Ethernet-based Industrial Communication

Protocols

Christoph Wimmer
Business Development Manager
Agenda
• Why Ethernet-based Protocols
• Overview of Ethernet-based Industrial Protocols
• Adding Deterministic I/O to NI PACs
Agenda
• Why Ethernet-based Protocols
• Overview of Ethernet-based Industrial Protocols
• Adding Deterministic I/O to NI PACs
Why Ethernet: Protocols
Modbus Modbus TCP/IP

DeviceNet EtherNet/IP

CanOPEN EtherCAT

PROFIBUS PROFInet

Traditional Industrial Ethernet Physical

Protocols Layer
Ethernet Adoption in Industrial
• Total Market $630M
Expected Trends in Type of Wireline Infrastructure Networks
• Ethernet Really Means: being used in Industrial Facilities

– Ethernet/IP
– PROFInet
– Modbus TCP/IP

Source: VDC 2006

Agenda
• Why Ethernet-based Protocols
• Overview of Ethernet-based Industrial Protocols
• Adding Deterministic I/O to NI PACs
Industrial Ethernet and OSI Model
7. Application
Modbus TCP/IP
6. Presentation Ethernet/IP,
PROFInet, and
5. Session EtherCAT,

4. Transport
TCP & UDP
3. Network IP

2. Data Link
Ethernet
1. Physical
Industrial Ethernet protocols are not all just
“Ethernet”, they add features for reliability and
determinism and the trade-off is compatibility
with standard Ethernet
Ethernet-based Industrial Protocols
• Modbus TCP/IP
• EtherCAT
• Ethernet/IP
• Profinet
Similarities
• Reuse layer 1 and 2 of OSI model
– What about the other 5 layers?
• Define master (scanner) and slave (adapter)
devices
• Address 1 or more target applications
– Non Real Time
– Real Time
– Hard Real Time
Application Targets
• Non Real Time
– Uses standard TCP/IP or UDP/IP
– Application: PLC to HMI or PLC to SCADA
• Real Time
– Provides added determinism w/ OTS hardware
– Application: Control data
• Hard Real Time
– Adds specific hardware to deliver determinism
– Application: Distributed Motion
Where Protocols Fit?

EtherCAT PROFInet (IRT)** Ethernet/IP CIP

Sync

PROFInet (RT)** Ethernet/IP

Modbus TCP/IP PROFInet (NRT)* Ethernet/IP

**Also PROFInet IO
*Also PROFInet CBA
Ethernet-based Industrial Protocols
• Modbus TCP/IP
• EtherCAT
• Ethernet/IP
• Profinet
Modbus TCP/IP Overview
• First industrial protocol on Ethernet (introduced 1999)
– Based on Modbus developed by Modicon in 1979
– Widely adopted and open Ethernet standard
• Advantages
– Uses standard Ethernet (hardware and TCP/IP transport layer)
– Open and relatively simple
• Disadvantages
– Not a hard real-time protocol
– Does not deliver determinism
 Modbus Data Items
Modbus Modbus Slave
Data Item Data Type Description Example
Read Write Read Write
000001–065535 Boolean value Yes Yes Yes Yes Accesses single-bit coils. 000001 = {000001}

100001–165535 Boolean value Yes No Yes Yes Accesses single-bit discrete inputs. 100002 = {100002}

Accesses individual bits of input registers and interprets

300001.1 = {the first
300001.1–365535.16 Boolean value Yes No Yes Yes them as logical TRUE or FALSE values. The least
bit of 300001}
significant bit is 1. The most significant bit is 16.

16-bit
Accesses 16-bit input registers as unsigned integers
300001–365535 unsigned Yes No Yes Yes ranging from 0 to 65,535.
300001 = {300001}
integer

Accesses individual bits of holding registers and

400002.16 = {the
400001.1–465535.16 Boolean value Yes Yes Yes Yes interprets them as logical TRUE or FALSE values. The
16th bit of 400002}
least significant bit is 1. The most significant bit is 16.

16-bit
Accesses 16-bit holding registers as unsigned integers
400001–465535 unsigned Yes Yes Yes Yes ranging from 0 to 65,535.
400002 = {400002}
integer
Ethernet-based Industrial Protocols
• Modbus TCP/IP
• EtherCAT
• Ethernet/IP
• Profinet
EtherCAT Overview
• EtherCAT - Ethernet Control Automation Technology
– Managed EtherCAT Technology Group (ETG)
– Open and based on standards, i.e. IEC 61158
• Advantages
– Hard Real Time industrial protocol
– Extremely efficient and straightforward communication
• Disadvantages
– Addresses only hard real time (?)
– Not designed for Standard TCP/IP packets and EtherCAT packets
Functional Principle: Ethernet “On the Fly”
Analogy Fast Train:
• “Train” (Ethernet Frame) does not stop
• Even when watching the “train” through a narrow window one sees the entire train
• “Car” (Sub-telegram) has variable length
• One can “extract” or “insert” single “person” (bits) or entire “groups” – even multiple
groups per train

Master
Slave Slave Slave Slave
Ethernet Frames
• EtherCAT commands are transported in the data area of an Ethernet
frame and can be coded via a special Ether Type
– Ether Type is limited to an Ethernet subnet (not relayed by routers)
Ethernet-based Industrial Protocols
• Modbus TCP/IP
• EtherCAT
• Ethernet/IP
• Profinet
EtherNet/IP Overview
• Dominant bus for Rockwell Automation
– Managed by Open Device Vendors Association (ODVA)
– Extends DeviceNET concepts to Ethernet
• Advantages
– Uses Ethernet transport layer (TCP and UDP)
• Disadvantages
– Can overload networks with UDP messages if note correctly
configured, recommend managed switches with IGMP snooping
Device Classes
• “Master”
Scanner Class • Initiate implicit and explicit communications

• “Slave”
Adapter Class • Only sends data if requested by a scanner
• Supports explicit and implicit messaging

• Used for set-up or on-demand data transfer

Messaging Class • Allows data transfer to be initiated by either
device.
EtherNet/IP Add-ons
CIP Sync
• Based on 1588
• Provide shared clock to devices

CIP Motion
• Builds on CIP Sync to perform distributed control for motion
• Uses clock sharing not QoS

CIP Safety
• Builds on DeviceNet Safety
• Intelligent devices with time-out parameters
Ethernet/IP Terminology
• TCP/IP
• Used to set parameters and initiate
Explicit Messages implicit communication

• UPD/IP multicast
• Used to communicate I/O data
Implicit Messages
• Normally set-up for cyclical updates
 Communication from LabVIEW to
ControlLogix PLCs
EtherNet/IP

Available for download from NI-Labs (ni.com/labs)

Ethernet-based Industrial Protocols
• Modbus TCP/IP
• EtherCAT
• Ethernet/IP
• PROFInet
PROFInet Overview
• Dominate bus for Siemens
– Application protocol that extends PROFIBUS to Ethernet
– Managed by PROFIBUS&PROFINET International (PI)
• Advantages
– Supports both standard and deterministic Ethernet traffic
– Uses IEEE-1588 and QoS to add determinism
• Disadvantages
– For RT/IRT managed switch with QoS is recommended
– Switch with ERTEC ASIC for most challenging apps.
Three Levels
• Non Real Time (NRT)
– PROFINET CBA
– For the commissioning of a plant
– Range of 100ms

• RT (Real-Time)
– PROFINET CBA and PROFINET IO
– IO applications
– Up to 10 ms cycle times

• IRT (Isochronous Real-Time)

– PROFINET IO
– Applications in drive systems
– Cycles time of less than 1ms Source Wikipedia
PROFInet Network cycle
• No “Start Period” message
– Clock synchronization via IEEE 1588 & asynchronous
• Red portion of the cycle (Isochronous)
• Green portion of the cycle (Asynchronous) – min 125 ms
Technology: IEEE-1588
• Technology to synchronize distributed clocks
• Accuracy based on clock jitter
Technology: IEEE-1588
HRT: Determinism and Performance

Organization Response Time Jitter Data Rate

(for 100 axles)
EtherCAT ~ 0.1 ms < 0.1 us 100 Mbits/s
Sercos-III < 0.5 ms < 0.1 us 100 Mbits/s
Profinet-IRT < 1 ms < 1 us 100 Mbits/s
Ethernet Powerlink < 1 ms < 1 us 100 Mbits/s
Ethernet/IP ~ 1 ms < 1 us 100 Mbits/s
Table 1. Real-time comparison of the various real-time methods
Standards-Based Real Time Ethernet Now Off-the-Shelf, by Klaus Zwerina

Table 1. Real-time comparison of the various real-time methods

Standards-Based Real Time Ethernet Now Off-the-Shelf, by Klaus Zwerina
Agenda
• Why Ethernet-based Protocols
• Overview of Ethernet-based Industrial Protocols
• Adding Deterministic I/O to NI PACs
NI System with Deterministic Distributed I/O

Host Computer

(TCP/IP)
(TCP/IP) NI PXI System
NI PXI System
with Ethernet Interface
with Ethernet Interface

NI cRIO-9074
NI cRIO-9074
(EtherCAT)
(EtherCAT)

NI 9144
NI 9144
NI Master Controllers
• Requirements
– CompactRIO or PXI RT system with 2 Ethernet ports
– NI-Industrial Communications for EtherCAT
 NI 9144 Expansion Chassis
2 Ports for
Daisy-Chaining

Rugged Chassis
• -40 to 70°C 8 Slots for
• 9-30V Input C Series
• Hazloc
• Shock/Vibe
LabVIEW Experience

CompactRIO
Chassis

{
NI 9144
Expansion {
Chassis
Deterministic
Distributed I/O
Demo
C Series I/O Modules
• Over 30 analog and digital modules supported
– All single-point measurements
– No waveform support (NI 9233/9234)
• Module-to-module and chassis-to-chassis
synchronization
• Compatibility with different NI chassis

EASY POWERFUL OPEN

Questions