1,6 weight is transported at a and a weight of 1,5 kg, a kg); if a plug-and-drive mo- predefined speed by a con- model tailored to the above tor is used, a size of 42 mm, veyor belt. For example, example is significantly which weighs just 0,4 kg, is if the belt is 4 m in length smaller and lighter than the sufficient. and has a roller diameter AC motor plus gear vari- Field-oriented control- of 6 cm to transport a part ant. Plug-and-drive motors led stepper motors behave load of 10 kg x 2 kg at a de- are stepper motors that al- like multipole servomotors. sired speed of 0,6 m/s, i.e. ready have the controller In addition, in most cases

48 CAN Newsletter 4/2013 they do not need any gearing because of the high torque in relation to speed. Only for high transport loads and very low speeds can a gear be necessary. Another point worthy of consideration is the efficiency. Whereas asynchronous motors (AC motors) build up a magnetic field in the rotor through the in- duced alternating field, synchronous motors, such as stepper motors or BLDC motors, have a permanent magnet in the rotor and thus at nominal speed have an efficiency factor ratio of 60 % to 80 %. The high efficiency of AC motors applies only to the bare motor, however. As part of new machinery directives, AC motors must Figure 2: Synchronization properties mean better processes or precision can be be equipped with soft start- achieved, even in the lower speed range; in the soldering example synchronization ers or standstill and speed properties mean the soldering time can be maintained exactly; varying soldering times monitoring. This reduces impair the soldering quality, and hence the long-term contacting efficiency. As for speed control, it is favorable to protects the motor bear- varied in the speed range servos – are recommend- use an AC motor plus ta- ings. The plug-and-drive of 25:1. If higher speeds ed for the lower speed chometer, which allows a motors contain a high-per- are needed with the same range or at speeds above speed range of approxi- formance microprocessor size and load, brushless 3000 rpm. Normal stepper mately 15:1 via a control that not only provides the DC motors (BLDC) are rec- motors, in contrast, are not unit. This method is also field-oriented control and ommended. These low- an alternative. They work favored if the speed re- controls the integrated pole motors are mainly in open loop, so deviations quired has not been exact- power output stage, but designed for higher speeds and false positioning can- ly determined at the start of also monitoring functions, (> 3000 rpm), but have not be detected. the project. The often-used e.g. for diagnosing over- much greater efficiency voltage/frequency control- load, blockage etc. Higher- than AC motors. The only ler causes higher losses in level movement states can drawback: They also need the driver at lower speeds. be queried via the inputs/ a gear. But their efficiency Commendable efficiencies outputs, logically linked is superior to AC motors. of approximately 60 % in and further processed in For the same transport task AC motors are not far off: the network via CANopen. (20 kg load + 5 kg belt), a the spur gear already ab- For straightforward set feed speed of 1,5 m/s (500 sorbs 18 % anyway and up and installation indepen- rpm) can be achieved with the driver decreases the dent of the CAN master, the a BLDC motor of 56 mm x power output even further. NanoCAN Window soft- 236 mm in size, including At speeds lower than the ware, which is used to read gear. These motors require nominal speed, the effi- and set all SDOs as well as external motor controllers ciency of an AC motor can to test runs in the various such as the SMCI36, which easily drop to less than modes without program- also has a field-oriented 30 %. ming knowledge, is avail- control and can also con- Stepper motors only able for Nanotec motor trol stepper motors. A CAN make sense as belt drives, controllers and plug-and- slave is integrated in the however, if they are operat- drive motors. Whether the same way as in plug-and- ed as multipole servos in a motor is operated in open drive motors. closed loop. The required or closed loop, can also be AC motors are reliable load current is adjusted by configured by manufactur- drives if the power require- the control loop and allows er-specific CAN objects. ments are constant and if the drive to respond flexi- The ideal operating size and energy efficiency bly to changing conditions. range of closed loop-driv- are irrelevant. But as soon Less heat is lost in the mo- en plug-and-drive motors as value is placed on flex- tor due to the efficient cur- ranges from 100 rpm to ibility, BLDC motors – such control Motion rent control. It remains 800 rpm, depending on as plug-and-drive stepper considerably cooler, which the motor type, and can be motors acting as multipole

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50 CAN Newsletter 4/2013 Solutions for Open Networks from one Source

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