EtherCAT Introduction 0802 GB

ETG, Februar 24th, 2008
EtherCAT is:
 faster
 Industrial
Ethernet
EtherCAT Introduction
 more flexible
to wire Guido Beckmann
 easier to
configure
EtherCAT Technology Group
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
28/02/22 EtherCAT: Ethernet Control Automation Technology
Industrial Ethernet
EtherCAT is:
 faster
 Industrial
EtherCAT Introduction
Ethernet
 more flexible
to wire
• Functional Principles
 easier to • Topology
configure
 lower cost • Benefits

 easier to
implement • Implementation
 well proven
• Application Fields
 open
 safety • Questions & Answers

 redundancy
 versatile
EtherCAT is the Ethernet Fieldbus
EtherCAT is: • EtherCAT is realtime down to the I/O level

 faster
• no underlying sub-systems any more
 Industrial
• no delays in gateways
Ethernet
• In- and outputs, sensors, drives, displays:
 more flexible
to wire everything on one system!
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is faster
EtherCAT is:
 faster
 Industrial
Ethernet
Transmission Rate: 2 x 100 Mbaud (Full-Duplex)
 more flexible
to wire
Update Times:
 easier to
configure • 256 digital I/O in 11 µs
 lower cost • 1000 digital I/O distributed to 100 nodes in 30 µs = 0.03 ms
 easier to
• 200 analog I/O (16 bit) in 50 µs, 20 kHz Sampling Rate
implement
 well proven • 100 Servo-Axis (each 8 Byte IN+OUT) in 100 µs = 0.1 ms

 open • 12000 digital I/O in 350 µs
 safety
 redundancy
 versatile
Functional Principle: Ethernet “on the Fly”
EtherCAT is:
Slave Device Slave Device
 faster
 Industrial
Ethernet EtherCAT Slave EtherCAT Slave
Controller Controller
 more flexible
to wire
 easier to
configure
Process data is extracted and inserted on the fly
 lower cost • Process data size per slave almost unlimited
 easier to (1 Bit…60 Kbyte, if needed using several frames)
implement
• Compilation of process data can change in each cycle,
 well proven
e.g. ultra short cycle time for axis, and longer cycles for
 open I/O update possible
 safety • In addition asynchronous, event triggered communication
 redundancy
 versatile
EtherCAT is:
Minimal protocol overhead via implicit addressing
 faster
 Industrial
IPC
Ethernet
 more flexible
to wire .. DVI
..
 easier to
configure
WKC
WKC
WKC
EH
EH
EH
Ethernet HDR FH Data Data Data CRC
 lower cost
• Optimized telegram structure for decentralised I/O
 easier to
implement • Communication completely in hardware: maximum
 well proven performance
 open
• no switches needed if only EtherCAT devices in the
network
 safety
• Outstanding diagnostic features
 redundancy
• Ethernet-compatibility maintained
 versatile
EtherCAT wiring is more flexible
EtherCAT is:
 faster Electrical Signal Variants: 100BaseTX and LVDS
 Industrial IPC
Ethernet
 more flexible
to wire
..
.. DVI
 easier to
configure Ethernet on LVDS
physical layer:
 lower cost for modular devices
 easier to
implement
Ethernet on
 well proven 100BASE-TX; any number of
up to 100 m, with
 open physical layer
transformer coupling
changes allowed
 safety
LVDS: Low Voltage Differential Signaling according to
 redundancy
ANSI/TIA/EIA-644, also used in IEEE 802.3ae (10Gigabit Ethernet)
 versatile
EtherCAT is:
 faster Switch
IPC
 Industrial
Ethernet
 more flexible
..
to wire
.. DVI
(optional!)
 easier to
configure
 lower cost
 easier to
implement
• Standard Switch can be used
 well proven
• With Switch: only one MAC address for up to 65535
nodes (segment addressing)
 open
• optional: Switch with VLAN Tagging allows for segment
 safety
adressing without MAC address
 redundancy
 versatile
Performance: Application Example
EtherCAT is: • 40 Axis (each 20 Byte Input- and Output-Data)

 faster • 50 I/O Station with a total of 560 EtherCAT Bus Terminals
 Industrial • 2000 Digital + 200 Analog I/O, Bus Length 500 m
Ethernet • Performance EtherCAT: Cycle Time 276µs
 more flexible at 44% Bus Load, Telegram Length 122µs
to wire
 easier to
configure
 lower cost
in spite of this cycle time still 56%
bandwidth remaining, e.g. for TCP/IP
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile * announced. Computed with Formulas from Ethernet Powerlink Spec V 2.0, App.3

Typical EtherCAT Device Architecture
EtherCAT is: EtherCAT Device

 faster
 Industrial optional
HTTP, FTP,… Application
Ethernet
 more flexible
to wire
TCP UDP Objects Cyclic
 easier to Synchronous
IP Asynchronous Communication
configure Communication (Implicit
(Explicit Addressing)
 lower cost Ethernet
Addressing)
 easier to EoE CoE CoE
implement Mailbox Process Data
 well proven
EtherCAT Slave Controller
 open
 safety Ethernet Physical Layer
 redundancy
 versatile
“Slow” Control Systems benefit, too!
EtherCAT is:
 faster Reaction time with legacy fieldbus I/O
 Industrial
Ethernet I PLC Task O I PLC Task O I PLC Task O I PLC Task O I PLC Task
 more flexible
to wire
Tmpd
 easier to
configure
Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle
 lower cost
 easier to
implement TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O
 well proven best case Reaction Time
worst case
 open Reaction Time Output
Input Input
 safety (Worst case) (best case)
Tmpd: Master Processing Delay
 redundancy
TI/O: Local I/O Update Time
 versatile (local Extension Bus + Firmware)
EtherCAT is:
 faster System Architecture with EtherCAT
 Industrial
 more flexible
to wire no dedicated Master Device any more
Tmpd
 easier to
configure
Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle
 lower cost
 easier to
implement TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O TI/O
 well proven no underlying extension bus any more
 open
 safety
 redundancy
 versatile
EtherCAT is:
 Industrial
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is:
 Industrial
 more flexible
to wire
 easier to
configure
 lower cost
 easier to TDMA (Time for Data Transfer

implement
T DMA (NIC) from/to Ethernet Controller via
 well proven Direct Memory Access):
 open neglectible
 safety T EtherCAT Cycle
 redundancy
 versatile
EtherCAT is:
 faster Reaction Time with EtherCAT
 Industrial
 more flexible
to wire
 easier to best
configure worst case case
Reaction Time
 lower cost Output
Input Input
 easier to (Worst case) (best case)
implement
 well proven • Reaction Time reduced significantly – with the same Controller Performance
 open • no underlying local I/O Cycles and extension bus delays any more
 safety • Due to the very simple protocol no dedicated master systems (e.g. plug in
cards) required
 redundancy
 versatile
Fieldbus: requires Mapping in Control System
EtherCAT is: • Traditional fieldbus system generate physical process image

• This has to be mapped to logical process image(s)
 faster
 Industrial
Ethernet
Control System, e.g. IPC
 more flexible
Feldbus Scanner/
node 1
to wire
DPRAM Master
logical process images
 easier to node 1
configure Data n
PLC Data
node 2 node 2
 lower cost
NC Data
 easier to
node 3
implement
node 4
 well proven node 3
 open
Mapping
 safety
 redundancy node 4
 versatile
Fieldbus: requires Mapping in Control System
EtherCAT is: • The same applies to control system with just one process image
• Resorting of process data (“Mapping”) is required, too
 faster
 Industrial
Ethernet
Control System, e.g. PLC
 more flexible
Feldbus Scanner/
node 1
to wire
DPRAM Master
logiscal process image
 easier to node 1
configure
node 2 node 2
 lower cost
Process
Data
 easier to
node 3
implement
node 4
 well proven node 3
 open
Mapping
 safety
 redundancy node 4
 versatile
EtherCAT: Mapping moved into Slave Devices
EtherCAT is:
IPC
 faster
 Industrial
Ethernet ..
..
DVI
232 Telegram Structure

 more flexible
logical process image: up to 4 GByte
Ethernet HDR HDR 1 PLC Data HDR 2 NC Data HDR n Data n CRC
to wire
 easier to
Data n
configure
PLC Data
 lower cost
NC Data
Sub- Sub- Sub-
 easier to Telegram 1 Telegram 2 Telegram n
implement
 well proven
• Control System is unburdened,
 open
Master becomes very simple
 safety 0
• Data is transmitted according to the application
 redundancy
requirements: extremely fast, flexibly and efficiently
 versatile
Direct Memory Access saves Time
EtherCAT is:
 faster
PC Control with Fieldbus Cards
 Industrial Fieldbus Cards: up to PC RAM
Ethernet 30% of CPU Time
 more flexible for Data Copying Scanner card, DP RAM
Control task
to wire PCI
CPU
bus memcopy
 easier to
configure
 lower cost
EtherCAT: NIC is
 easier to PC Control with EtherCAT
PCI Bus Master, Data PC RAM
implement
is provided by DMA, NIC card, DMA transfer CPU
 well proven Control task
directly to PC RAM :
 open
• CPU relieved PCI
DMA
bus
 safety • more Performance
 redundancy
 versatile
EtherCAT Distributed Clocks
EtherCAT is:
 faster Precise Synchronisation (<< 1 µs!) by exact
 Industrial adjustment of distributed clocks
Ethernet S
M
 more flexible ∆t
to wire IPC
 easier to
configure S S
..
.. DVI
 lower cost
 easier to
implement
S S S S S
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT Propagation Delay Measurement (I)
EtherCAT is:
 faster EtherCAT Node measures time difference
 Industrial between leaving and returning frame
Ethernet
 more flexible
to wire
 easier to EtherCAT Frame

vom Master
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT Propagation Delay Measurement (II)
EtherCAT is:
 faster Propagation delays between any nodes can be
 Industrial computed
Ethernet
 more flexible
to wire IPC
 easier to
configure
..
.. DVI
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT Distributed Clocks
EtherCAT is: Long Term Scope View of two seperated Devices

 faster
300 Nodes in between, 120m Cable Length
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure Simultaneousness:
~15 ns
 lower cost
Jitter: ~ +/-20ns
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is Industrial Ethernet!
EtherCAT is: • Any Ethernet Device can be connected to Switchport

 faster
• Access to Webserver with Standard-Browser Webserver
 Industrial
Ethernet virtual
Ethernet
 more flexible Switch
Functionality Switchport
to wire
IPC
 easier to
configure
 lower cost
..
.. DVI
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
Switchport: Any Ethernet Protocol
EtherCAT is: • Interface to any Ethernet Device or Network

 faster • Ethernet Frames are inserted into EtherCAT Protocol
 Industrial • “Ethernet over EtherCAT”
Ethernet
 more flexible EtherCAT Switchport

to wire
 easier to Ethernet MAC PHY

configure
 lower cost RX1 RX2TX

RX RX3 RX4
µC
 easier to Fragmentation
implement
Mailbox Process Data
 well proven
PHY EtherCAT MAC / DLL PHY
 open
TX2
TX3
TX1 TX1
TX3
TX2
 safety
 redundancy
 versatile
EtherCAT is Industrial Ethernet!
EtherCAT is: • Virtual Ethernet Switch routes any Ethernet Frame

 faster
• From inside as well as from outside the segment
 Industrial
Ethernet virtual
Switchport
Ethernet
 more flexible Switch
Functionality
to wire
IPC
 easier to Switch
configure
 lower cost
..
.. DVI
 easier to
implement
 well proven
Switch
 open
 safety
 redundancy
 versatile
Vertical Integration (I)
EtherCAT is:
 faster
 Industrial ...via Switch

Ethernet
 more flexible IPC

Switch
to wire
 easier to
configure ..
.. DVI
 lower cost
 easier to + any Ethernet Protocol can be used

implement
+ requires only one Ethernet Port (at IPC/Controller)
 well proven
 open
- but: performance reduced by switch delay (and generic
Ethernet traffic)
 safety
 redundancy
 versatile
Vertical Integration (II)
EtherCAT is:
 faster
...via Switchport Terminal
 Industrial
Ethernet

to wire
 easier to
configure ..
.. DVI
 lower cost

implement
+ requires only one Ethernet Port (at IPC/Controller)
 well proven
 open
+ EtherCAT performance is not limited
 safety
 redundancy
 versatile
Vertical Integration (III)
EtherCAT is:
 faster ...via 2nd Ethernet Port
 Industrial
Ethernet

to wire
 easier to
configure ..
.. DVI
 lower cost

implement
+ EtherCAT performance is not limited
 well proven
 open
- requires second Ethernet Port (at IPC/Controller)
 safety
 redundancy
 versatile
EtherCAT: Flexible System Architecture
EtherCAT is: Master ↔ Slave

 faster Master ↔ Master
 Industrial Slave ↔ Slave
Ethernet Master
IPC
 more flexible
to wire
 easier to Switch
configure ..
.. DVI
 lower cost
Master
 easier to IPC
implement
 well proven
..
 open
.. DVI
 safety
 redundancy
 versatile
EtherCAT is:
 faster Standard Ethernet Topology: Star
 Industrial not ideal – here a test setup for demo purposes ;-)
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is:
 faster Line-Topology: any number of nodes lined up
 Industrial IPC
Ethernet
 more flexible
to wire
..
.. DVI
 easier to
configure
 lower cost
 easier to
implement
 well proven
up to
65535
 open
nodes
 safety
 redundancy
 versatile
EtherCAT is:
 faster Topology-Variant: “Daisy Chain”
 Industrial IPC
Ethernet
 more flexible
to wire
..
.. DVI
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy Cable: Standard CAT5 Cable

without “Crossover”
 versatile
EtherCAT is:
 faster Topology-Variant: “Daisy Chain” with Drop Lines
 Industrial IPC
Ethernet
 more flexible
to wire
..
.. DVI
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety

 versatile
EtherCAT is:
 faster flexible tree structures – arbitrarily extendable
 Industrial IPC
Ethernet
 more flexible
to wire
..
.. DVI
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety

 versatile
EtherCAT instead of PCI
EtherCAT is: Protection of your investment:
 faster
• Seamless integration of
existing fieldbus devices
• Process image update-time
via PCI (500 Bytes input
and output data each): 400µs
• Process image update-time
via EtherCAT (1500 Bytes
input and output data): 150µs
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT instead of PCI
EtherCAT is: • No Slots in Control System

(IPC or SPS) required any more
 faster • Nevertheless maximum expandability
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost EtherCAT
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is easier to configure
EtherCAT is:
 faster Addressing:
 Industrial
Ethernet
• No manual address setting required
 more flexible
to wire
• Addresses can be assigned automatically
 easier to • Addresses can be kept – no new addressing if
configure
nodes are added
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is easier to configure
EtherCAT is:
 faster
Topology:
 Industrial • Automatic topology target/actual comparison
Ethernet
Diagnosis:
 more flexible
to wire • Diagnosis with exact localisation
 easier to
configure Network planning:
 lower cost • Performance independent of:
 easier to
implement
– Slave implementation
 well proven – Topology (no Switches/Hubs)
 open
 safety
 redundancy
 versatile
EtherCAT is lower costs (I):
Engineering
EtherCAT is:
 faster Less effort for Network planning:
 Industrial • Simplified Configuration
Ethernet
 more flexible
• Default settings will so,
to wire no network tuning
 easier to
configure
Improved Diagnosis:
 lower cost • Faster Error Handling leads to less Downtime
 easier to
implement
Faster Setup:
 well proven • no Address setting required
 open
 safety
 redundancy
 versatile
EtherCAT is lower costs
EtherCAT is:
 faster
 Industrial Master:
Ethernet no dedicated plug in card (co-processor),
 more flexible on-board Ethernet Port is fine
to wire
 easier to
configure
Slave:
 lower cost - low cost Slave Controller
 easier to - FPGA or ASIC
implement - no powerful µC needed
 well proven
 open Infrastructure:
 safety - no Switches/Hubs required
 redundancy - Standard Ethernet Cabling
 versatile
EtherCAT Slave Controller Features (Generic)
EtherCAT is: • Handles Real-time Protocol in Hardware

 faster
• Integrated Communication State Machine
 Industrial
• Network Performance independent of
Ethernet
– Slave-µC Performance
 more flexible
to wire – Protocol Stack
 easier to
configure
• For usage with or without µC (Host-CPU)
 lower cost
• Integrated DPRAM (1…8kByte)
 easier to
• Integrated Distributed Clock Handling
implement – Ultra precise interrupts to µC
 well proven
 open
 safety
 redundancy
 versatile
ASIC Slave Controller Features (ET1100/1200)
EtherCAT is: ASIC

 faster
 Industrial ET1100 ET1200

Ethernet Housing BGA128, QFN48
0,8mm pitch, 0,5mm pitch,
 more flexible
to wire 10x10mm 7x7mm
 easier to FMMU 8 3
configure
Sync-Manager 8 4
 lower cost
RAM 8 kByte 1 kByte
 easier to
implement Distributed Clocks  
 well proven PDI – digital I/O 32bit 16bit
 open PDI - SPI  
 safety
PDI – 8/16 bit µC Intel -
 redundancy
No of Ports 4 2 (1 x MII)
 versatile
EtherCAT Slave Controller ASICs
EtherCAT is:
 faster
 Industrial
Ethernet
ET1200
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
ET1100
 well proven
 open
 safety
ET1100 + ET1200 ASIC
(Beckhoff)
 redundancy
 versatile
EtherCAT Slave Implementation
EtherCAT is:
 faster
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
EtherCAT Interface for I/O Terminal, ET1200 ASIC
(Beckhoff)
 redundancy
 versatile
EtherCAT is:
 faster
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
EtherCAT Interface with ET1100 ASIC
(Beckhoff)
 redundancy
 versatile
IP-Core Slave Controller Features (ET1810/1812)
EtherCAT is: FPGA

 faster
IP-Core: Altera
 Industrial
Ethernet ET1810/1812
 more flexible
Supported FPGA Types Cyclone I,II (+III), Stratix I+II
to wire
 easier to No. of FMMU 0..8 (configurable)

configure
Sync-Manager 0..8 (configurable)
 lower cost
RAM 1..60 kByte (configurable)
 easier to
implement Distributed Clocks 
 well proven PDI – digital I/O 32bit
 open PDI - SPI 
 safety
PDI – 8/16 bit µC (+Avalon®) 
 redundancy
No of Ports 2 x MII / RMII
 versatile
IP-Core Slave Controller Features (ET1815)
EtherCAT is: FPGA

 faster
IP-Core: Xilinx
 Industrial
Ethernet ET1815
 more flexible
Supported FPGA Types Spartan 3+3E+3A,
to wire
Virtex II+II Pro+4+5
 easier to
configure No. of FMMU 0..8 (configurable)
 lower cost Sync-Manager 0..8 (configurable)
 easier to RAM 1..60 kByte (configurable)
implement
 well proven
Distributed Clocks 
 open PDI – digital I/O 32bit
 safety PDI - SPI 
 redundancy PDI – 8/16 bit µC (+OPB®) 
 versatile No of Ports 2 x MII / RMII
IP-Core Configuration Options (ET18xx)
EtherCAT is: Number of Logic Elements (LE)

 faster depends on configuration
 Industrial
Ethernet Examples:
 more flexible Small Configuration: ~ 5800 LE
to wire •32Bit digital IO, 1kByte RAM,
 easier to •without Distributed Clocks
configure • 2 FMMU, 2 SyncManager
 lower cost
 easier to XL-Configuration: ~15000 LE

implement •16Bit µC Interface, 32kByte RAM,
 well proven • with Distributed Clocks,
• 8 FMMUs, 8 SyncManager
 open
 safety
DC: ~ 3100 LE, SM: ~400 LE, FMMU: ~600 LE
 redundancy
 versatile
IP-Core Slave Controller Features (netX)
EtherCAT is: netX 100/500

 faster
 Industrial
Ethernet netX 100/500
 more flexible Housing PBGA 345, 22x22mm
to wire
No. of FMMU 3
 easier to
configure Sync-Manager 4
 lower cost RAM 256 Bytes Mailbox, 256
Bytes Process Data
 easier to
implement Distributed Clocks 
 well proven digital I/O 16
 open PDI – µC 32Bit Data, 24 Bit Address
 safety No of Ports 2
 redundancy Specials Multi Protocol Support,
Integrated: PHYs, ARM µC
 versatile
EtherCAT is:
 faster
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
EtherCAT Interface, NETX 500
(Hilscher)
 redundancy
 versatile
EtherCAT is:
 faster
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
EtherCAT Interface Board, Anybus-S
(HMS)
 redundancy
 versatile
EtherCAT Slave Controller without Host CPU
EtherCAT is: 4 Groups of 8 binary Signals

 faster 8 I/O 8 I/O 8 I/O 8 I/O
 Industrial
Ethernet
EtherCAT
I/O Application
 more flexible Slave
to wire Controller
Process Data Service Data
 easier to Dual Port Memory non volatile Data EEPROM
configure
 lower cost Sync-Manager, FMMU Registers
 easier to
implement Auto-Forwarder with Loop Back
 well proven EtherCAT MAC EtherCAT MAC

MII MII
 open
 safety
Trafo
Trafo
RJ45
RJ45
PHY PHY
 redundancy
 versatile
EtherCAT Slave Controller without Host CPU
4 Groups of 8 binary Signals
EtherCAT is:  EtherCAT State Machine 8 I/O 8 I/O 8 I/O 8 I/O
 faster handled by EtherCAT

Slave Controller I/O Application EtherCAT
Slave
Controller
 Industrial Process Data Service Data
Ethernet  No Mailbox Dual Port Memory non volatile Data
 No Object Dictionary Sync-Manager, FMMU Registers
 more flexible
to wire  Up to 32 signals can be Auto-Forwarder with Loop Back
connected directly EtherCAT MAC

MII
EtherCAT MAC
MII
 easier to  32 Bit input interface
configure
 32 Bit output
Trafo
Trafo
RJ45
RJ45
PHY PHY
 lower cost  24 Bit input / 8 Bit output

 easier to  16 Bit input / 16 Bit output
implement  8 Bit input / 24 Bit output
 well proven
 Boot Configuration and
Slave Informationen (Identification) in
 open serial E²PROM
 safety
 redundancy
 No Software required
 versatile
EtherCAT Slave Controller with Host CPU
EtherCAT is: Host CPU HTTP,

FTP,… RAM for TCP/IP
 faster and complex
Service
TCP/IP Applications
 Industrial Process Data Data
(optional)
Ethernet
 more flexible EtherCAT

Application Mapping
to wire Slave
Controller
Process Data Mailbox
 easier to EEPROM
Dual Port Memory non volatile Data
configure
 lower cost
Sync-Manager, FMMU Registers
 easier to
implement Auto-Forwarder with Loop Back
 well proven
EtherCAT MAC EtherCAT MAC
 open MII MII
 safety
Trafo
Trafo
RJ45
RJ45
 redundancy PHY PHY

 versatile
Host CPU HTTP,
EtherCAT is: 8/16 Bit µC Interface

and complex
Service
TCP/IP Applications
Process Data Data
 faster  Demultiplexed Application Mapping

(optional)
EtherCAT
 Industrial  Intel Signal Types Process Data Mailbox

Slave
Controller
Ethernet  Polarity configurable

Dual Port Memory non volatile Data
 more flexible (BUSY, INT) Sync-Manager, FMMU Registers
to wire  Typical µC: Auto-Forwarder with Loop Back
EtherCAT MAC EtherCAT MAC
 easier to  Intel 80x86, Infineon 80C16x, MII MII
configure Hitachi SH1, ST10, ARM,
Trafo
Trafo
RJ45
RJ45
PHY PHY
TI TMS320 Serie
 lower cost
 easier to
implement
SPI - Interface
 well proven
 Up to 10 MBaud
 open
 µC is SPI Master
 safety Typical µC:
 redundancy  Microchip PIC, DSPic, Intel 80C51,…
 versatile
Host CPU HTTP,
EtherCAT is:
Features Process Data

Service
Data
TCP/IP
and complex
Applications
 faster
 EtherCAT State Machine
(optional)
EtherCAT
Application Mapping
Slave
 Industrial
 CoE (CANopen over EtherCAT):
Controller
Process Data Mailbox
Ethernet Dual Port Memory non volatile Data
 Mailbox with SDO Protocol Sync-Manager, FMMU Registers

 more flexible
to wire  Object Dictionary with Auto-Forwarder with Loop Back
Mandatory Objects EtherCAT MAC

MII
EtherCAT MAC
MII
 easier to
configure  Device Type
Trafo
Trafo
RJ45
RJ45
PHY PHY
 lower cost
 Identity Object
 Physical Address
 easier to
 PDO Mapping and related Objects
implement
 Sync Manager Communication Type
 well proven
 Sync Manager PDO Relation
 open  or: SoE (Servodrive profile (IEC61491*) over EtherCAT)
 safety  optional: EoE (Ethernet over EtherCAT)
 redundancy
 versatile * also known as SERCOS Standard

EtherCAT Slave Evaluation Kit by Beckhoff
EtherCAT is: Programmer for PIC Programm &

EtherCAT
 faster Slave Controller Board FPGA Debug Interface Power
Supply
 Industrial
Ethernet
 more flexible
to wire
 easier to
PDI
configure
Selector
Basic
 lower cost Board
EL9800
 easier to
implement SPI
 well proven
 open
 safety
32 bit
 redundancy 8/16bit µC PIC over SPI
parallel
interface
interface
 versatile
EtherCAT Slave Evaluation Kit by Beckhoff
EtherCAT is: Overview

 faster
 Industrial • EL9800 Evaluation Base Board with

Ethernet – 24V Power Supply
 more flexible
– ESC Interface ribbon cable connectors
to wire – MicroChip PIC 8Bit µC
 easier to
– FPGA programming interface
configure • FB1120 100BASE-TX-Piggyback ESC Board
• USB Cable (for PIC Programming)
 lower cost
• 1:1 D-Sub25 Cable (for FPGA Programming)
 easier to • TwinCAT 2.10 (Evaluation License)
implement
• Slave Sample Code Licence (C Source) for PIC Controller and others
 well proven • Manual
 open
 safety
• Optional: 1 Day Workshop
Recommendation!
 redundancy
 versatile
Slave Evaluation Kit by EBV
EtherCAT is:
Overview
 faster  The DBC2C20 is a Cyclone II Development Board with several I/O
transceiver for industrial communication purposes. The following
 Industrial features are integrated:
Ethernet
 EP2C20F484C7
 more flexible  LVDS TFT interface
to wire
 16Mbyte SDRAM
 easier to  1Mbyte SRAM
configure
 8Mbyte flash
 lower cost  2x CAN transceiver
 easier to  4x RS485 transceiver
implement  2x 12 pin connector
 well proven  16bit 24V I/O interface
 open  8x User LEDs
 2 digit seven segment display
 safety
 on board 3.3V / 1.2V power supply
 redundancy
 versatile
Slave Evaluation Kit by Hilscher
EtherCAT is: netX 100 Starter Board Overview

 faster
 Industrial  NXSB100 Board

Ethernet
 EtherCAT Slave Evaluation Plattform
 more flexible with/for NetX100
to wire  The most economical way of familiarizing oneself
 easier to with the software development of the netX.
configure  4 MByte of Flash and 8 MByte SDRAM.
 lower cost  A RS232C, a USB and a JTAG interface
are available for loading and debugging.
 easier to
 Two EtherCAT Ports, a PROFIBUS and a
implement
DeviceNet interface are available for
 well proven communication. The Dual-port-memory that can
also be configured as extension bus or general
 open
I/Os are output on a pin strip
 safety
 redundancy
 versatile
EtherCAT Slave Sample Code by Beckhoff
EtherCAT is: Slave Sample Code

 faster
 Industrial • Bus handling contained in EtherCAT Controller

Ethernet
• Handling of enhanced EtherCAT State Machine
 more flexible
to wire • Mailbox Handling
 easier to • Protocol Handler for
configure
– CoE (CANopen over EtherCAT)
 lower cost
– FoE (File Access over EtherCAT)
 easier to – EoE (Ethernet over EtherCAT)
implement
– SoE (Servodrive Profile over EtherCAT)
 well proven
• Example applications to all variants
 open
• For usage in own products – comes with Evaluation Kit!
 safety
 redundancy
Code is also used in Beckhoff Products
 versatile
Microcontroller Requirements (Slave Host CPU)
EtherCAT is:
 faster
• Simple (I/O) Devices do not require a µC at all
 Industrial
Ethernet • Tasks of µC in more complex devices:
 more flexible – Process data – Exchange with the application
to wire
– Object Dictionary Handling
 easier to
configure – Handling of Application Parameter
 lower cost
(Communication Parameter are handled by ESC)
– TCP/IP Stack Handling – if required
 easier to
implement • µC-Performance is determined by Device
 well proven Application, not by EtherCAT Communication
 open  In many cases an 8bit µC is sufficient
 safety
 redundancy
 versatile
EtherCAT is easier to implement
EtherCAT is: Master:

 faster
• Master Sample Code (Source)
 Industrial
• EtherCAT configuration tool
Ethernet
Control Task
 more flexible
to wire System
Device
Description
Configuration
 easier to (XML) Tool
configure
Process
Image
 lower cost Description
(XML)
 easier to Network
implement • XML Data formats Description
HDR Process Data
incl. Boot-Up
(XML)
 well proven
 open
EtherCAT Master
 safety
 redundancy Standard Ethernet MAC

 versatile
Master Implementations: RTOS
EtherCAT is: Selection of Real Time Operating Systems

 faster used with EtherCAT Masters:
 Industrial
• eCos
Ethernet • InTime
 more flexible • Proconos OS
to wire • Real Time Java
 easier to • RMOS open source
configure • RT Kernel code available
 lower cost • RT Linux
• RTXC Quadros
 easier to
implement • QNX
 well proven
• VxWin + CeWin
• VxWorks
 open
• Windows CE
 safety • Windows XP/XPE with Codesys-SP
 redundancy • Windows XP/XPE with TwinCAT RT-Extension
 versatile
• XENOMAI Linux
EtherCAT is well proven
EtherCAT is: • in series production since 2003

 faster • more nodes shipped than
PROFINET, Powerlink V 2
 Industrial
Ethernet and SERCOS III alltogether…
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT Architecture + Device Profiles

 faster
HTTP, FTP,…The SERCOS* Device Application The
File System,
 Industrial Bootloader
Standard CANopen
Ethernet
Standard
 more flexible
to wire IDN Object Dictionary Process Data
TCP UDP
 easier to
IP Service Channel SDO PDO
configure File Access AT
EN 50325-4 Map-
IEC 61800-7-204
MDT
 lower cost Ethernet IEC 61800-7-201 ping
IEC 61800-7-304 IEC 61800-7-301
 easier to FoE EoE SoE CoE CoE/SoE
 well proven
 open
 redundancy
 versatile *SERCOS interface™ is a trademark by SI e.V.

Typical EtherCAT Device Architecture

 faster Device
HTTP, FTP,… Application Profile
 Industrial optional Definitions
Ethernet
 more flexible
to wire
TCP UDP Parameters Cyclic
 easier to Synchronous
IP Asynchronous Communication
configure Communication (Implicit
(Explicit Addressing)
 lower cost Ethernet
Addressing)
 easier to EoE CoE/SoE CoE/SoE
 well proven
 open
 redundancy
 versatile
IEC 61491 EtherCAT Servodrive Architecture

 faster
HTTP, FTP,…
Servodrive
 Industrial optional Application
Ethernet
 more flexible
to wire IEC 61800-7-204
TCP UDP IDN
Process Data: is the
 easier to AT / MDT
configure IP Service Channel SERCOS*
Ethernet
Servodrive Profile IEC 61800-7-204 Drive
 lower cost Mapping to EtherCAT: IEC 61800-7-304
Profile
 easier to EoE SoE SoE
 well proven
 open
 redundancy
 versatile * SERCOS interface™ is a trademark by SI e.V.

EtherCAT in IEC 61800-7:
Profiles for electrical power drive systems
EtherCAT is: IEC 61800-7: Generic Interface and use of profiles for power drive systems
 faster
IEC 61800-7-1: Interface Definition
 Industrial
Ethernet Annex A: Annex B: Annex C: Annex D:
Mapping to Mapping to Mapping to Mapping to
 more flexible
to wire DS402 CIP PROFIdrive SERCOS
 easier to
configure IEC 61800-7-200: Profile Specifications
 lower cost IEC 61800-7-201: IEC 61800-7-202: IEC 61800-7-203: IEC 61800-7-204:
Profile Profile Profile Profile
 easier to
implement
CiA 402 CIP Motion PROFIdrive SERCOS
 well proven
IEC 61800-7-300: Mapping of Profiles to Network Technologies
 open
 safety
IEC 61800-7-301 B C IEC 61800-7-304
Mapping to Mapping to Mapping to ... ... Mapping to Mapping to Mapping to
 redundancy CANopen EtherCAT EPL SERCOS I/II SERCOS III EtherCAT
 versatile
EtherCAT is an open technology
EtherCAT is:
 faster
 Industrial
Ethernet • Foundation: November 2003
• Tasks: Support, Advancement and Promotion of EtherCAT
• Already more than 650* member companies from
38 countries in 6 continents:
– Device Manufacturers
 more flexible
– End Users
– Technology-Provider
• Membership is open to everybody
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile •as of Feb 2008

Membership Development
EtherCAT is: As of Feb 11th, 2008: 682 Members
 faster
700
 Industrial 634
Ethernet
575 600
 more flexible since Nov 06: 515
to wire
+ 230, + 57% 500
458
 easier to
404
configure 400
357
 lower cost 321
285 300
 easier to 240
214
implement 188
169 200
136
 well proven 89
117
59
33 100
 open
Nov Feb Mai Aug
 safety 03 04 04 04
Nov Feb Mai
Aug Nov Feb
04 05 05 Mai Aug Nov 0
05 05 06 Feb Mai Aug
06 06 06 Nov
 redundancy 07 07 07 07
 versatile
ETG Team worldwide
EtherCAT is:
 faster
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
ETG Office
 well proven Japan
ETG Headquarter Tokyo
ETG Office Germany ETG Office
 open North America Nuremberg China
ETG Office
Austin, TX Beijing Korea
Seoul
 safety
 redundancy
 versatile
Members from 38 Countries, 6 Continents
EtherCAT is:
 faster
Australia Austria Belarus Belgium Brazil Canada
 Industrial
Ethernet
 more flexible China Croatia Czech Rep Denmark Finland France

to wire
 easier to
configure
Germany Greece Hungary India Israel Italy Japan
 lower cost
 easier to
implement Korea Liechtenstein Netherlands Norway Poland Russia Serbia
 well proven
 open
Singapore Slovakia Slovenia South Africa Spain Sweden
 safety
 redundancy
Switzerland Taiwan Turkey Ukraine United Kingdom USA
 versatile
EtherCAT Technology Group Members (as of Sept 2007)
EtherCAT is:
 faster
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
ETG: Active Members
EtherCAT is: • Much more important than membership figures: how many are
 faster active, how many implement the technology?
 Industrial • May 2007: More than 330 Implementation Kits sold to ETG Members
Ethernet (30% Master, 70% Slaves), plus there are Open Core masters!
 more flexible • Hannover Fair 2007: 46 Vendors with over 90 different EtherCAT
to wire Devices at ETG booth
 easier to – among those 20 drives
configure and 20 different
 lower cost
Masters in function,
using 10 different
 easier to operating systems
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT: Large Product Selection
EtherCAT is:
 faster
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
I/O
Controller
 well proven
Servo Drives
 open Variable Speed Drives
 safety Sensors, Hydraulic Valves
 redundancy
Slave + Master Development Kits
HMI, Control Panels, Pneumatic Valves,…
 versatile
Adoption Rate in Motion Control
EtherCAT is: 50
 faster 43 as of 01/2008:
45
15 additional Servo Drive Supplier
 Industrial vendors show
Ethernet
40
36 EtherCAT Fieldbus Support
35 Servo Drives according to
 more flexible
to wire 30
31 Servos Drive Market Survey
 easier to
conducted by largest
25
configure German Automation
 lower cost
20
16
Magazine 8/2007
15
15 13
 easier to 12
implement
Industrial Ethernet
10
7 6 6
 well proven 4
5
2 2 2 1 1 1 1 1
 open 0
t I t I t
 safety pe n bus AT ne I/I t /IP bu s inet bu s l ink ne link s-II ync CP ln e / IO ara
n
o of i C e s e d f r r q o o s T o P
AN Pr
r ic
h e ev erc her
o n
M
o
Pr
o e e n
nt ow Sy h a
tr /
rc Jet u s nt r FI V
 redundancy C t t I c S e b o
E D S E P e od C
M M
 versatile
EtherCAT Servo Drive Suppliers
(Products shown in Public as of Jan 2008)
EtherCAT is:
 faster
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT Servo Drive Suppliers
(Products shown in Public as of Jan 2008)
Manufacturer Drive
EtherCAT is: ACS Motion Control SPiiPlus CM
AMK KE/KW
 faster Baumüller bmaXX4000 bmaXX3000 bmaXX1000
Beckhoff AX2000 AX5000
 Industrial Bosch Rexroth IndraDrive Cs
Copley Controls Accelnet
Ethernet Danaher Motion S300 S700 Sdrive 305
DSP WILDCAT 400
 more flexible Elmo Motion Control SimplIQ
to wire Emerson Control Techniques Unidrive SP
ESR Pollmeier TrioDrive
Föhrenbach unipos C220
 easier to Hitachi AD Series
configure IDAM DSMRW
Jenaer Antriebstechnik ECOVARI0 414
 lower cost KEB Combiver F5
Kuhnke Ventura Fuxx
Lenze Lforce 9400
 easier to LinMot E1150
implement LS Industrial Systems XGT
Lust Antriebstechnik ServoOne
 well proven Metronix DIS-2
Moog MSD
Parker Compax3M
 open Samsung Electronics SNC/DSK?
Schneider Berger Lahr IclA
 safety Sdrive Sdrive® Standard
Servo Dynamics EC Series
SEW Eurodrive MOVIDRIVE® MDX60B/61B
 redundancy Stöber MDS5000 FDS5000
TDE Macno OpenDrive
 versatile
EtherCAT is an open technology
• Protocol is disclosed completely:
EtherCAT is:
• EtherCAT is IEC and ISO Standard
(IEC 61158, IEC 61784-2, ISO 15745-4)
• Slave Controller from several sources available

• Slave Controller provides interoperability
 faster
• Master Stacks for various RTOS available
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
Safety over EtherCAT: Features (I)
EtherCAT is: • Safety over EtherCAT (FSoE) defines a safety

 faster
communication layer for the transportation of safety process
 Industrial data between safety over EtherCAT devices.
Ethernet
 more flexible • FSoE is an open technology within the EtherCAT

to wire Technology Group (ETG).
 easier to
configure • The protocol is approved by an independent Notified Body
 lower cost
(TÜV Süd Rail).
 easier to • Residual Error Probability R(p) < 10-9
implement
• The protocol is developed according to IEC 61508
 well proven
 open • It meets the Safety Integrity Level SIL 3

 safety
 redundancy
 versatile
Safety over EtherCAT: Software Architecture
EtherCAT is: Device 1 Device 2
 faster
Safety Safety
 Industrial Application Application
Ethernet
Standard Standard
 more flexible Application Application
to wire
Safety
 easier to
FSoE FSoE over
configure EtherCAT
Protocol Protocol
 lower cost
EtherCAT EtherCAT EtherCAT
 easier to Communication Interface Communication Interface DLL and AL
implement
 well proven EtherCAT Telegram
 open
Safety data container (FSoE Frame)
 safety
 redundancy Black channel approach

with safety and non-safety data on the same bus
 versatile
Safety over EtherCAT: Hardware Architecture
EtherCAT is: 1-channel communication system

 faster Model A according to IEC 61784-3 Annex A
 Industrial
Ethernet
Device 1 Device 2
 more flexible
to wire
Controller A Controller B Controller B Controller A
 easier to Safety Safety Safety Safety
configure Protocol Protocol Protocol Protocol
 lower cost
 easier to EtherCAT EtherCAT

implement Slave Controller Slave Controller
 well proven PHY PHY PHY PHY

 open Transformer Transformer Transformer Transformer
 safety RJ45 RJ45 RJ45 RJ45
 redundancy
 versatile
Safety over EtherCAT: Features (II)
EtherCAT is: • FSoE Frame is mapped in the cyclic PDOs

 faster
– Minimum FSoE Frame-Length: 6 Byte
 Industrial
Ethernet – Maximum FSoE Frame-Length: Depending on the
 more flexible number of safe process data of the Slave Device
to wire
 easier to
– Therefore the protocol is suitable for safe I/O as well
configure as for functional safe motion control
 lower cost
• Confirmed transfer from the FSoE Master to the FSoE
 easier to Slave and vice versa.
implement
 well proven • Safe Device Parameter can be downloaded from the

 open
Master to the Slave at Boot-Up of a FSoE Connection
 safety • Certified products with Safety over EtherCAT are available
 redundancy since 2005.
 versatile
Safety over EtherCAT: Frame Structure
EtherCAT is: Ethernet-Telegram FSoE Frame

 faster Ethernet EtherCAT 1. Data- 2. Data- The FSoE Frame is a
FSC
Header Header gram gram data container
 Industrial
mapped in the
Ethernet
FSoE Frame process data of the
 more flexible devices.
to wire A new FSoE Frame
is recognized if at
 easier to
least one bit has
configure changed according
Safe Safe
CMD CRC_0 CRC_1 Conn ID to the last frame.
 lower cost Data Data
For every 2 Byte
 easier to SafeData a 2 Byte CRC
implement is calculated.
 well proven Up to n Byte SafeData
can be transmitted.
 open
 safety
 redundancy
 versatile
Safety over EtherCAT: Implementations
EtherCAT is: • Decentralized Safety-Logic

 faster • Standard PLC routes the safety messages
 Industrial
Ethernet
IPC
 more flexible
to wire
Safety Inputs
inputs Safety
 easier to
configure ..
..
Outputs
DVI
 lower cost
 easier to
Standard
implement
PLC
 well proven
S
 open
S
 safety
Safety Drives Safety S
 redundancy
Logic S
 versatile
Safety over EtherCAT: Features (III)
EtherCAT is: • The FSoE specification has no restrictions according to:

 faster
– Communication layer and interface
 Industrial
Ethernet The communication layer is not part of the safety
 more flexible measures: black channel (assumed unsolved bit
to wire error rate: p= 10-2
 easier to
configure – Transmission speed
 lower cost – Length of safe process data
 easier to
implement • Routing via unsafe gateways, fieldbus systems or
 well proven backbones is possible.
 open
 safety
 redundancy
 versatile
EtherCAT: High availability
EtherCAT is:
 faster
 Industrial • Cabling redundancy

Ethernet
 more flexible
to wire
• Hot Swap of devices
 easier to
configure • Master redundancy with Hot-Stand-By
 lower cost
 easier to • Hot-Connect of network segments

implement
 well proven
 open
 safety
 redundancy
 versatile
Without Redundancy: Normal Operation
EtherCAT is: Master

 faster
RX Unit TX Unit
 Industrial
Ethernet
RX TX
 more flexible
to wire MAC 1
 easier to RX TX
configure
 lower cost
 easier to
implement
 well proven   
 open Slave 1 Slave M-1 Slave N
 safety RX TX RX TX RX TX
 redundancy
... ...
TX RX TX RX TX RX
 versatile
Without Redundancy: Cable Failure
EtherCAT is: Master

 faster
RX Unit TX Unit
 Industrial
Ethernet
RX TX
 more flexible
to wire MAC 1
 easier to RX TX
configure
 lower cost
 easier to
implement
 well proven    
 open Slave 1 Slave M-1 Slave M+1 Slave N
 safety RX TX RX TX RX TX RX TX
 redundancy
... ...
TX RX TX RX TX RX TX RX
 versatile
Without Redundancy: Node Failure
EtherCAT is: Master

 faster
RX Unit TX Unit
 Industrial
Ethernet
RX TX
 more flexible
to wire MAC 1
 easier to RX TX
configure
 lower cost
 easier to
implement
 well proven    
 open Slave 1 Slave M-1 Slave M Slave M+1 Slave N
 safety RX TX RX TX RX TX RX TX RX TX
 redundancy
... ...
TX RX TX RX TX RX TX RX TX RX
 versatile
With Redundancy: Normal Operation
EtherCAT is: Master

 faster
RX Unit TX Unit
Only 2nd
 Industrial
RX TX Ethernet Port
Ethernet
required – no
 more flexible
special
to wire MAC 1 MAC 2 Interface Card
 easier to RX TX RX TX
configure
 lower cost
 easier to
implement
 well proven   
 open Slave 1 Slave M-1 Slave N
 safety RX TX RX TX RX TX
 redundancy
... ...
TX RX TX RX TX RX
 versatile
With Redundancy: Cable Failure
EtherCAT is: Master

 faster
RX Unit TX Unit
 Industrial
RX TX
Ethernet
 more flexible
to wire MAC 1 MAC 2
configure
 lower cost
 easier to
implement
 well proven    
 open Slave 1 Slave M-1 Slave M+1 Slave N
 safety RX TX RX TX RX TX RX TX
 redundancy
... ...
TX RX TX RX TX RX TX RX
 versatile
With Redundancy: Node Failure
EtherCAT is: Master

 faster
RX Unit TX Unit
 Industrial
RX TX
Ethernet
 more flexible
to wire MAC 1 MAC 2
configure
 lower cost
 easier to
implement
 well proven    
 open Slave 1 Slave M-1 Slave M Slave M+1 Slave N
 safety RX TX RX TX RX TX RX TX RX TX
 redundancy
... ...
TX RX TX RX TX RX TX RX TX RX
 versatile
EtherCAT Application Fields, or:
Why do Companies chose EtherCAT?
EtherCAT is: High Performance
 faster
EtherCAT is the fastest Industrial Ethernet Technology
 Industrial
Ethernet Flexible Topology
 more flexible Benefit not only for widely distributed applications
to wire
 easier to Ease of Use

configure
Easy configuration and maintenance
 lower cost
Low Cost
 easier to
implement Inexpensive implementation + Infrastructure
 well proven Functional Safety
 open
Safety communication integrated
 safety
 redundancy
 versatile
Decisive Factors: Performance
EtherCAT is: EtherCAT is the fastest Industrial Ethernet Technology

 faster
 Industrial The need for speed:

Ethernet Everything that is high end motion control
 more flexible
to wire For example
 easier to • Robotics
configure • Hydraulic / Electric Presses
 lower cost • Machine Tool Applications
 easier to
• CNC functionality
implement • Printing
 well proven • Woodworking machines
 open • Packaging Machines
 safety
• Injection Molding
• Any measurement application
 redundancy
• Any closed loop control
 versatile
EtherCAT is: Example: Robotics:

 faster The worlds first Java Powered
 Industrial Robot is EtherCAT based.
Ethernet
 more flexible University of Lund, Sweden:

to wire
Robot controller implemented
 easier to on standard PC with
configure Real Time Java.
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
Photo used with permission from CNET Networks, Inc., Copyright 2007. All rights reserved.
 versatile
EtherCAT is: Example: Hydraulic Presses

 faster Dieffenbacher: Presses and more
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
Decisive Factors: Performance BMW Research & Innovation Center,
Munich, Germany
EtherCAT is: Example: Test Bed Application

 faster BMW AG: Engine Test Bed
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile Photos: BMW AG

Example: Measurement Application:
Airbus Testrack for High-Lift-System
EtherCAT is:
Ingenieurgesellschaft IgH: High Lift Slat Flap Testrig (HLSTR)
 faster
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Printing Systems

 faster
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Machines with CNC functionality

 faster Laserplus Oy: Welding Transfer line for steel sandwich-plates
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Woodworking Machines

 faster Nobilia Werke: Kitchen Production
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Packaging Machine

 faster Huhtamaki Molded Fiber Technology,
 Industrial the Netherlands
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Packaging Machines

 faster Radiator Specialty, (NC), USA: Filling and Packaging Line
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Postpress Processing Machine

 faster Ferag, Switzerland:
 Industrial Flexible, modular strapping without bundle turning (SmartStrap)
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Postpress Processing Machine

 faster Ferag, Switzerland:
 Industrial Flexible, modular strapping without bundle turning (SmartStrap)
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Injection Molding

 faster Husky (Canada): HyPAC
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Injection Molding

 faster SAB, Thailand: Injection Molding and Extrusion Machine
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Ultra fast metal cutting

 faster Hydropulsor, Sweden
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Blow molding machinery

 faster Graham Engineering Corporation (GEC), USA: Performance and
 Industrial increased efficiency
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Semiconductor + FPD Manufacturing

 faster NewYoung Mtech Co.,Ltd, Korea, EtherCAT w. 570 DI/DO, 480 AI/AO
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
EFEM : End Front
 lower cost Equipment Module
(Wafer Transfer System)
 easier to
implement
 well proven
 open
 safety Heating Chamber
 redundancy
HMI Wafer Transportation Robot
 versatile
Decisive Factors: Performance, Ease of Use
EtherCAT is: Example: Integrated System

 faster Zumtobel, Austria: Production of luminaires for SCUBAs
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
Decisive Factors: Performance, Function. Safety
EtherCAT is: Example: Tube-End-Forming-Machine

 faster IWM Automation, Germany: EtherCAT and Safety over EtherCAT
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
Decisive Factors: Topology
EtherCAT is: Example: Automation of dynamic storage

 faster Dürkopp Fördertechnik, Germany:
 Industrial Realtime position detection, 5000 distributed I/O points
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
Decisive Factors: Performance, Ease of Use
EtherCAT is: Example: Extrusion blow molding machine

 faster SAB Plastmach Co., Ltd, Thailand
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
Decisive Factors: Performance, Flexibility
EtherCAT is: Example: Shrink packing machine

 faster Conflex, USA
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
Decisive Factors: Costs
EtherCAT is: Example: Automated Warehousing

 faster Constructor Finland Oy, Finland
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Test stand software for steering systems

 faster Birke Systemtechnik, Germany
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Bridge absorption system

 faster Dubrovnik (Croatia): Absorption of vibrations
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Snow Blower Control

 faster Berchtold, Austria:
Systems of up to 1000 snow makers
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
Decisive Factors: Ease of Use
EtherCAT is:
EtherCAT is easier to use:
 faster
 Industrial • No Hassle with Address Switches

Ethernet
• No Bandwidth or performance issues,
 more flexible
to wire no network tuning
 easier to
configure • Simple Configuration
 lower cost • Meaningful Diagnosis Information
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Mat Welding Machine

 faster Progress, Italy
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
EtherCAT is: Example: Coil Wire

 faster Processing Machine
 Industrial Progress, Italy
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
Decisive Factors: Costs
EtherCAT is: Example: Edge Banding Machine

 faster IMA: Novimat Concept
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
Decisive Factors: Functional Safety
EtherCAT is: Example: Tire Testing System

 faster Seichter, Germany
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
 open
 safety
 redundancy
 versatile
That‘s EtherCAT!
EtherCAT is:
 faster www.ethercat.org
 Industrial
Ethernet
 more flexible
to wire
 easier to
configure
 lower cost
 easier to
implement
 well proven
Guido Beckmann
 open
 safety Ostendstr. 196
90482 Nuremberg, Germany
 redundancy Phone. +49 911 54056-20, Fax -29
 versatile g.beckmannn@ethercat.org

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ETG, Februar 24th, 2008

 lower cost • Benefits

 safety • Questions & Answers

EtherCAT is: • EtherCAT is realtime down to the I/O level

 well proven • 100 Servo-Axis (each 8 Byte IN+OUT) in 100 µs = 0.1 ms

EtherCAT is: • 40 Axis (each 20 Byte Input- and Output-Data)

28/02/22 EtherCAT: Ethernet Control Automation Technology

EtherCAT is: EtherCAT Device

 easier to EoE CoE CoE

implement Mailbox Process Data

 safety Ethernet Physical Layer

 easier to TDMA (Time for Data Transfer

EtherCAT is: • Traditional fieldbus system generate physical process image

232 Telegram Structure

 easier to EtherCAT Frame

EtherCAT is: Long Term Scope View of two seperated Devices

EtherCAT is: • Any Ethernet Device can be connected to Switchport

EtherCAT is: • Interface to any Ethernet Device or Network

 more flexible EtherCAT Switchport

 easier to Ethernet MAC PHY

 lower cost RX1 RX2TX

EtherCAT is: • Virtual Ethernet Switch routes any Ethernet Frame

 Industrial ...via Switch

 more flexible IPC

 easier to + any Ethernet Protocol can be used

 more flexible IPC

 easier to + any Ethernet Protocol can be used

 more flexible IPC

 easier to + any Ethernet Protocol can be used

EtherCAT is: Master ↔ Slave

 redundancy Cable: Standard CAT5 Cable

 redundancy Cable: Standard CAT5 Cable

 redundancy Cable: Standard CAT5 Cable

EtherCAT is: Protection of your investment:

EtherCAT is: • No Slots in Control System

 lower cost EtherCAT

EtherCAT is: • Handles Real-time Protocol in Hardware

EtherCAT is: ASIC

 Industrial ET1100 ET1200

EtherCAT is: FPGA

 easier to No. of FMMU 0..8 (configurable)

EtherCAT is: FPGA

EtherCAT is: Number of Logic Elements (LE)

 easier to XL-Configuration: ~15000 LE

EtherCAT is: netX 100/500

EtherCAT is: 4 Groups of 8 binary Signals

 lower cost Sync-Manager, FMMU Registers

 well proven EtherCAT MAC EtherCAT MAC

EtherCAT is:  EtherCAT State Machine 8 I/O 8 I/O 8 I/O 8 I/O

 faster handled by EtherCAT

Ethernet  No Mailbox Dual Port Memory non volatile Data

 No Object Dictionary Sync-Manager, FMMU Registers

connected directly EtherCAT MAC

 lower cost  24 Bit input / 8 Bit output

EtherCAT is: Host CPU HTTP,

 more flexible EtherCAT

 redundancy PHY PHY

EtherCAT is: 8/16 Bit µC Interface

 faster  Demultiplexed Application Mapping

 Industrial  Intel Signal Types Process Data Mailbox

Ethernet  Polarity configurable

 more flexible (BUSY, INT) Sync-Manager, FMMU Registers

to wire  Typical µC: Auto-Forwarder with Loop Back

EtherCAT MAC EtherCAT MAC