Cover Slide Read and Delete

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

EtherCAT Introduction: This slide set intends to provide an overview

over the most important features of the EtherCAT technology.
Please do not forward the slides in PPT format only as PDF!
It is allowed to modify the slides according to own preferences and
presentation style e.g. by deleting some slides or adding
information regarding own EtherCAT products.
It is, however, prohibited explicitly to use slides or elements from the
slides (e.g. pictures) for any other purpose than to introduce and
promote the EtherCAT technology.
The animations have been developed with and for Microsoft
PowerPoint 2003. Some elements will not work with earlier versions.
For comments regarding the slides please contact [email protected]

- Versatile

Nuremberg, May 2009,

EtherCAT Technology Group

EtherCAT Technology Group, 2009

The Ethernet Fieldbus.

Why Ethernet for Automation?

EtherCAT is:
- Faster
- Synchronization

- Industrial Ethernet
- Flexible
- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance

Today at controller level: state-of-the-art

Advantages for fieldbuses:

lower costs because the use of commodity technology

Ethernet technology is driven by the office sector
access to internet technology (e.g. webserver)
reduction of interfaces

But: Common Ethernet does not achieve fieldbus

requirements as
Low cost, performance, deterministic (real time),

- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

EtherCAT - The Ethernet Fieldbus.

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

EtherCAT is real time down to the I/O level

No underlying sub-systems any more
No delays in gateways
In- and outputs, sensors, actuators, drives, displays:
everything in one system!

- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

EtherCAT is faster
EtherCAT is:

Transmission Rate:
2 x 100 Mbit/s (Fast Ethernet, Full-Duplex)

- Faster
- Synchronization
- Industrial Ethernet
- Flexible
- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance

Update Times:

256 digital I/O in 11 s

1000 digital I/O distributed to 100 nodes in 30 s = 0.03 ms
200 analog I/O (16 bit) in 50 s, 20 kHz Sampling Rate
100 Servo-Axis (each 8 Byte In + Out) in 100 s = 0.1 ms
12000 digital I/O in 350 s

- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

EtherCAT is faster
EtherCAT is:
- Faster
- Synchronization

Bandwidth Usage of Ethernet for I/O and Drives:

Ethernet Frame: 84 Bytes
incl. Preamble + IPG (interpacket gap)

- Industrial Ethernet
- Flexible

Data pay load:

e.g. 2 Bit..6 Byte

- Easier to configure
22 Bytes

- Cost effective

Ethernet Header

- Easier to implement
- Well proven
- Open

Data: 46 Bytes

CRC

12 Bytes

IPG

Request with output data

Master

I/O

Response with input data

- Conformance
- Safety

4 Bytes

Ethernet Header

Data: 46 Bytes

CRC

Node
reaction
time

IPG

- Redundancy
- Versatile

with 4 Byte input + 4 Byte output per node:

4,75% application data ratio at 0 s reaction time/node
1,9% application data ratio at 10 s reaction time/node

EtherCAT Technology Group, 2009

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

Bandwidth Usage Comparison:

At 4 Byte user data per node:
Polling / Timeslicing: ~ 2..5 %

From 2 Bit user data per node:

EtherCAT: ~ 80..97 % (Full Duplex, 2 x 100 MBit/s)

- Cost effective
- Easier to implement

100

- Well proven

90

- Open

80

- Conformance

70

- Safety
- Redundancy
- Versatile

60
50
40
30
20
10
0

Polling /
Timeslicing

EtherCAT Technology Group, 2009

EtherCAT

Functional Principle: Ethernet on the fly

EtherCAT is:
- Faster
- Synchronization
- Industrial Ethernet
- Flexible

Car
27

- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

Analogy Fast Train:

Train (Ethernet Frame) does not stop
Even when watching Train through narrow window one
sees the entire Train
Car (Sub-Telegram) has variable length
One can extract or insert single persons (Bits) or entire
groups (Bytes) even multiple groups per train

EtherCAT Technology Group, 2009

Functional Principle: Ethernet on the fly

EtherCAT is:
- Faster

Slave Device

Slave Device

EtherCAT Slave
Controller

EtherCAT Slave
Controller

- Synchronization
- Industrial Ethernet
- Flexible
- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

Process data is extracted and inserted on the fly:

Process data size per slave almost unlimited
(1 Bit60 Kbyte, if needed using several frames)
Compilation of process data can change in each cycle, e.g.
ultra short cycle time for axis, and longer cycles for I/O
update possible
in addition asynchronous, event triggered communication

EtherCAT Technology Group, 2009

Functional Principle: Ethernet on the fly

EtherCAT is:
Master

- Faster
- Synchronization
- Industrial Ethernet
- Flexible
- Easier to configure

ECAT HDR

- Well proven

PLC Data

NC Data

HDR 2

Ethernet Header

HDR 2

- Easier to implement

HDR 1

- Cost effective
Data n

Ethernet

- Open
- Conformance
- Safety
- Redundancy
- Versatile

Minimal protocol overhead via implicit addressing

Optimized telegram structure for decentralized I/O
Communication completely in hardware: maximum
(+ predictable!) performance
No switches needed if only EtherCAT devices in the network
Outstanding diagnostic features
Ethernet-compatibility maintained

EtherCAT Technology Group, 2009

10

Performance: Application Example

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

40 Axis (each 20 Byte Input- and Output-Data)

50 I/O Station with a total of 560 EtherCAT Bus
Terminals
2000 Digital + 200 Analog I/O, Bus Length 500 m
Performance EtherCAT: Cycle Time = 276 s
at 44 % Bus Load, Telegram Length = 122 s

- Easier to implement
- Well proven
- Open
- Conformance
- Safety

276 s

EtherCAT

in spite of this cycle time still 56%

bandwidth remaining, e.g. for TCP/IP

479 s

SERCOS III

- Redundancy
- Versatile

763 s

Profinet IRT

2347 s

Pow erlink

6355 s

Profinet I/O
0

EtherCAT Technology Group, 2009

1000

2000

3000

4000

5000

6000

7000

11

Slow Control Systems benefit, too

EtherCAT is:

Reaction time with legacy fieldbus I/O:

- Faster
- Synchronization
- Industrial Ethernet

PLC Task

PLC Task

PLC Task

PLC Task

PLC Task

- Flexible
- Easier to configure
- Cost effective

Tmpd

- Easier to implement
- Well proven
- Open

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

- Conformance
- Safety
- Redundancy

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

best case reaction time

worst case reaction time

- Versatile
Input

Input

(worst case)

(best case)

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

EtherCAT Technology Group, 2009

12

Slow Control Systems benefit, too

EtherCAT is:

System Architecture with EtherCAT:

- Faster
- Synchronization
- Industrial Ethernet

PLC Task

PLC Task

PLC Task

PLC Task

PLC Task

- Flexible
- Easier to configure

no dedicated Master Device any more

- Cost effective

Tmpd

- Easier to implement
- Well proven
- Open

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

Bus Cycle

- Conformance
- Safety
- Redundancy

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

on underlying extension bus any more

- Versatile

EtherCAT Technology Group, 2009

13

Slow Control Systems benefit, too

EtherCAT is:

System Architecture with EtherCAT:

- Faster
- Synchronization
- Industrial Ethernet

PLC Task

PLC Task

PLC Task

PLC Task

PLC Task

- Flexible
- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open

TDMA (NIC)

- Conformance
- Safety
- Redundancy

TEtherCAT Cycle

- Versatile

EtherCAT Technology Group, 2009

TDMA = Time for Data Transfer

from/to Ethernet Controller via
Direct Memory Access: neglectible

14

Slow Control Systems benefit, too

EtherCAT is:

Reaction Time with EtherCAT:

- Faster
- Synchronization
- Industrial Ethernet

PLC Task

PLC Task

PLC Task

PLC Task

PLC Task

- Flexible
- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance

best case

worst case

EtherCAT
Bus Cycle

Input

Input

(worst case)

(best case)

Output

- Safety
- Redundancy
- Versatile

Reaction time reduced significantly with the same controller

performance
no underlying local I/O cycles and extension bus delays any
more
Due to the very simple protocol no dedicated master
systems (e.g. plug-in cards) required
EtherCAT Technology Group, 2009

15

Fieldbus: requires Mapping in Control System

EtherCAT is:

- Faster
- Synchronization
- Industrial Ethernet

Traditional fieldbus system generate physical process

image
This has to be mapped to logical process image(s)

- Flexible
- Easier to configure
- Cost effective
- Easier to implement

Control System, e.g. IPC

- Well proven

DPRAM
Fieldbus Scanner/Master

- Open
- Conformance
- Redundancy
- Versatile

Node 1
Data n

logical process images

- Safety

Node 1

Node 2

PLC Data

NC Data

Node 3

Node 2

Node 3

Node 4

Mapping

EtherCAT Technology Group, 2009

Node 4

16

Fieldbus: requires Mapping in Control System

EtherCAT is:

- Faster
- Synchronization
- Industrial Ethernet

The same applies to control system with just one process

image
Resorting of process data (Mapping) is required, too

- Flexible
- Easier to configure
- Cost effective
- Easier to implement

Control System, e.g. IPC

- Well proven
- Open

DPRAM
Fieldbus Scanner/Master

- Conformance

Node 1

- Redundancy
- Versatile

Logical process image

- Safety
Node 2

ProcessData

Node 3

Node 1

Node 2

Node 3

Node 4

Mapping

EtherCAT Technology Group, 2009

Node 4

17

EtherCAT: Mapping moved into Slave Devices

Master

EtherCAT is:
- Faster
- Synchronization

- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy

Ethernet Header

ECAT HDR

PLC Data

NC Data

HDR 2

- Easier to configure

HDR 2

logical process images up to 4 GByte

- Flexible

HDR 1

- Industrial Ethernet

Data n

Ethernet

Data n
PLC Data

NC Data

Datagram 1

Datagram 2

Datagram n

- Versatile

Control System is unburdened, master becomes very

simple
Data is transmitted according to the application
requirements: extremely fast, flexibly and efficiently

EtherCAT Technology Group, 2009

18

Direct Memory Access saves time

EtherCAT is:

- Faster
- Synchronization
- Industrial Ethernet
- Flexible

Fieldbus cards:
up to 30% of CPU
time for data
copying

PC Control with Fieldbus cards

PC RAM
Scanner card, DP RAM

Control task
PCI

- Easier to configure

CPU

memcopy

bus

- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT:
MAC is PCI Bus
master, data is
provided by DMA
directly to PC RAM:
CPU relieved more
performance

EtherCAT Technology Group, 2009

PC Control with EtherCAT

PC RAM
CPU

Control task

PCI
MAC

DMA
bus

19

EtherCAT Propagation Delay Measurement (1)

EtherCAT is:
- Faster

EtherCAT Node measures time difference between

leaving and returning frame

- Synchronization
- Industrial Ethernet
- Flexible
- Easier to configure
- Cost effective
- Easier to implement
- Well proven

EtherCAT Frame
Processing Direction

- Open

EtherCAT Frame

- Conformance

Forwarding Direction

- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

20

EtherCAT Propagation Delay Measurement (2)

EtherCAT is:
- Faster

EtherCAT Node measures time difference between

leaving and returning frame

- Synchronization
- Industrial Ethernet
- Flexible
- Easier to configure
- Cost effective

IPC
Master

- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

21

Distributed Clocks

EtherCAT is:
- Faster

Precise Synchronization (<< 1 s!) by exact adjustment

of Distributed Clocks

- Synchronization
- Industrial Ethernet
- Flexible

- Easier to configure
- Cost effective

IPC
Master

- Easier to implement
- Well proven

- Open
- Conformance
- Safety

- Redundancy
- Versatile

EtherCAT Technology Group, 2009

22

External Clock Synchronization: IEEE 1588

EtherCAT is:
- Faster

Switchport with integrated IEEE 1588 Boundary Clock

IEEE 1588
Grandmaster

- Synchronization
- Industrial Ethernet
- Flexible

- Easier to configure
- Cost effective

Boundary
Clock

Master

- Easier to implement
- Well proven

- Open
- Conformance
- Safety

- Redundancy
- Versatile

EtherCAT Technology Group, 2009

23

Distributed Clocks
EtherCAT is:
- Faster
- Synchronization

Long Term Scope View of two separated devices

300 Nodes in between, 120m Cable Length

- Industrial Ethernet
- Flexible
- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open

Simultaneity: ~15 ns

- Conformance

Jitter: ~ +/-20ns

- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

24

EtherCAT is Industrial Ethernet!

EtherCAT is:
- Faster
- Synchronization
- Industrial Ethernet

3
3

EtherCAT uses Standard Ethernet Frames: IEEE 802.3

Alternatively via UDP/IP (if IP Routing is needed)
no shortened frames

- Flexible
Standard Ethernet Frame

- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety

48 Bit

48 Bit

16 Bit

16 Bit

DA

SA

EtherType

Header

Embedded in Standard Ethernet

Frame, EtherType 0x88A4

- Redundancy
- Versatile

Ethernet Header

48 -1498 Byte
DatagramEthernet
1 Datagram
Daten2

Datagram n

0..32
Byte

32 Bit

Pad.

CRC

Pad.

CRC

EtherCAT Telegram

160 Bit

64 Bit

IP Header

UDP H.

16 Bit
Header

48 -1470 Byte
EtherCAT Data

Or: via UDP/IP

UDP Port 0x88A4

EtherCAT Technology Group, 2009

11 Bit

1 Bit

4 Bit

Length

Res.

Type

25

EtherCAT is Industrial Ethernet!

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

3
3

fully transparent for TCP/IP

all Internet technologies (HTTP, FTP, Webserver,)
available without restricting the real time capabilites!
full tool access to devices at real time operation
with and without TCP/IP

- Cost effective
- Easier to implement

EtherCAT Slave Device

- Well proven
- Open
- Conformance
- Safety

Standard
TCP/IP
Stack

- Redundancy

Ethernet
Application
TCP

Real Time
Application

UDP
Acyclic
Data

IP

- Versatile
Mailbox

Process Data

EtherCAT MAC / DLL

Ethernet PHY

EtherCAT Technology Group, 2009

Ethernet PHY

26

EtherCAT is Industrial Ethernet!

EtherCAT is:
- Faster
- Synchronization

3
3

Any Ethernet Device can be connected to Switchport

Access to Webserver with Standard Browser

- Industrial Ethernet
- Flexible

Virtual Ethernet
Switch
Functionality

- Easier to configure
- Cost effective
- Easier to implement

Master

Webserver

Switchport

- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

27

EtherCAT is Industrial Ethernet!

EtherCAT is:
- Faster
- Synchronization

3
3

Virtual Ethernet Switch routes any Ethernet Frame

From inside as well as from outside the segment

- Industrial Ethernet
- Flexible
Virtual Ethernet
Switch
Functionality

- Easier to configure
- Cost effective
- Easier to implement

Switchport

Master

- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

Ethernet
Switch

EtherCAT Technology Group, 2009

28

Switchport: Any Ethernet Protocol

EtherCAT is:
- Faster
- Synchronization
- Industrial Ethernet

3
3

Interface to any Ethernet Device or Network

Ethernet Frames are inserted into EtherCAT Protocol:
Ethernet over EtherCAT

- Flexible
- Easier to configure

EtherCAT Switchport

- Cost effective
- Easier to implement

Ethernet MAC

PHY

- Well proven
- Open
RX1

- Conformance
- Safety

RX RX3
RX2TX
C

RX4

Fragmentation

- Redundancy
Mailbox

- Versatile
PHY
TX2
TX3
TX1

Process Data

EtherCAT MAC / DLL

PHY

TX1
TX3
TX2

EtherCAT Technology Group, 2009

29

Vertical Integration (1)

EtherCAT is:
- Faster
- Synchronization

via Switchport

3
3
Master

- Industrial Ethernet
- Flexible
- Easier to configure
- Cost effective
- Easier to implement

Switchport

- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

+ any Ethernet Protocol can be used

+ requires only one Ethernet Port (at IPC/Controller)
+ EtherCAT performance is not limited

EtherCAT Technology Group, 2009

30

Vertical Integration (2)

EtherCAT is:
- Faster
- Synchronization

...via 2. Ethernet Port

3
3
Master

- Industrial Ethernet
- Flexible
- Easier to configure
- Cost effective
- Easier to implement

2nd Ethernet
Port

- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

+ any Ethernet Protocol can be used

+ EtherCAT performance is not limited
but: requires second Ethernet Port (at IPC/Controller)

EtherCAT Technology Group, 2009

31

Vertical Integration (3)

EtherCAT is:
- Faster
- Synchronization

via Switch

3
3
Master

- Industrial Ethernet
- Flexible
- Easier to configure
- Cost effective
- Easier to implement

Ethernet
Switch

- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

+ any Ethernet Protocol can be used

+ requires only one Ethernet Port (at IPC/Controller)
but: performance reduced by switch delay (and generic
Ethernet traffic)

EtherCAT Technology Group, 2009

32

EtherCAT wiring is more flexible

EtherCAT is:
- Faster
- Synchronization
- Industrial Ethernet

Standard Ethernet Topology: Star

3
3
3

- Flexible
- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

33

EtherCAT wiring is more flexible

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

3
3
3

Flexible tree structures arbitrarily extendable

Topology variants like Line, Star, Tree, Daisy Chain
+ Drop Lines possible; can be used in any combination!
Up to 65.535 nodes for each EtherCAT segment
Standard Ethernet cabling
Line

- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance

Master

- Safety
- Redundancy
- Versatile

Star/Tree

EtherCAT Technology Group, 2009

Drop Line

34

EtherCAT wiring is more flexible

EtherCAT is:
- Faster
- Synchronization
- Industrial Ethernet

Ethernet Signal Variants of EtherCAT:

100BASE-TX (up to 100 m between 2 nodes)
100BASE-FX (longer distances between 2 nodes)
LVDS (for modular devices)

3
3
3

- Flexible
- Easier to configure

LVDS*

- Cost effective

100 m

- Easier to implement
- Well proven
- Open

Master

- Conformance
- Safety

Ethernet on
100BASE-TX
up to 100 m
with transformer
coupling

- Redundancy
- Versatile

Ethernet on LVDS* physical layer:

for modular devices

Ethernet on
100BASE-FX
(fibre optics)
for longer
distances

Any number of physical layer changes allowed

*LVDS: Low Voltage Differential Signaling according to ANSI/TIA/EIA-644,
also used in IEEE 802.3ae (10Gigabit Ethernet)

EtherCAT Technology Group, 2009

35

EtherCAT Extra Large System Test

EtherCAT is:
- Faster
- Synchronization
- Industrial Ethernet

3
3
3

- Flexible
- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

10.056
EtherCAT Nodes

EtherCAT Technology Group, 2009

36

EtherCAT instead of PCI

- Synchronization

3
3

Protection of your investment

smooth migration path from legacy fieldbus to EtherCAT
seamless integration of existing fieldbus devices, e.g.:

- Industrial Ethernet

EtherCAT is:
- Faster

- Flexible
- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

AS-Interface
CAN, CANopen
CC-Link
ControlNet
DeviceNet
Ethernet/IP
FIPIO
Interbus
IO-Link
Lightbus
LONWorks
Modbus Plus, RTU, TCP
MPI
PROFIBUS
PROFINET IO

maximum system expandability with low cost fieldbus gateways

EtherCAT Technology Group, 2009

37

EtherCAT instead of PCI

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

3
3
3

Update Times (examples):

Process image update-time
via PCI (500 Bytes input and output data each): 400 s
Process image update-time
via EtherCAT (1.500 Bytes input and output data): 150 s

- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

38

EtherCAT instead of PCI

EtherCAT is:
- Faster
- Synchronization
- Industrial Ethernet

3
3
3

No Slots in Control System (IPC or PLC) required any

more
Nevertheless maximum expandability

- Flexible
- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT

EtherCAT Technology Group, 2009

39

EtherCAT is easier to configure

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Synchronization

- Easier to configure

Addressing
No manual address setting required
Addresses can be assigned automatically
Addresses can be kept
no new addressing if nodes are added

- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

40

EtherCAT is easier to configure

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Synchronization

Topology:
Automatic topology target/actual comparison

Diagnosis:
Diagnosis with exact localization

- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety

Network planning:
Performance independent of:
Slave implementation
Topology (no Switches/Hubs)

- Redundancy
- Versatile

EtherCAT Technology Group, 2009

41

EtherCAT is lower costs (1): Engineering

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

- Synchronization

- Cost effective

Implementation / Tools:
Standard Network Monitor Tools, e.g. MS Network Monitor
or Wireshark: free of charge
Parser Software: free of charge

- Easier to implement

Less effort for Network planning:

Simplified configuration
Default settings will work, no network tuning

- Well proven
- Open
- Conformance
- Safety

- Redundancy

Improved Diagnosis:
Faster error handling leads to less downtime

- Versatile

Faster Setup:
No address setting required

EtherCAT Technology Group, 2009

42

EtherCAT is lower costs (2): Hardware

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

- Synchronization

Master:
no dedicated plug in card (co-processor)
on-board Ethernet Port is fine

- Cost effective

Slave:
low cost Slave Controller

- Easier to implement

FPGA or ASIC

- Well proven

for simple devices: no C needed

no powerful C needed

- Open
- Conformance

32 Bit
C

- Safety
- Redundancy
- Versatile

Infrastructure:
no Switches/Hubs required
Standard Ethernet Cabling + Connectors

EtherCAT Technology Group, 2009

43

EtherCAT is easier to implement: Slave

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety

Slave Implementation:
All time critical functions implemented on ASIC or FPGA
ESC handles Real-time Protocol in Hardware

Integrated Communication State Machine

Network Performance independent of
Slave-C Performance
Protocol Stack

For usage with or without C (Host CPU)

Integrated DPRAM (18kByte)
Integrated Distributed Clock Handling
Ultra precise interrupts to C

- Redundancy
- Versatile

EtherCAT Technology Group, 2009

44

EtherCAT Slave Controller Features: ASIC (1)

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective
- Easier to implement

Name

ET1100

ET1200

netX5

Type

ASIC

ASIC

ASIC

Package

BGA128
0,8mm Pitch

QFN48
0,5mm Pitch

BGA201
0,8mm Pitch

Size

10 x 10 mm

7 x 7 mm

13 x 13 mm

serial/parallel
(8/16-bit, async)*

serial*

serial (SPI),
parallel (8/16/32-bit,
async)

32

8-16*

16

8 kByte

1 kByte

6 kByte

SyncManager

FMMUs

Yes

Yes

Yes

2-4 (MII/E-bus)*

2-3 (E-bus/max.
1xMII)*

2 (MII)

Routable with
standard PCB

Multi Protocol
Support

Hardware Supplier

C Interface

- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

Digital I/O
DPRAM

Distributed Clocks
No. Of Ports
Specials

* configurable

EtherCAT Technology Group, 2009

45

EtherCAT Slave Controller Features: ASIC (2)

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective
- Easier to implement
- Well proven
- Open

Name

netX 100

netX 500

netX50

Type

ASIC

ASIC

ASIC

Package

BGA345
1mm Pitch

BGA345
1mm Pitch

PBGA
1mm Pitch

Size

22x22 mm

22x22 mm

19x19 mm

C-Bus
(internal, 32-bit)

C-Bus
(internal, 32-bit)

C-Bus
(internal, 32-bit)

16 (GPIO)

16 (GPIO)

32 (GPIO)

256/400 Byte
(Mailbox/Process
Data)

256/400 Byte
(Mailbox/Process
Data)

6 kByte

SyncManager

FMMUs

Yes

Yes

Yes

2 (100BASE-TX)

2 (100BASE-TX)

2 (100BASE-TX)

Multi Protocol
Support, Integrated:
PHYs, ARM-9 C

Multi Protocol
Support, Integrated:
PHYs, ARM-9 C

Multi Protocol
Support, Integrated:
PHYs, ARM-9 C

Hardware Supplier

C Interface
Digital I/O

- Conformance
- Safety

DPRAM

- Redundancy
- Versatile

Distributed Clocks
No. Of Ports
Specials

EtherCAT Technology Group, 2009

46

EtherCAT Slave Controller Features: FPGA

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

Name

ET1810/ET1811/ET1812

ET1815/ET1816/ET1817

Type

FPGA + IP Core

FPGA + IP Core

Cyclone I+II+III,
Stratix I+II+III+IV+GX+II GX,
Arria GX

Spartan
3+3E+3A+3AN+3ADSP,
Virtex II+II Pro+II Pro X+4+5

Hardware Supplier

Supported Chips

- Easier to implement

Package

FPGA dependent

FPGA dependent

- Well proven

Size

FPGA dependent

FPGA dependent

C Interface

serial/parallel
(8/16-bit, async)
AVALON*

serial/parallel
(8/16bit, async)
OPB*

8-32*

8-32*

1...60 kByte*

1...60 kByte*

SyncManager

08*

08*

FMMUs

08*

08*

Distributed Clocks

Yes*

Yes*

2 (MII)

2 (MII)

Several IP Core License

models available

Several IP Core License

models available

- Open
- Conformance
- Safety
- Redundancy
- Versatile

Digital I/O
DPRAM

No. Of Ports
Specials
EtherCAT Technology Group, 2009

* configurable

47

EtherCAT is easier to implement: Master

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

Master Implementation:
e.g. with Master Sample Code (Source)
EtherCAT Configuration Tool
XML Data format of ESI and ENI

- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

48

EtherCAT is easier to implement: Master

- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3

Example: Master with just one process image

typical e.g. for small controllers with one control task
up to 1488 Byte Process data size
Header for Process Data communication remains constant
Ethernet Header

ECAT

DA

SA

Type

Frame
HDR

6 Bit

6 Bit

2 Bit

2 Bit

EtherCAT Telegram
EtherCAT
HDR
10 Bit

Ethernet

Data

WKC

EtherCAT is:

Pad.

0.1486 Byte

032 4 Byte

FCS

- Well proven
- Open
- Conformance

constant header

- Safety
- Redundancy
- Versatile

completely sorted
(mapped) process data

Working
Counter:
constant

Padding Bytes and

CRC generated by
Ethernet Controller
(MAC)

Master can be implemented with minimal effort

No separate communication processor required (e.g. on
plug-in card)
Much simpler that legacy fieldbus systems
Very much simpler than competing Industrial Ethernet
approaches
EtherCAT Technology Group, 2009

49

EtherCAT is well proven

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

In series production since 2003

Numerous applications
Great product variety of
available EtherCAT products

- Easier to implement 3
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

50

EtherCAT Architecture + Device Profiles

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

EtherCAT Device
File System,
Bootloader

- Open

TCP

UDP
IP

Ethernet
FoE

- Redundancy

Object Dictionary

Service Channel

SDO

IEC 61800-7-204
IEC 61800-7-304

EN 50325-4
IEC 61800-7-201
IEC 61800-7-301

EoE

SoE

CoE

Mailbox

- Versatile

The CANopen
Standard

IDN

File Access

- Conformance
- Safety

DEVICE Application

The SERCOS*
Standard

- Easier to implement 3
- Well proven

HTTP, FTP,

Process Data

PDO
Mapping

AT
MDT

CoE/SoE
Process Data

EtherCAT Slave Controller

Ethernet Physical Layer

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

EtherCAT Technology Group, 2009

51

Typical EtherCAT Device Architecture

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven

EtherCAT Device
HTTP, FTP,

Device Profile
Profile
Device
Definitions
Definitions

TCP

UDP
IP

- Open
- Conformance

DEVICE Application

optional

Ethernet

- Safety

Parameters
Asynchronous
Communication
(Explicit
Addressing)

EoE

- Redundancy

CoE/SoE
Mailbox

- Versatile

Cyclic
Synchronous
Communication
(Implicit
Addressing)

CoE/SoE
Process Data

EtherCAT Slave Controller

Ethernet Physical Layer

EtherCAT Technology Group, 2009

52

IEC 61491 EtherCAT Servodrive Architecture

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven

EtherCAT Device
HTTP, FTP,

TCP

UDP
IP

Ethernet

- Safety

IDN
Service Channel

- Open
- Conformance

Servodrive Application

IEC 61800-7204
is the
SERCOS*
Drive Profile

optional

Servodrive Profile IEC 61800-7-204

Mapping to EtherCAT: IEC 61800-7-304

EoE

- Redundancy

SoE
Mailbox

- Versatile

Process Data:
AT / MDT

SoE
Process Data

EtherCAT Slave Controller

Ethernet Physical Layer

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

EtherCAT Technology Group, 2009

53

EtherCAT in IEC 61800-7

EtherCAT is:
- Faster

IEC 61800-7: Generic Interface and use of profiles for power drive systems

- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

IEC 61800-7-1: Interface Definition

Annex A:
Mapping to
DS402

- Open
- Conformance

Annex C:
Mapping to
PROFIdrive

Annex D:
Mapping to
SERCOS*

IEC 61800-7-200: Profile Specifications

- Easier to implement 3
- Well proven

Annex B:
Mapping to
CIP

IEC 61800-7-201:
Profile
CiA 402

IEC 61800-7-202:
Profile
CIP Motion

IEC 61800-7-203:
Profile
PROFIdrive

IEC 61800-7-204:
Profile
SERCOS*

- Safety
- Redundancy

IEC 61800-7-300: Mapping of Profiles to Network Technologies

- Versatile
IEC 61800-7-301
Mapping to Mapping to Mapping to
CANopen
EPL
EtherCAT

B
...

C
...

IEC 61800-7-304
Mapping to Mapping to Mapping to
SERCOS I/II SERCOS III EtherCAT

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

EtherCAT Technology Group, 2009

54

EtherCAT is an open technology

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven

- Open
- Conformance

- Safety
- Redundancy

Foundation: November 2003

Tasks: Support, Advancement and Promotion of
EtherCAT
The worlds largest organization dedicated to Industrial
Ethernet
more than 940* member companies from
45 countries in 6 continents:
Device Manufacturers
End Users
Technology Providers

- Versatile

Membership is open to everybody

*as of Feb 2009

EtherCAT Technology Group, 2009

55

EtherCAT is an open technology

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

Protocol is disclosed completely:

EtherCAT is IEC, ISO and SEMI Standard
(IEC 61158, IEC 61784, ISO 15745, SEMI E54.20)

Slave Controller from several sources available

Slave Controller provides interoperability
ETG organizes Interoperabilitly Testing (Plug Fests),
Workshops and Seminars
Conformance Testing + Certificates

EtherCAT Technology Group, 2009

56

EtherCAT is an open technology

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

Master Stacks for various RTOS available*,

including Open / Shared Source!

eCos
Intime
Linux with RT-Preempt
MICROWARE OS-9
On Time RTOS-32
PikeOS
Proconos OS
Real-Time Java
RMOS
RT Kernel
RT-Linux
RTXC Quadros
RTAI Linux
QNX
VxWin + CeWin
VxWorks
Windows CE
Windows XP/XPE with CoDeSys SP RTE
Windows XP/XPE with TwinCAT RT-Extension
XENOMAI Linux
*as of May 2009

EtherCAT Technology Group, 2009

57

EtherCAT Technology Group and IEC

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven

Management Board of IEC has approved Liaison of

EtherCAT Technology Group with IEC SC65C WG
11/12/13 + JWG10 (SC65C: Digital Communication)

Thus ETG is official IEC Standardization Partner

- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

58

ETG Team Worldwide

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven

- Open
- Conformance
- Safety
- Redundancy

ETG Office
Japan

- Versatile
ETG Office
North America
Austin, TX

ETG Headquarters
Tokyo
Germany
ETG Office
ETG Office
Nuremberg
China
Korea
Beijing
Seoul

EtherCAT Technology Group, 2009

59

ETG Membership Development

- Flexible

- Easier to configure

3
3

- Cost effective

1000

900

820

800

766
696

- Easier to implement 3

700

634

May-04

Nov-03

33

500
400
300
200
100

EtherCAT Technology Group, 2009

Nov-07

- Versatile

May-07

- Redundancy

Nov-06

- Safety

May-06

- Conformance

Nov-05

- Open

600

575
515
458
404
357
321
285
240
214
188
169
117136
59 89
May-05

Nov-04

- Well proven

1000

940
881

May-09

- Industrial Ethernet

3
3
3

- Synchronization

Nov-08

- Faster

As of April 2009: 1000 Members

May-08

EtherCAT is:

60

Members from 45* Countries, 6 Continents

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

Australia

Austria

Belarus

Belgium

Denmark

Bosnia and
Herzegovina

Finland

Brazil

Canada

China

Croatia

Czech Rep

Hungary

India

Israel

Italy

Japan

Korea

Liechtenstein

Lithuania

Mexico

Netherlands

New Zealand

Norway

Poland

Portugal

Romania

Russia

France

Germany

Greece

- Easier to implement 3
- Well proven

- Open
- Conformance
- Safety
- Redundancy
- Versatile
Serbia

Singapore

Slovakia

Slovenia

South Africa

Spain

Sweden

Switzerland

Taiwan

Thailand

Turkey

Ukraine

United Kingdom

USA

*as of April 2009

EtherCAT Technology Group, 2009

61

ETG: Active Members

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

Much more important than membership figures: How

many are active, how many implement the technology?
Dec 2008: More than 690 Implementation Kits sold to
ETG Members (25% Master, 75% Slaves), plus there are
Open + Shared Source masters!
SPS/IPC/Drives 2008: 60 Vendors with over 180 different
EtherCAT Devices at ETG booth:
25 different drives from
16 manufacturers jointly
operating in one network
15 different functional
Masters in one setup,
using 10 different
operating systems
Safety devices (master
+ slave devices) from 2
manufacturers operating
in one system
Master to Master and
redundancy live demo

EtherCAT Technology Group, 2009

62

EtherCAT: Large Product Selection

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

I/O, Controller, HMI, Servo Drives, Variable Speed Drives

Sensors, Slave + Master Development Kits
Control Panels, Hydraulic Valves
and Pneumatic Valves,

- Easier to implement 3
- Well proven

- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

63

Conformance and Interoperability

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

3
3

Conformance and interoperability are very important

factors for the success of a communication technology
Conformity to the specification is an obligation to all users of
the EtherCAT technology
Therefore the EtherCAT Conformance Test Tool (CTT) is
used
Test Cases for the CTT are provided by the Working Group
Conformance within the ETG community
The EtherCAT Conformance Test proves conformance
officially with issuing a certificate after passing the test at an
offical EtherCAT Test Center (ETC)

EtherCAT Technology Group, 2009

64

Safety over EtherCAT: Features (1)

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

It meets the Safety Integrity Level (SIL) 3

Residual Error Probability R(p) < 10-9

- Safety
- Redundancy
- Versatile

Safety over EtherCAT (FSoE) defines a safety

communication layer for the transportation of safety
process data between Safety over EtherCAT devices.
FSoE is an open technology within the EtherCAT
Technology Group (ETG).
The protocol is developed according to IEC 61508

The protocol is approved by an independent Notified

Body (TV)

EtherCAT Technology Group, 2009

65

Safety over EtherCAT: Features (2)

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

Minimum FSoE Frame-Length: 6 Byte

Maximum FSoE Frame-Length: depending on the number of
safe process data of the Slave Device
Therefore the protocol is suitable for safe I/O as well as for
functional safe motion control

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety
- Redundancy
- Versatile

FSoE Frame is mapped in the cyclic PDOs

Confirmed transfer from the FSoE Master to the FSoE

Slave and vice versa.
Safe Device Parameter can be downloaded from the
Master to the Slave at Boot-Up of a FSoE Connection
Certified products with Safety over EtherCAT are
available since 2005.
EtherCAT Technology Group, 2009

66

Safety over EtherCAT: Features (3)

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

Communication layer and interface

The communication layer is not part of the safety measures:
black channel
(assumed unsolved bit error rate: p = 10-2)
Transmission speed
Length of safe process data
(lenght of safe process data is arbitrary)

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety
- Redundancy
- Versatile

The FSoE specification has no restrictions according to:

Routing via unsafe gateways, fieldbus systems or

backbones is possible

EtherCAT Technology Group, 2009

67

Safety over EtherCAT: Routing

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

Can be routed via non-safe gateways

Can be routed via fieldbus systems
One Safety technology for (almost) all bus systems

- Safety
- Redundancy
- Versatile

EtherCAT Technology Group, 2009

68

Safety over EtherCAT: Software Architecture

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

Black channel approach

with safety and non-safety data on the same bus
Device 1

Device 2

Safety
Application

Safety
Application

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety
- Redundancy
- Versatile

Standard
Application

Standard
Application

Safety over
EtherCAT
Protocol

Safety over
EtherCAT
Protocol

EtherCAT
Communication Interface

EtherCAT
Communication Interface

Safety
over
EtherCAT
EtherCAT
DLL and AL

EtherCAT Telegram

Safety data container (FSoE Frame)

EtherCAT Technology Group, 2009

69

Safety over EtherCAT: Hardware Architecture

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

One channel communication system

Model A according to IEC 61784-3 Annex A
Device 1
Controller A
Safety
Protocol
Controller A
Safety
Protocol

- Safety

Controller B
Safety
Protocol
Controller B
Safety
Protocol

Controller B
Safety
Protocol
Controller A
Safety
Protocol

EtherCAT
Slave Controller

EtherCAT
Slave Controller

PHY

- Redundancy
- Versatile

Device 2

PHY

Magnetics Magnetics

RJ45

EtherCAT Technology Group, 2009

RJ45

PHY

Controller A
Safety
Protocol
Controller B
Safety
Protocol

PHY

Magnetics Magnetics

RJ45

RJ45

70

Safety over EtherCAT: Frame Structure

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

Ethernet telegram
Ethernet
Header

EtherCAT
Header

- Open

3
3

- Conformance

- Safety
- Redundancy
- Versatile

2. Datagram FSC

Safety over EtherCAT frame

- Easier to implement 3
- Well proven

1. Datagram

CMD

SafeData

CRC_0

SafeData

CRC_1

Conn ID

Safety over EtherCAT frame

The FSoE Frame is a data container mapped in the process data
of the devices
A new FSoE Frame is recognized if at least one bit has changed
according to the last frame
For every 2 Byte SafeData a 2 Byte CRC is calculated
Up to n Byte SafeData can be transmitted
EtherCAT Technology Group, 2009

71

Safety over EtherCAT: Safety Measures

EtherCAT is:
- Faster

Measure

- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety
- Redundancy
- Versatile

Error

Sequence
Number

Watchdog

Connection
ID

CRC
Calculation

Unintended repetition
Loss
Insertion
Incorrect sequence
Corruption
Unacceptable delay
Masquerade
Repeating memory errors
in Switches
Incorrect forwarding
between segments

EtherCAT Technology Group, 2009

72

Safety over EtherCAT: Implementation Example

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

Decentralized Safety-Logic
Standard PLC routes the safety messages
Standard
PLC

Safety Inputs

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

Safety Outputs

- Safety
- Redundancy
- Versatile
S
S
S

Safety Drives

EtherCAT Technology Group, 2009

Safety Logic

73

Safety over EtherCAT: Advantages

EtherCAT is:
- Faster

safe and standard communication in one channel

- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety
- Redundancy
- Versatile

Fully integrated solution:

Reduction of fieldbuses and interfaces
Central configuration, diagnosis and maintenance for
safe and unsafe I/O in one tool
Safety application makes full use of EtherCAT
advantages:

Short reaction times

Almost unlimited number of nodes
Large network extensions
Cable redundancy options
High Flexibility with Hot Connect

EtherCAT Technology Group, 2009

74

EtherCAT: High availability

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety

Cabling redundancy
2nd Ethernet port needed on master side only

Hot Swap of devices

Hot Connect of network segments
Master Redundancy with Hot Swap

Hot Connect
Group

Master

- Redundancy
- Versatile

EtherCAT Technology Group, 2009

75

Without Redundancy: Normal Operation

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

EtherCAT Master

- Open

3
3

- Conformance

- Safety

- Redundancy
- Versatile

TX Unit

RX

TX
MAC 1

- Easier to implement 3
- Well proven

RX Unit

RX

TX

Slave 1

Slave 2

Slave N

RX

TX

RX

TX

...
TX

RX

EtherCAT Technology Group, 2009

RX

TX

TX

RX

...
TX

RX

76

Without Redundancy: Cable Failure

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

EtherCAT Master

- Open

3
3

- Conformance

- Safety

- Redundancy
- Versatile

TX Unit

RX

TX
MAC 1

- Easier to implement 3
- Well proven

RX Unit

RX

Slave 1

Slave 2

RX

TX

RX

TX

TX

RX

TX

...
TX

RX

EtherCAT Technology Group, 2009

Slave N

Slave N-1

RX

TX

TX

RX

...
TX

RX

TX

RX

77

Without Redundancy: Node Failure

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

EtherCAT Master

- Open

3
3

- Conformance

- Safety

- Redundancy
- Versatile

TX Unit

RX

TX
MAC 1

- Easier to implement 3
- Well proven

RX Unit

RX

Slave 1

Slave 2

RX

TX

RX

TX

TX

Slave N-2

Slave N-1

RX

RX

TX

TX

...
TX

RX

EtherCAT Technology Group, 2009

Slave N
RX

TX

TX

RX

...
TX

RX

TX

RX

TX

RX

78

With Redundancy: Normal Operation

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible
- Easier to configure

- Synchronization

- Cost effective

EtherCAT Master
RX Unit

TX Unit

RX

TX

3
3

MAC 1

MAC 2

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety

- Redundancy
- Versatile

RX

TX

RX

Only 2nd Ethernet

Port required
no special
Interface Card

TX

Slave 1

Slave 2

Slave N

RX

TX

RX

TX

...
TX

RX

EtherCAT Technology Group, 2009

RX

TX

TX

RX

...
TX

RX

79

With Redundancy: Cable Failure

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible
- Easier to configure

- Synchronization

- Cost effective

EtherCAT Master
RX Unit

TX Unit

RX

TX

3
3

MAC 1

MAC 2

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety

- Redundancy
- Versatile

RX

TX

RX

TX

Slave 1

Slave 2

Slave N-1

Slave N

RX

TX

RX

TX

RX

TX

...
TX

RX

EtherCAT Technology Group, 2009

RX

TX

TX

RX

...
TX

RX

TX

RX

80

With Redundancy: Node Failure

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible
- Easier to configure

- Synchronization

- Cost effective

EtherCAT Master
RX Unit

TX Unit

RX

TX

3
3

MAC 1

MAC 2

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety

- Redundancy
- Versatile

RX

Slave 1

Slave 2

RX

TX

RX

TX

TX

RX

TX

Slave N-2

Slave N-1

Slave N

RX

RX

TX

TX

...
TX

RX

EtherCAT Technology Group, 2009

RX

TX

TX

RX

...
TX

RX

TX

RX

TX

RX

81

EtherCAT: various system architecture

EtherCAT is:
- Faster
- Synchronization
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Cost effective

Master to Slave
Slave to Slave
Master to Master
M2S

Switchport

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety

- Redundancy

Master
M2M
Switch
Gateways

- Versatile

M2S
Master

EtherCAT Technology Group, 2009

S2S

82

EtherCAT and Wireless Communication

EtherCAT is:
- Faster
- Synchronization

- Industrial Ethernet

3
3

- Flexible

- Easier to configure

3
3

- Cost effective

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety

- Redundancy

Wireless Devices can be connected via Switchport

Wireless segment does not slow down EtherCAT
communication
Protocol: EtherCAT Automation Protocol

Pushed and/or Polled Process Data Exchange

Wireless Segment transparent for Master Device

Master

Switchport

e
Eth

to
Au
T
r CA

oc o
r ot
P
n
atio

- Versatile

e.g. RFID Reader

EtherCAT Technology Group, 2009

83

Why do Companies choose EtherCAT?

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety

- Redundancy

- Versatile

High Performance
EtherCAT is the fastest Industrial Ethernet technology

Flexible Topology
Benefit not only for widely distributed applications

Ease of Use
Easy configuration and maintenance

Low Cost
Inexpensive implementation & infrastructure

Functional Safety
Safety communication integrated

Product Variety
Great variety of available EtherCAT products

EtherCAT Technology Group, 2009

84

EtherCAT Application Fields

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety

- Redundancy

- Versatile

Fast applications, e.g.:

packaging machines
high speed presses
injection molding machines
woodworking machines
machine tooling (CNC)
test beds
robotics

Widely distributed applications, e.g.:

materials handling
logistics
data acquisition

EtherCAT Technology Group, 2009

85

EtherCAT Application Fields

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety

- Redundancy

Due to low cost master and simple wiring as well:

Small Embedded Controller
Small PLCs
Any PC based Control Application
with or without real time requirements

EtherCAT allows one to apply fieldbus technology where

cost issues require direct wiring today

- Versatile

EtherCAT Technology Group, 2009

86

EtherCAT - The Ethernet Fieldbus.

Please visit

EtherCAT is:
- Faster
- Industrial Ethernet

3
3
3

- Flexible

- Easier to configure

3
3

- Synchronization

- Cost effective

www.ethercat.org
for more information

- Easier to implement 3
- Well proven
- Open

3
3

- Conformance

- Safety

- Redundancy

3
3

- Versatile

EtherCAT Technology Group

ETG Headquarters
Ostendstr. 196
90482 Nuremberg, Germany
Phone: +49 911 54056 20
[email protected]
EtherCAT Technology Group, 2009

87