EtherCAT WorkshopCERN 120920

EtherCAT Workshop @ CERN Sept 20, 2012
Agenda
Detailed EtherCAT Technology introduction:
functional principle, topology, performance,
synchronization, diagnosis, implementation, redundancy,
safety, costs, Martin Rostan
Executive Director,
EtherCAT application overview: EtherCAT Technology Group
m.rostan@ethercat.org
why do automation system engineers choose EtherCAT? +49 911 540 56-11
How to implement an EtherCAT Slave Device

if CERN is considering to implement own devices, too.
Q&A, Open discussion

The Ethernet Fieldbus.
21.09.2012
EtherCAT - The Ethernet Fieldbus.
EtherCAT is: EtherCAT is real time down to the I/O level

- Faster
No underlying sub-systems any more
- Synchronization
- Industrial Ethernet
- Flexible Topology
- Easier to configure
- Cost effective
- Easier to implement
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile
September 2012 EtherCAT Technology Group, 2012

EtherCAT is: Other technologies need local I/O cycles + gateways

- Faster
- Synchronization
RAM
Master for Local

Extension Bus
- Flexible Topology
Controller
Fieldbus
Driver
- Easier to configure CPU
- Cost effective
I/O
I/O
I/O
I/O
- Well proven Flash
- Open
- Conformance
- Safety
- Redundancy RAM
- Versatile
Controller
Fieldbus
Driver
I/O
CPU
Flash

EtherCAT is: EtherCAT: Real time down to the I/O

- Faster
- Synchronization
- Flexible Topology
Controller
Controller
Controller
Controller
Controller
EtherCAT
EtherCAT
EtherCAT
EtherCAT
EtherCAT
Driver
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT is: EtherCAT is real time down to the I/O level

- Faster
No underlying sub-systems any more
- Synchronization
No delays in gateways
- Flexible Topology In- and outputs, sensors, actuators, drives, displays:
- Easier to configure everything in one system!
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT is faster
EtherCAT is: Transmission Rate:

- Faster 2 x 100 Mbit/s (Fast Ethernet, Full-Duplex)
- Synchronization
- Flexible Topology Update Times:
- Easier to configure 256 digital I/O in 11 s
- Cost effective
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
- Well proven
- Open 100 Servo-Axis (each 8 Byte In + Out) in 100 s = 0.1 ms
- Conformance 12000 digital I/O in 350 s
- Safety
- Redundancy
- Versatile

EtherCAT is faster
EtherCAT is: Bandwidth Usage of Ethernet for I/O and Drives:

- Faster Ethernet Frame: 84 Bytes
- Synchronization incl. Preamble + IPG (interpacket gap)
- Flexible Topology Data pay load:
- Easier to configure e.g. 2 Bit..6 Byte
22 Bytes 4 Bytes 12 Bytes
- Cost effective
- Easier to implement Ethernet Header Data: 46 Bytes CRC IPG
- Well proven Node

Request with output data
- Open Master I/O reaction
Response with input data time
- Conformance
- Safety Ethernet Header Data: 46 Bytes CRC IPG
- Redundancy
- Versatile
with 4 Byte input + 4 Byte output per node:

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

EtherCAT is faster
EtherCAT is: Bandwidth Usage Comparison:

- Faster At 4 Byte user data per node:
- Synchronization
Polling / Timeslicing: ~ 2..5 %
From 2 Bit user data per node:
- Flexible Topology
EtherCAT: ~ 80..97 % (Full Duplex, 2 x 100 MBit/s)
- Cost effective
- Easier to implement 100
- Well proven 90
80
- Open
70
- Conformance
60
- Safety
50
- Redundancy
40
- Versatile
30
20
10
0
Polling / EtherCAT
Timeslicing

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

Functional Principle: Ethernet on the Fly
EtherCAT is:
- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile
Efficient: Typically only one Ethernet Frame per Cycle

Ideal Bandwidth Utilization for maximum Performance
EtherCAT is:
- Faster Slave Device Slave Device
- Synchronization
EtherCAT Slave EtherCAT Slave
- Flexible Topology Controller Controller
- Cost effective
- Well proven
- Open
Process data is extracted and inserted on the fly:
- Conformance Process data size per slave almost unlimited
- Safety (1 Bit60 Kbyte, if needed using several frames)
- Redundancy Compilation of process data can change in each cycle, e.g.
- Versatile ultra short cycle time for axis, and longer cycles for I/O
update possible
in addition asynchronous, event triggered communication

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

Slow Control Systems benefit, too
EtherCAT is: Reaction time with legacy fieldbus I/O:

- Faster
- Synchronization
I PLC Task O I PLC Task O I PLC Task O I PLC Task O I PLC Task
- Flexible Topology
- Cost effective Tmpd
- Well proven
- Open
Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle
- Conformance
- Safety
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
- Redundancy
best case reaction time
- Versatile
worst case reaction time
Input Input Output

(worst case) (best case)
Tmpd: Master Processing Delay

TI/O: Local I/O Update Time
(local Extension Bus + Firmware)

EtherCAT is: System Architecture with EtherCAT:

- Faster
- Synchronization
- Flexible Topology
- Easier to configure no dedicated Master Device any more
- Cost effective Tmpd
- Well proven
- Open
Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle Bus Cycle
- Conformance
- Safety
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
- Redundancy
on underlying extension bus any more
- Versatile

EtherCAT is: System Architecture with EtherCAT:

- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
TDMA = Time for Data Transfer
- Safety TDMA (MAC) from/to Ethernet Controller via
- Redundancy
Direct Memory Access:
- Versatile neglectible
TEtherCAT Cycle

EtherCAT is: Reaction Time with EtherCAT:

- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Easier to implement best case
worst case
- Well proven
- Open
EtherCAT Input Input Output
- Conformance (worst case) (best case)
Bus Cycle
- Safety
- Redundancy
- Versatile
Reaction time reduced significantly with the same controller
performance
no underlying local I/O cycles and extension bus delays any more
Due to the very simple protocol no dedicated master systems
(e.g. plug-in cards) required

Fieldbus: requires Mapping in Control System
EtherCAT is: Traditional fieldbus system generate physical process image

- Faster
This has to be mapped to logical process image(s)
- Synchronization
- Flexible Topology
- Easier to configure Control System, e.g. IPC
Feldbus Scanner/
node 1
- Cost effective
DPRAM Master
logical process images
node 1
- Well proven Data n
- Open PLC Data

node 2 node 2
- Conformance
NC Data
- Safety
node 3
- Redundancy
node 4
- Versatile node 3
Mapping
node 4

Fieldbus: requires Mapping in Control System
EtherCAT is: The same applies to system with just one process image
- Faster
Resorting of process data (Mapping) is required, too
- Synchronization
- Flexible Topology
- Easier to configure Control System, e.g. PLC
Feldbus Scanner/
node 1
- Cost effective
DPRAM Master
logical process image
node 1
- Well proven
- Open node 2 node 2
- Conformance
- Safety
node 3
- Redundancy
node 4
- Versatile node 3
Mapping
node 4

EtherCAT: Mapping moved into Slave Devices
EtherCAT is: Master
- Faster
- Synchronization
logical process images up to 4 GByte
- Flexible Topology
- Cost effective
HDR 1
HDR 2
HDR 3
ECAT
Ethernet Header
HDR PLC Data NC Data Data n Ethernet
- Well proven Data n
- Open PLC Data

- Conformance
- Safety NC Data
Datagram 1 Datagram 2 Datagram n
- Redundancy
- Versatile
Control System is unburdened, master becomes very

simple
Data is transmitted according to the application
requirements: extremely fast, flexibly and efficiently
Direct Memory Access saves time
EtherCAT is: Fieldbus cards: PC Control with Fieldbus cards

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

EtherCAT Propagation Delay Measurement (1)
EtherCAT is: EtherCAT Node measures time difference between

- Faster leaving and returning frame
- Synchronization
- Flexible Topology
- Cost effective
EtherCAT Frame
- Well proven Processing Direction
- Open EtherCAT Frame
- Conformance Forwarding Direction
- Safety
- Redundancy
- Versatile

EtherCAT Propagation Delay Measurement (2)
EtherCAT is: EtherCAT Node measures time difference between

- Faster leaving and returning frame
- Synchronization
- Flexible Topology
IPC
Master
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

Distributed Clocks
EtherCAT is: Precise Synchronization (<< 1 s!) by exact adjustment

- Faster of Distributed Clocks
- Synchronization
- Flexible Topology
M
S
IPC
Master t
- Cost effective
- Well proven S
S
- Open
- Conformance
- Safety S S S S
- Redundancy
- Versatile

Distributed Clocks
EtherCAT is: Long Term Scope View of two separated devices

- Faster 300 Nodes in between, 120m Cable Length
- Synchronization
- Flexible Topology
Interrupt
Node 1
- Cost effective
- Well proven Simultaneousness:
- Open
~15 ns
- Conformance Jitter: ~ +/-20ns

- Safety
- Redundancy
- Versatile
Interrupt
Node 300

Synchronization of multiple Networks
EtherCAT is: EtherCAT networks can be coupled via EtherCAT Bridge

- Faster Bridge provides hardware synchronization of several networks
- Synchronization
- Flexible Topology
M1
- Cost effective
- Well proven
M2
- Open
- Conformance
- Safety
- Redundancy M3
- Versatile

Synchronization of multiple Networks
EtherCAT is: EtherCAT networks can be coupled via EtherCAT Bridge

- Faster Bridge provides hardware synchronization of several networks
- Synchronization
- Flexible Topology
M1
- Cost effective
- Well proven
M2
- Open
- Conformance
- Safety
- Redundancy M3
- Versatile

External Clock Synchronization: IEEE 1588
EtherCAT is: Switchport with integrated IEEE 1588 Boundary Clock

- Faster
- Synchronization IEEE 1588
Grandmaster
- Flexible Topology
M Boundary
- Easier to configure S Clock
- Cost effective Master
- Well proven S
S
- Open
- Conformance
- Safety S S S S
- Redundancy
- Versatile

EtherCAT is Industrial Ethernet!
EtherCAT is: EtherCAT uses Standard Ethernet Frames: IEEE 802.3

- Faster Alternatively via UDP/IP (if IP Routing is needed)
- Synchronization
no shortened frames
- Flexible Topology
MTU: max. 1514 Byte
- Cost effective
48 Bit 48 Bit 16 Bit 16 Bit 48 -1498 Byte 32 Bit
Destination Source EtherType Header EtherCAT Datagrams CRC
- Well proven
- Open Embedded in Standard Ethernet
Frame, EtherType 0x88A4 1n EtherCAT
- Conformance Datagrams
- Safety
160 Bit 64 Bit 16 Bit 48 -1470 Byte
- Redundancy
Ethernet H. IP Header UDP H. Header EtherCAT Datagrams CRC
- Versatile
Or: via UDP/IP
UDP Port 0x88A4 11 Bit 1 Bit 4 Bit
Length Res. Type

EtherCAT is: fully transparent for TCP/IP

- Faster all Internet technologies (HTTP, FTP, Webserver,)
- Synchronization available without restricting the real time capabilities!
- Flexible Topology
- Easier to configure EtherCAT Slave Device
- Cost effective
- Easier to implement Ethernet Real Time
Standard
- Well proven Application Application
TCP/IP
- Open Stack
- Conformance
TCP UDP
- Safety Acyclic
IP
- Redundancy Data
- Versatile
Mailbox Process Data
EtherCAT MAC / DLL
Ethernet PHY Ethernet PHY

EtherCAT is: Any Ethernet Device can be connected to Switchport

- Faster Access to Webserver with Standard Browser
- Synchronization
- Flexible Topology Webserver
Virtual Ethernet
- Easier to configure Switch
- Cost effective Functionality
Switchport
Master
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT is: Virtual Ethernet Switch routes any Ethernet Frame

- Faster From inside as well as from outside the segment
- Synchronization
- Flexible Topology
Virtual Ethernet
Switch
- Cost effective Functionality Switchport
Master
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile
Ethernet
Switch

Switchport: Any Ethernet Protocol
EtherCAT is: Interface to any Ethernet Device or Network

- Faster Ethernet Frames are inserted into EtherCAT Protocol:
- Synchronization
Ethernet over EtherCAT
- Flexible Topology
EtherCAT Switchport
- Cost effective
- Easier to implement Ethernet MAC PHY
- Well proven
- Open
RX1 RX RX3
RX2TX RX4
- Conformance C
- Safety Fragmentation
- Redundancy
- Versatile Mailbox Process Data
PHY EtherCAT MAC / DLL PHY
TX2
TX3
TX1 TX1
TX3
TX2

EtherCAT is: Master TCP/IP Stack can provide remote Mailbox access
- Faster via TCP/IP to any EtherCAT device ideal for tools.
- Synchronization No need for TCP/IP stack in each device: cost reduction
- Flexible Topology
Master TCP/IP
- Easier to configure Stack provides Online access to
access to Mailbox device
- Cost effective
protocol
- Easier to implement Switchport
Master
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

Vertical Integration (1)
EtherCAT is: via Switchport

- Faster
- Synchronization
- Industrial Ethernet Master
- Flexible Topology
- Cost effective
- Well proven Switchport
- Open
- Conformance
- Safety
+ any Ethernet Protocol can be used
- Redundancy + requires only one Ethernet Port (at IPC/Controller)
- Versatile
+ EtherCAT performance is not limited

EtherCAT is: ...via 2. Ethernet Port

- Faster
- Synchronization
- Flexible Topology
- Cost effective
2nd Ethernet
- Well proven Port
- Open
- Conformance
- Safety
- Redundancy + EtherCAT performance is not limited
- Versatile
- but: requires second Ethernet Port (at IPC/Controller)

EtherCAT is: via Switch

- Faster
- Synchronization
- Flexible Topology
- Cost effective
Ethernet
- Well proven Switch
- Open
- Conformance
- Safety
- Redundancy + requires only one Ethernet Port (at IPC/Controller)
- Versatile
- but: performance reduced by switch delay (and generic
Ethernet traffic)

EtherCAT wiring is more flexible
EtherCAT is: Standard Ethernet Topology: Star

- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT is: Flexible topologies arbitrarily extendable

- Faster Topology variants like Line, Star, Tree, Daisy Chain
- Synchronization + Drop Lines possible; can be used in any combination!
Up to 65.535 nodes for each EtherCAT segment
- Flexible Topology
Standard Ethernet cabling
Line
- Cost effective
- Well proven
- Open
Master
- Conformance
- Safety
- Redundancy
- Versatile
Drop Line
Star/Tree

ERP
EtherCAT is: EtherCAT Automation Protocol
- Faster HMI
- Synchronization (e.g OPC,
Thin Client) Switch
HMI
- Flexible Topology
EtherCAT EtherCAT EtherCAT
- Cost effective Master Master Master
- Well proven Slave Slave Slave Slave Slave
- Open Device Device Device Device Device
- Conformance
Slave Slave Slave Slave Switch- EtherCAT EtherCAT
- Safety Device Device Device Device port Master Master
- Redundancy
Slave redundancy Slave Slave Slave
(optional) Slave
- Versatile Device Device Device Device Device
Slave Slave Slave Slave Slave

Device Device Device Device Device
Slave Slave Slave Slave Slave

Device Device Device Device Device
EtherCAT Device Protocol processed on the fly

EtherCAT Extra Large System Test
EtherCAT is:
- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile
10.056
EtherCAT Nodes

EtherCAT is: Ethernet Signal Variants of EtherCAT:

- Faster 100BASE-TX (up to 100 m between 2 nodes)
- Synchronization 100BASE-FX (up to 20 km between 2 nodes (single mode fibre) )
- Flexible Topology
LVDS (for modular devices)
- Easier to configure LVDS*
- Cost effective 100 m
- Well proven 20 km
- Open
Master
- Conformance
- Safety
- Redundancy Ethernet on Ethernet on
100BASE-TX 100BASE-FX
- Versatile up to 100 m (fibre optics)
with transformer up to 20 km
coupling Ethernet on LVDS* physical layer:
for modular devices
Any number of physical layer changes allowed

*LVDS: Low Voltage Differential Signaling according to ANSI/TIA/EIA-644,
also used in IEEE 802.3ae (10 Gigabit Ethernet)
EtherCAT instead of PCI
EtherCAT is: Protection of your investment

- Faster smooth migration path from legacy fieldbus to EtherCAT
- Synchronization seamless integration of existing fieldbus devices, e.g.:
- Industrial Ethernet AS-Interface
- Flexible Topology BACnet MS/TP
- Easier to configure CANopen
- Cost effective CC-Link
- Easier to implement ControlNet
- Well proven DeviceNet
- Open Ethernet/IP
- Conformance FIPIO
- Safety Interbus
- Redundancy IO-Link
- Versatile Lightbus
LonWorks
Modbus Plus, RTU, TCP
PROFIBUS
PROFINET IO

maximum system expandability with low cost fieldbus gateways
EtherCAT is: Update Times:

- Faster Process image update-time
- Synchronization via PCI (500 Bytes input and output data each): 400 s
Process image update-time
- Flexible Topology
via EtherCAT (1.500 Bytes input and output data): 150 s
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

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

- Faster more
- Synchronization Nevertheless maximum expandability
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile
EtherCAT

EtherCAT is easier to configure
EtherCAT is:
- Faster
Topology:

- Synchronization Automatic Topology Expected/Actual Comparison
- Flexible Topology Diagnosis: Every node
- Easier to configure constantly
- Cost effective
Diagnosis with exact Localization monitors
checksum
- Well proven M
- Open
Bit errors are
- Conformance detected and
- Safety localized
- Redundancy
- Versatile
Even Timing Errors (e.g. Time Window for Actual Values

missed) are detected and stored locally in the chip

EtherCAT is easier to configure
EtherCAT is: Network planning:

- Faster Performance independent of:
- Synchronization
- Industrial Ethernet Slave implementation
- Flexible Topology (no Stacks involved in Process Data Communication)
- Easier to configure Topology (no Switches/Hubs)
Addressing
- Cost effective
- Well proven No manual address setting required
- Open No IP- or MAC-Address Handling Required
- Conformance
- Safety
Addresses can be assigned automatically
- Redundancy Addresses can be kept
- Versatile no new addressing if nodes are added

Configuration: Classical Fieldbus Systems
EtherCAT is: 1. Select + Plan Topology according to System Limitations

- Faster 2. Configure Node Address at Slave Device
- Synchronization
3. Select and Configure Baudrate,
- Flexible Topology
depending on:
- Network Length + Topology
- Cost effective - EMI-Environment
- Easier to implement - Application Requirements
- Well proven 4. Select Device Description Files (GSD, EDS) in
- Open
Configuration Tool
- Conformance
- Safety
5. Select and Configure Communication Parameters,
- Redundancy such as:
- Versatile - cyclic Polling
- event driven Communication
- synchronized or free running
6. Allocate physical to logical Process Image (Mapping)

Configuration: EtherCAT
EtherCAT is: 1. Select + Plan Topology according to System Limitations

- Faster 2. Configure Node Address at Slave Device
- Synchronization
3. Select and Configure Baudrate,
- Flexible Topology
depending on:
- Network Length + Topology
- Cost effective - EMI-Environment
- Easier to implement - Application Requirements
- Well proven 4. Select Device Description Files (GSD, EDS) in
- Open
Configuration Tool
- Conformance
- Safety
5. Select and Configure Communication Parameters,
- Redundancy such as:
- Versatile - cyclic Polling
- event driven Communication
- synchronized or free running
6. Allocate physical to logical Process Image (Mapping)

EtherCAT is lower costs (1): Engineering
EtherCAT is: Less effort for Network planning:

- Faster Simplified configuration
- Synchronization
- Industrial Ethernet Default settings will work, no network tuning
- Flexible Topology
Improved Diagnosis:

- Cost effective Faster error handling leads to less downtime
Faster Setup:
- Well proven
- Open No address setting required
- Conformance
Implementation / Tools:
- Safety
- Redundancy Standard Network Monitor Tools,
- Versatile e.g. MS Network Monitor or Wireshark: free of charge
Parser Software: free of charge

EtherCAT is lower costs (2): Hardware
EtherCAT is: Master:

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

Device + Infrastructure Cost Comparison
EtherCAT is:
- Faster
Example Configuration

- Synchronization (e.g. Beckhoff Products)
PLC (CX1000)
- Flexible Topology
- Easier to configure 10 Bus Stations
- Cost effective
- Easier to implement 400 DI / 400 DO
- Well proven
- Open
100 m Cable
- Conformance
11 Bus Connectors
- Safety
(Fieldbus)
- Redundancy
- Versatile 21 Bus Connectors
(EtherCAT)
Inexpensive Compact
Fieldbus Couplers

Device + Infrastructure Cost Comparison
EtherCAT is: Example

- Faster Configuration List Price* Difference
- Synchronization
- Flexible Topology
100 % -
- Cost effective
- Easier to implement 121,5 % + 21,5 %
- Well proven
- Open
- Conformance
123,7 % + 23,7 %
- Safety
- Redundancy
- Versatile
121,9 % + 21,9 %
And just for reference:
143,7 % + 43,7 %
Profinet RT / Ethernet/IP: switches not taken into account
* Beckhoff Price List 01/2010
Why such significant Price Differences?
Master/Scanner Card EtherCAT: no Master HW
6%
Bus Coupler with CPU and Bus Coupler and Digital I/O:
local extension bus master just EtherCAT Slave Controller
RAM
Master for Local

Extension Bus
Controller
Controller
EtherCAT
EtherCAT
Controller
Driver
Fieldbus
Driver
CPU 12%
Flash
T-Junction Connectors Simple Straight Connectors
2%

EtherCAT is easier to implement
EtherCAT is: Slave Implementation:

- Faster All time critical functions implemented on ASIC or FPGA
- Synchronization ESC handles Real-time Protocol in Hardware
Integrated Communication State Machine
- Flexible Topology
- Easier to configure Network Performance independent of

- Cost effective Slave-C Performance
- Easier to implement Protocol Stack
- Well proven For usage with or without C (Host CPU)
- Open Integrated DPRAM (18kByte)
- Conformance
Integrated Distributed Clock Handling
- Safety
- Redundancy
Ultra precise interrupts to C
- Versatile

EtherCAT Slave Controller Variety
TI's Sitara and

other C + P families
Hilscher Hilscher
netX 50 netX 51/52/6
Beckhoff
ET1100
Hilscher Beckhoff
netX 100/500 ET1200
IP-Core for FPGA of

Intel Atom E6x5C IP-Core for
Altera Cyclone-V
IP-Core for
IP-Core for Xilinx
Altera Spartan-6 IP-Core for
IP-Core Stratix-IV Xilinx Kintex-7
Xilinx IP-Core for
Spartan-3 Xilinx

Artix -7 + Zynq
IP-Core for IP-Core for IP-Core for
ESC10/20: Altera Altera Altera IP-Core for
Altera Cyclone-I Cyclone-II Cyclone-III Cyclone-IV Altera Stratix-V

EtherCAT Slave Controller Features: ASIC (1)
EtherCAT is: Name ET1100 ET1200

- Faster Type ASIC ASIC
- Synchronization
- Industrial Ethernet Hardware Supplier
- Flexible Topology
Package BGA128 QFN48
- Easier to configure 0,8mm Pitch 0,5mm Pitch
- Cost effective Size 10 x 10 mm 7 x 7 mm
- Easier to implement C Interface serial/parallel serial*
- Well proven (8/16bit, sync/async)*
- Open
Digital I/O 8-32* 8-16*
- Conformance
General Purpose I/O 0-32* 0-12*
- Safety
DPRAM 8 kByte 1 kByte
- Redundancy
SyncManager 8 4
- Versatile
FMMUs 8 3
Distributed Clocks Yes Yes
No. Of Ports 2-4 (MII/E-bus)* 2-3 (EBUS/max. 1xMII)*
Specials BGA routable with -

standard PCB
* configurable
EtherCAT Slave Controller Features: ASIC (2)
EtherCAT is:
Name netX 100 netX 500 netX50
- Faster Type ASIC ASIC ASIC
- Synchronization
- Flexible Topology
- Easier to configure BGA345 BGA345 PBGA324
Package
1mm Pitch 1mm Pitch 1mm Pitch
- Cost effective
- Easier to implement Size 22x22 mm 22x22 mm 19x19 mm
- Well proven C-Bus C-Bus C-Bus

C Interface
(internal, 32-bit) (internal, 32-bit) (internal, 32-bit)
- Open
General Purpose I/O 16 16 32
- Conformance
256/512 Byte 256/512 Byte
- Safety DPRAM (Mailbox/Process (Mailbox/Process 6 kByte
- Redundancy Data) Data)
- Versatile SyncManager 4 4 8
FMMUs 3 3 8
Distributed Clocks Yes Yes Yes
No. Of Ports 2 (100BASE-TX) 2 (100BASE-TX) 2 (100BASE-TX)
Multi Protocol Multi Protocol Multi Protocol
Specials Support, Integrated: Support, Integrated: Support, Integrated:
PHYs, ARM-9 C PHYs, ARM-9 C PHYs, ARM-9 C

ESC Features: Micro-Processor
EtherCAT is:
Name Sitara AM3357/3359
- Faster
Type ARM MPU
- Synchronization
- Flexible Topology 324NFBGA
Package
- Easier to configure 0,8mm Pitch
- Cost effective Size 15 * 15 mm
200 MHz interconnect
- Well proven C Interface
(internal, 32bit)
- Open
Digital I/O 8/8
- Conformance
General Purpose I/O >32
- Safety
DPRAM 8 kByte
- Redundancy
SyncManager 8
- Versatile
FMMUs 8
Distributed Clocks Yes
No. Of Ports 2 MII
Multi Protocol Support, ARM Cortex A8

Specials
(275720 MHz)

EtherCAT Slave Controller Features: FPGA
Name ET1810/ET1811/ET1812 ET1815/ET1816/ET1817

EtherCAT is:
- Faster Type Altera FPGA + IP Core Xilinx FPGA + IP Core
- Synchronization Hardware
Supplier
Cyclone II+III+IV E, IV GX, Spartan 3+3E+3A+3AN+3A DSP
- Flexible Topology Stratix I+II+III+IV+V, GX, II GX, Spartan 6,
- Easier to configure Supported Chips
Arria GX, II GX, II GZ, Kintex 7+ 7LP
- Cost effective Intel Atom E6x5C Virtex 4+5+6+7+7LP
- Easier to implement Package FPGA dependent FPGA dependent
- Well proven Size FPGA dependent FPGA dependent
- Open serial/parallel serial/parallel
- Conformance C Interface (8/16-bit, async) (8/16bit, async)
AVALON* PLB, OPB*
- Safety
Digital I/O 8-32* 8-32*
- Redundancy
DPRAM 1...60 kByte* 1...60 kByte*
- Versatile
SyncManager 08* 08*
FMMUs 08* 08*
Distributed Clocks Yes* Yes*
No. Of Ports 1-3 (MII / max. 2 RMII) 1-3 (MII / max. 2 RMII)
Several IP Core License models Several IP Core License models

Specials
available available
* configurable
IP-Core Configuration Options (ET18xx)
EtherCAT is: FPGA resource consumption depends on configuration

- Faster Examples:
- Synchronization
Small Configuration: ~ 6,000 LE (Altera Cyclone I)
~ 3,700 Slices (Xilinx Spartan-3E)
- Flexible Topology
32Bit digital IO, 1kByte RAM,
- Cost effective
without Distributed Clocks, Small Register Set
- Well proven
2 FMMU, 2 SyncManager
- Open Max. Configuration: ~ 17,000 LE (Altera Cyclone I)
- Conformance ~ 11,000 Slices (Xilinx Spartan-3E)
- Safety SPI Slave, 60kByte RAM,
- Redundancy with Distributed Clocks, Full Register Set
- Versatile 8 FMMUs, 8 SyncManager
Altera (LEs): DC: ~3,000, SM: ~500, FMMU: ~600

Xilinx (Slices): DC: ~1,900, SM: ~350, FMMU: ~400

EtherCAT is easier to implement: Slave
EtherCAT is: Slave Sample Code

- Faster Bus handling contained in EtherCAT Controller
- Synchronization Handling of enhanced EtherCAT State Machine
Mailbox Handling
- Flexible Topology
- Easier to configure Protocol Handler for:
- Cost effective CoE (CANopen over EtherCAT)
- Easier to implement FoE (File Access over EtherCAT)
- Well proven EoE (Ethernet over EtherCAT)
- Open SoE (Servodrive Profile over EtherCAT)
- Conformance
Example applications for each protocol
- Safety
For usage in own products comes with the Beckhoff
- Redundancy
Evaluation Kit!
- Versatile
Code is also used in Beckhoff Products

EtherCAT Slave Implementation: Modules
EtherCAT is: Slave Communication Modules

- Faster EtherCAT Interface with ET1100 ASIC (FB1111)
- Synchronization
EtherCAT Interface with Altera/Xilinx* FPGA (FB1122/1130)
- Flexible Topology
- Cost effective
- Well proven
EEPROM
- Open ESC
- Conformance
- Safety
- Redundancy Status PHY
LEDs Magnetics
- Versatile RJ45
FB1111 FB1122 FB1130
*IP Core required

EtherCAT is: EtherCAT Interface comX with netX 500 ASIC

- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT is: EtherCAT Interface Anybus-S with FPGA

- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
- Safety
EtherCAT Plug-In module
- Redundancy
- Versatile

EtherCAT Slave Implementation: Eva-Boards
EtherCAT is: EtherCAT Evaluation kit EL98xx

- Faster
- Synchronization
with Slave Sample Code (Source)
- Flexible Topology
EtherCAT Slave Controller as ASIC or FPGA
- Easier to configure Full EtherCAT Master Evaluation License included
- Cost effective Several PDI (32 Bit Digital I/O, 8/16-Bit C, SPI) available
PIC on-board with debugger interface
- Well proven
- Open SPI
- Conformance PIC over SPI
32 Bit Digital I/O

- Safety PDI Selector Interface
- Redundancy 8/16-bit uC
Interface
- Versatile
Power
Supply
PIC Program and

Debug Interface
Programmer Base Board

for FPGA EL9800
EtherCAT
Slave Controller Board

EtherCAT is: Cyclone III Development Board DBC3C40

- Faster EtherCAT Slave Controller as FPGA (Cyclone III)
- Synchronization 2 x 10/100 Ethernet PHY
- Industrial Ethernet LVDS TFT interface
- Flexible Topology 16 Mbyte SDRAM
- Easier to configure 1Mbyte SRAM
- Cost effective 8 Mbyte flash
- Easier to implement Security Eprom
- Well proven 1 x UART transceiver
- Open 2 x CAN transceiver
- Conformance 4 x RS485 transceiver
- Safety USB 2.0 OTG
- Redundancy Temperature Sensor
- Versatile 32 pin I/O connector
16 bit 24V I/O interface
8 x User LEDs
2 digit seven segment display
4 user buttons
navigation key

EtherCAT is: netX100 Network Evaluation Board

- Faster
- Synchronization
with EtherCAT protocol stack
- Flexible Topology
- Easier to configure EtherCAT Slave Controller as ASIC (netX100)

- Cost effective Can work as Master or Slave in the network
- Easier to implement 4 MByte 16-Bit Flash
- Well proven 8 MByte 32-Bit SDRAM
- Open Two Ethernet Ports with Switch and Hub Functionality
- Conformance Fieldbus Interface for AS-Interface (Master only), CANopen, CC-
- Safety Link, DeviceNet, InterBus (Master only), PROFIBUS
- Redundancy USB 1.1 Device
- Versatile
RS232C-Interface
JTAG-Interface
16 Switches as Digital Inputs
16 LEDs as Digital Outputs
Two Digit Address Switch
Reset and Boot Buttons
EtherCAT is: netX500 RE Evaluation Board

- Faster
- Synchronization
with Sample Code (on demand)
- Flexible Topology
- Easier to configure EtherCAT Slave Controller as ASIC (netX500)

- Cost effective Several PDI available
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT Slave Controller without Host Controller
EtherCAT is:
- Faster 4 Groups of 8 binary Signals

- Synchronization 8 I/O 8 I/O 8 I/O 8 I/O
- Flexible Topology EtherCAT
- Easier to configure I/O Application Slave

Controller
- Cost effective Process Data Service Data
- Easier to implement EEPROM
Dual Port Memory non volatile Data
- Well proven
- Open
Sync-Manager, FMMU Registers
- Conformance
- Safety
Auto-Forwarder with Loop Back
- Redundancy
- Versatile
EtherCAT MAC EtherCAT MAC
MII MII
RJ45
Trafo
RJ45
Trafo
PHY
PHY

EtherCAT Slave Controller without Host Controller
EtherCAT is: Features

- Faster EtherCAT State Machine
- Synchronization handled by ESC
- Industrial Ethernet (EtherCAT Slave Controller)
- Flexible Topology No Mailbox
No Object Dictionary
- Cost effective
- Easier to implement Up to 32 signals can be
- Well proven connected directly
- Open 32 Bit input interface
- Conformance 32 Bit output
- Safety 24 Bit input / 8 Bit output
- Redundancy 16 Bit input / 16 Bit output
- Versatile 8 Bit input / 24 Bit output
Boot Configuration and Slave Information (Identification) in
serial EPROM
No Software required

EtherCAT Slave Controller with Host Controller
EtherCAT is:
Host Controller HTTP,
- Faster FTP, RAM for TCP/IP
and complex
- Synchronization Service
TCP/IP Applications
- Industrial Ethernet Process Data Data (optional)
- Flexible Topology
- Easier to configure EtherCAT
Application Mapping Slave
- Cost effective
Controller
- Easier to implement Process Data Mailbox
- Well proven Dual Port Memory non volatile Data EEPROM
- Open
- Conformance Sync-Manager, FMMU Registers
- Safety
- Redundancy
Auto-Forwarder with Loop Back
- Versatile
EtherCAT MAC EtherCAT MAC

MII MII
RJ45
Trafo
RJ45
Trafo
PHY
PHY

EtherCAT is: 8/16-bit C Interface

- Faster Demultiplexed
- Synchronization Intel Signal Types
Polarity configurable (BUSY, INT)
- Flexible Topology
- Easier to configure Typical C:
- Cost effective Intel 80x86, Infineon 80C16x,
- Easier to implement Hitachi SH1, ST10, ARM,
- Well proven TI TMS320 Serie,
- Open
- Conformance SPI
- Safety
Up to 10 MBaud
- Redundancy
C is SPI Master
- Versatile
Typical C:
Microchip PIC, DSPic, Intel 80C51,

EtherCAT is: Features:

- Faster EtherCAT State Machine
- Synchronization CoE (CANopen over EtherCAT):
Mailbox with SDO Protocol
- Flexible Topology
Object Dictionary with Mandatory Objects
Device Type
- Cost effective
Identity Object
Physical Address
- Well proven
PDO Mapping and related Objects
- Open
Sync Manager Communication Type
- Conformance Sync Manager PDO Relation
- Safety
or:
- Redundancy
SoE (Servodrive profile (IEC61800-7-204*) over EtherCAT)
- Versatile
optional: EoE (Ethernet over EtherCAT)
* also known as SERCOS Standard

Microcontroller Requirements (Slave Host Controller)
EtherCAT is: Simple (I/O) Devices do not require a C at all

- Faster Tasks of C in more complex devices:
- Synchronization
Process data exchange with the application
- Flexible Topology
Object Dictionary Handling
- Easier to configure Handling of Application Parameter
- Cost effective (Communication Parameter are handled by ESC)
- Easier to implement TCP/IP Stack Handling if required
- Well proven
C-Performance is determined by Device Application,
- Open
- Conformance
not by EtherCAT Communication
- Safety In many cases an 8-bit C is sufficient
- Redundancy
- Versatile

EtherCAT is easier to implement: Master
EtherCAT is: Master Implementation:

- Faster e.g. with Master Sample Code (Source)
- Synchronization EtherCAT Configuration Tool
XML Data format of ESI and ENI
- Flexible Topology
- Easier to configure Process Data (PD) Image
description
- Cost effective EtherCAT
Application
Realtime
- Easier to implement Configuration Tool
- Well proven
Process Data Mailbox
Parser
- Open .xml Image Services
.xml
.xml .xml
- Conformance init req. resp.

EtherCAT Slave EtherCAT Network cyclic
acyclic
EtherCAT Master
- Safety Information (ESI) Files Information (ENI) File commands
commands
- Redundancy
EtherCAT Master Driver
- Versatile optional; for online functionality
(e.g. scanning for devices) Realtime
Ethernet Frames
Network Driver
Standard Ethernet MAC

EtherCAT is easier to implement: Master
EtherCAT is: Example: Master with just one process image

- Faster typical e.g. for small controllers with one control task
- Synchronization up to 1488 Byte Process data size
- Industrial Ethernet Header for Process Data communication remains constant
- Flexible Topology
- Easier to configure Ethernet Header ECAT EtherCAT Datagram Ethernet

WKC
- Cost effective DA SA Type
Frame EtherCAT
Data Pad. FCS
HDR HDR
- Easier to implement 6 Bit 6 Bit 2 Bit 2 Bit 10 Bit 0.1486 Byte 2 032 4 Byte
- Well proven
- Open
constant header completely sorted Working Padding Bytes and
- Conformance (mapped) process data Counter: CRC generated by
constant Ethernet Controller
- Safety (MAC)
- Redundancy Master can be implemented with minimal effort

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

EtherCAT is well proven
EtherCAT is: In Series Production since 2003, outstanding Product Variety

- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT is an open technology
EtherCAT is: Protocol is disclosed completely:

- Faster EtherCAT is IEC, ISO and SEMI Standard
- Synchronization
(IEC 61158, IEC 61784, ISO 15745, SEMI E54.20)
- Flexible Topology
- Cost effective
- Well proven
- Open Slave Controller from several sources available
- Conformance
- Safety
Slave Controller provides interoperability
- Redundancy ETG organizes Interoperabilitly Testing
(Plug Fests), Workshops and Seminars
- Versatile
Conformance Testing + Certificates

EtherCAT Technology Group and IEC
EtherCAT is: Management Board of IEC has approved Liaison of

- Faster EtherCAT Technology Group with IEC SC65C WG
- Synchronization 11/12/13 + JWG10 (SC65C: Digital Communication)
- Flexible Topology
- Cost effective
- Well proven
Thus ETG is official IEC Standardization Partner

- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT in IEC 61800-7
EtherCAT is:
IEC 61800-7: Generic Interface and use of profiles for power drive systems
- Faster
- Synchronization IEC 61800-7-1: Interface Definition
Annex A: Annex B: Annex C: Annex D:
- Flexible Topology Mapping to Mapping to Mapping to Mapping to
- Easier to configure CiA402 CIP PROFIdrive SERCOS*

- Cost effective
- Easier to implement IEC 61800-7-200: Profile Specifications
- Well proven
- Open IEC 61800-7-201: IEC 61800-7-202: IEC 61800-7-203: IEC 61800-7-204:
Profile Profile Profile Profile
- Conformance CiA402 CIP Motion PROFIdrive SERCOS*
- Safety
- Redundancy IEC 61800-7-300: Mapping of Profiles to Network Technologies
- Versatile
IEC 61800-7-301 IEC 61800-7-304
B C
Mapping to Mapping to Mapping to ... ... Mapping to Mapping to Mapping to
CANopen** EPL EtherCAT SERCOS I/II SERCOS III EtherCAT
*SERCOS interface is a trademark of SI e.V.

**CANopen is a trademark of CAN in Automation e.V.
EtherCAT Architecture + Device Profiles
EtherCAT is:
- Faster EtherCAT Device

- Synchronization File System, HTTP, FTP, DEVICE Application
- Industrial Ethernet Bootloader
The SERCOS* The CANopen**
- Flexible Topology Process Data
Standard Standard
- Cost effective
TCP UDP IDN Object Dictionary
- Well proven IP Service Channel SDO
PDO
AT
File Access EN 50325-4 Map-
- Open MDT
IEC 61800-7-204 IEC 61800-7-201 ping
Ethernet IEC 61800-7-304
- Conformance IEC 61800-7-301
- Safety FoE EoE SoE CoE CoE/SoE
- Redundancy Mailbox Process Data

- Versatile
EtherCAT Slave Controller
Ethernet Physical Layer
*SERCOS interface is a trademark of SI e.V.

**CANopen is a trademark of CAN in Automation e.V.
EtherCAT Master OS Technology Variety
EtherCAT is: EtherCAT Masters implemented on wide range of RTOS*

eCos
- Faster Integrity
INtime
- Synchronization Linux with RT-Preempt
- Industrial Ethernet Microware OS-9
MQXTM
- Flexible Topology On Time RTOS-32
Oracle Solaris (SunOS)
PikeOS
- Cost effective Proconos OS
QNX
- Easier to implement Real-Time JavaTM
- Well proven RMOS
RTKernel
- Open RT-Linux
RTX
- Conformance RTXC
- Safety RTAI Linux
SCALE-RT
- Redundancy TKernel
VxWin + CeWin+ RTOS32Win+LxWin
- Versatile VxWorks
Windows CE
Windows Embedded mit IntervalZero RTX
Windows XP/XPE mit CoDeSys SP RTE
Windows XP/XPE mit TwinCAT RT-Extension
Windows Vista, 7
XOberon
XENOMAI Linux
C/OS-IITM
*as of July 2012

Typical EtherCAT Device Architecture
EtherCAT is:
- Faster EtherCAT Device
- Synchronization
HTTP, FTP, DEVICE Application
- Industrial Ethernet optional
- Flexible Topology Device Profile
Device Profile
Definitions
Definitions
- Cost effective
- Easier to implement TCP UDP Parameters Cyclic
Synchronous
- Well proven IP Asynchronous
Communication
Communication
- Open (Implicit
(Explicit
Ethernet Addressing)
- Conformance Addressing)
- Safety
EoE CoE/SoE CoE/SoE
- Redundancy
Mailbox Process Data
- Versatile
EtherCAT Slave Controller
Ethernet Physical Layer

EtherCAT is an open technology
EtherCAT is:
- Faster
- Synchronization
- Flexible Topology Foundation: November 2003
- Easier to configure Tasks: Support, Advancement and Promotion of
- Cost effective
EtherCAT
- Well proven
The worlds largest fieldbus organization
- Open More than 2100* member companies from
- Conformance 55 countries in 6 continents:
- Safety
Device Manufacturers
- Redundancy
- Versatile
End Users
Technology Providers
Membership is open to everybody
*as of August 2012

ETG Team Worldwide
Dr. Guido Andrea Bock, Geng Cheng, Bin (Beryl) Fan, Oliver Fels, Florian Hammel, Florian Hfele, Rainer Hoffmann, Liliane Hgel,
Beckmann, GER GER CHN CHN GER GER GER GER GER
EtherCAT is:
- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Well proven Dr. YanQiang Liu, Prof Dr. Yong-Seon Masanori Obata, Thomas Rettig, Martin Rostan, Makiko Hori, Joseph P. Stubbs, Fengjiao (Jojo) Fu Key Yoo,
CHN Moon, KOR JPN GER GER JPN USA CHN KOR
- Open
- Conformance
- Safety
- Redundancy
- Versatile ETG Office
Japan
ETG Headquarters Yokohama
ETG Office Germany ETG Office
North America Nuremberg ETG Office
Seattle, WA
China
Beijing Korea
Seoul

EtherCAT Technology Group Structure
EtherCAT is:
- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

ETG Membership Development
As of August 31st, 2012: 2105 Members

EtherCAT is:
- Faster
- Synchronization 2000
- Flexible Topology August 2011 August 2012:
- Easier to configure + 380
1500
- Cost effective
- Well proven
- Open
1000
- Conformance
- Safety
- Redundancy
- Versatile 500
0
Nov-03
Nov-04
Nov-05
Nov-06
Nov-07
Nov-08
Nov-09
Nov-10
Nov-11
Feb-04
Aug-04
Feb-05
Feb-06
Feb-07
Feb-08
Feb-09
Feb-10
Feb-10
Feb-12
Aug-05
Aug-06
Aug-07
Aug-08
Aug-09
Aug-10
Aug-11
Aug-12
May-11
May-04
May-05
May-06
May-07
May-08
May-09
May-10
May-12
ETG Membership Distribution
100%
90%
Asia
80%
70%
EtherCAT Technology America
60%
Group is a truly
Global Organization
50% Europe
35 w/o Germany > 2100
members
40%
members
30%
Germany
20%

ETG Members Asia
EtherCAT is:
August 31st 2012:
- Faster
631 Asian Members

700
- Synchronization
Asia (others)
- Flexible Topology 600 Japan Aug 2011 Aug 2012:
China+Taiwan + 164!
- Cost effective 500
- Easier to implement Korea
- Well proven 400
- Open
- Conformance 300
- Safety
- Redundancy
200
- Versatile
100

ETG Members China / Taiwan
EtherCAT is:
August 31st 2012:
- Faster
240 Members from

250 China+Taiwan
- Synchronization
- Industrial Ethernet Taiwan
- Flexible Topology
200
China Aug 2011 Aug 2012:
- Cost effective
+ 39%
- Well proven
150

- Open
- Conformance
100
- Safety
- Redundancy
- Versatile
50

ETG Members Japan
EtherCAT is:
August 31st 2012:
- Faster
247 Japanese Members

Japan
- Flexible Topology
- Easier to configure 200 Aug 2011 Aug 2012:
- Cost effective + 40% (!)
- Well proven 150

- Open
- Conformance
100
- Safety
- Redundancy
- Versatile
50

ETG Members America
EtherCAT is:
August 31st 2012:
- Faster
282 American Members

- Flexible Topology
250 America (others) Aug 2011 Aug 2012:
- Easier to configure + 32%
- Cost effective Canada
- Easier to implement 200
- Well proven USA
- Open 150
- Conformance
- Safety
100
- Redundancy
- Versatile
50

Members from 55* Countries, 6 Continents
EtherCAT is:
- Faster Bosnia and
Argentina Australia Austria Belarus Belgium Brazil Bulgaria
Herzegovina
- Synchronization
- Flexible Topology Canada China Columbia Croatia Czech Rep Denmark Finland
- Cost effective
- Easier to implement France Germany Greece Hungary India Iran Ireland Israel
- Well proven
- Open
- Conformance Italy Japan Korea Lebanon Latvia Liechtenstein Lithuania Luxemburg
- Safety
- Redundancy
Malta Mexico Netherlands New Zealand Norway Poland Portugal Romania
- Versatile
Russia San Marino Serbia Singapore Slovakia Slovenia South Africa Spain
Sweden Switzerland Taiwan Thailand Turkey Ukraine United Kingdom USA
September 2012 EtherCAT Technology Group, 2012 *as of August 2012

How many members invest in the technology?
One indicator: implementation kits sold.

EtherCAT is:
- Faster Until now, Beckhoff alone has sold over 1400 kits
- Synchronization (78% slave kits, 22%(!) master kits)
- Flexible Topology
+ there are slave implementation kits + master stacks from
many other vendors*, such as
Beck IPC
- Cost effective
acontis
Deutschmann
EBV Elektronik
esd
- Well proven
Hilscher igH
- Open
HMS anybus IXXAT Automation
- Conformance

Master
IXXAT Automation Kithara
- Safety
koenig-pa Koenig-PA
Slave
- Redundancy
port MicroSys
- Versatile
Red one Profimatics
Soft Servo Systems Sybera
ST Microelectronics
Terasic Technologies
Tetra
Xilinx * Only those listed that have entered their
offering in the EtherCAT Product Guide

ETG: Active Members
EtherCAT is: Hannovermesse 2012: 65 Vendors with over 280 different

- Faster EtherCAT Devices at ETG booth:
- Synchronization 35 different drives from 24 manufacturers
- Industrial Ethernet jointly operating in one network
- Flexible Topology
25 different functional Masters in one setup,
using 10 different operating systems
- Cost effective
- Easier to implement Safety devices (master + slave devices) from
- Well proven several manufacturers operating in one system

- Open
- Conformance
- Safety
- Redundancy
- Versatile

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

EtherCAT Drive Suppliers
EtherCAT is:
- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile
September 2012 (Vendors that ship or have announced EtherCAT drives as of 9/2012. Not all products shipping yet)
Adoption Rate in Masters (Controller)
EtherCAT is:
- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile
September 2012 (Vendors that ship or have announced EtherCAT master devices as of 9/2012. Not all products shipping yet)
Adoption Rate in I/O: EtherCAT
ABB Knestel
EtherCAT is: Ackermann Kolektor Synatec
ACS Motion Control Kollmorgen
- Faster Addi-Data Kuhnke
Adlink Lenze
- Synchronization
AFT Fahrzeugtechnik M-System
- Industrial Ethernet Algo System MaVi
Amoy Dynamics Messung
- Flexible Topology Anca MicroControl
AutomationX Microinnovations/Eaton
- Easier to configure B&R Mikrap
Balluff MKS Instruments
- Cost effective Baumller MKT Systemtechnik
BBH MSC
- Easier to implement Beckhoff MTT
Belden Murrelektronik
- Well proven
Berghof M-System
- Open Bosch Rexroth National Instruments
Brunner Omron
- Conformance CEC Panasonic SUNX
CSM Power Instruments
- Safety Deif Prima Electro
Dina Elektronik Schweitzer Engineering
- Redundancy dSPACE Laboratories / SEL
Eckelmann SEW Eurodrive
- Versatile esd Shanghai Xinhua
Festo SHF
Gantner SMC
Grossenbacher Sontheim
HBM Industrie Elektronik
Helmholz TETRA
IDS TexComputer
Imc/Additive TR Elektronik
Jger Messtechnik Turck
Jumo
Unidor
KEB
Unitro
KEBA
VIPA
September 2012 Keyence (Vendors that ship or have announced EtherCAT I/O devices as of 9/2012. Not all products shipping yet)
Wago
Conformance and Interoperability
EtherCAT is:
- Faster
- Synchronization
- Flexible Topology Conformance and interoperability are very important
- Easier to configure factors for the success of a communication technology
- Cost effective Conformity to the specification is an obligation to all users of
the EtherCAT technology
- Well proven
Therefore the EtherCAT Conformance Test Tool (CTT) is
- Open
used
- Conformance
- Safety Test Cases for the CTT are provided by the Working Group
- Redundancy Conformance within the ETG community
- Versatile The EtherCAT Conformance Test proves conformance
with issuing a certificate after passing the test at an official
EtherCAT Test Center (ETC)

Safety over EtherCAT
EtherCAT is: Material feeding

Muting
- Faster
Two-Hand control
- Synchronization
- Industrial Ethernet Protection of workspace
- Flexible Topology e.g. with Laser scanner
- Cost effective
- Easier to implement Emergency
stop
- Well proven
- Open Operator
- Conformance Diagnosis
- Safety
- Redundancy Safely-limited
- Versatile Position / Speed
Door guarding Setup /

with Maintenance
Interlocking
Safety guard

Modern Machine Safety Concepts

Safety over EtherCAT: Features
EtherCAT is:
- Faster
- Synchronization
- Flexible Topology Safety over EtherCAT (FSoE) defines a safety
- Easier to configure communication layer for the transportation of safety
- Cost effective process data between Safety over EtherCAT devices.
- Well proven
FSoE is an open technology within the EtherCAT

- Open
Technology Group (ETG).
- Conformance The protocol is developed according to IEC 61508
- Safety It meets the Safety Integrity Level (SIL) 3
- Redundancy
Residual Error Probability R(p) < 10-9
- Versatile
The protocol is approved by an independent Notified
Body (TV)

Safety over EtherCAT: Features (2)
EtherCAT is:
- Faster
- Synchronization
- Flexible Topology FSoE Frame is mapped in the cyclic PDOs
- Easier to configure Minimum FSoE Frame-Length: 6 Byte
- Cost effective
Maximum FSoE Frame-Length: depending on the number of
safe process data of the Slave Device
- Well proven
Therefore the protocol is suitable for safe I/O as well as for
- Open
- Conformance
functional safe motion control

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

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

Safety over EtherCAT: Software Architecture
EtherCAT is: Device 1 Device 2

- Faster
- Synchronization Safety Safety
- Industrial Ethernet Application Application
- Flexible Topology
- Easier to configure Standard Standard
Application Application
- Cost effective
- Easier to implement Safety over Safety over Safety
- Well proven EtherCAT EtherCAT over
Protocol Protocol EtherCAT
- Open
- Conformance EtherCAT EtherCAT EtherCAT
- Safety Communication Interface Communication Interface DLL and AL
- Redundancy
- Versatile EtherCAT Telegram
Safety data container (FSoE Frame)
EtherCAT is used as a "black channel"

It contains safety and standard information

Safety over EtherCAT: Hardware Architecture
EtherCAT is: One channel communication system

- Faster According to model A of IEC 61784-3 Annex A
- Synchronization
- Flexible Topology Device
- Cost effective Controller A Controller B
- Easier to implement Safety Safety
Protocol Protocol
- Well proven Controller A Controller B
- Open Safety Safety
- Conformance
Protocol Protocol

Magnetics
Magnetics
RJ45
RJ45
- Safety
PHY
PHY
EtherCAT
- Redundancy Slave Controller
- Versatile In Out
Port Port

Safety over EtherCAT: Frame Structure
Device 1
EtherCAT is:
FSoE Frame
- Faster Safety
Application
- Synchronization The FSoE Frame is
Standard embedded as a
- Industrial Ethernet Application
Container in the
- Flexible Topology process data of the
- Easier to configure FSoE device.
Protocol
- Cost effective Each device detects
- Easier to implement EtherCAT a new FSoE Frame,
Communication interface if at least one Bit in
- Well proven the FSoE Frame is
- Open EtherCAT Frame changed.
- Conformance Ethernet EtherCAT 1. Data- Every 2 Byte SafeData
FSoE
2. Data-
HDR
- Safety Process Data FSC are checked by a 2
Header Header gram gram
- Redundancy Byte CRC
- Versatile FSoE Frame The maximum number
of SafeData is
therefore not
restricted by the
protocol.
Safe Safe Safe
CMD CRC_0 CRC_1 CRC_n Conn ID
Data 0 Data 1 Data n

Safety over EtherCAT: Safety Measures
EtherCAT is:
Measure Sequence Connection CRC
- Faster Watchdog
Error Number ID Calculation
- Synchronization Unintended repetition
Loss
- Flexible Topology
- Easier to configure Insertion
- Cost effective Incorrect sequence
- Well proven Corruption

- Open Unacceptable delay
- Conformance Masquerade
- Safety
Repeating memory errors
- Redundancy
in Switches
- Versatile
Incorrect forwarding

between segments

Safety over EtherCAT: Implementation Example
EtherCAT is: Decentralized Safety-Logic

- Faster Standard PLC routes the safety messages
- Synchronization
- Industrial Ethernet Standard
PLC Safety Inputs
- Flexible Topology
- Cost effective
- Well proven Safety Outputs
- Open
- Conformance
- Safety
- Redundancy
- Versatile
S
S
Safety Drives Safety Logic
S

Safety over EtherCAT: Advantages
EtherCAT is: Fully integrated solution:

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

Without Redundancy: Normal Operation
EtherCAT is:
- Faster EtherCAT Master
- Synchronization
- Industrial Ethernet RX Unit TX Unit
- Flexible Topology RX TX
- Cost effective MAC 1
RX TX
- Well proven
- Open
- Conformance
- Safety
J J J
- Redundancy
- Versatile
Slave 1 Slave 2 Slave N

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

Without Redundancy: Cable Failure
EtherCAT is:
- Synchronization
RX TX
- Well proven
- Open
- Conformance
- Safety
J J
- Redundancy
- Versatile L L
Slave 1 Slave 2 Slave N-1 Slave N
RX TX RX TX RX TX RX TX
... ...
TX RX TX RX TX RX TX RX

Without Redundancy: Node or Cable Failure
EtherCAT is:
- Synchronization
RX TX
- Well proven
- Open
- Conformance
- Safety
J J
- Redundancy
- Versatile L L
Slave 1 Slave 2 Slave N-2 Slave N-1 Slave N
RX TX RX TX RX TX RX TX RX TX
... ...
TX RX TX RX TX RX TX RX TX RX

With Redundancy: Normal Operation
EtherCAT is:
- Faster
Only 2nd
EtherCAT Master
- Synchronization
Ethernet
Port required
no special
- Flexible Topology RX TX Interface Card
- Cost effective MAC 1 MAC 2
RX TX RX TX
- Well proven
- Open
- Conformance
- Safety
J
- Redundancy
- Versatile J J
Slave 1 Slave 2 Slave N
RX TX RX TX RX TX
... ...
TX RX TX RX TX RX

With Redundancy: Cable Failure
EtherCAT is:
- Synchronization
RX TX RX TX
- Well proven
- Open
- Conformance
- Safety
J J
- Redundancy
- Versatile J J
Slave 1 Slave 2 Slave N-1 Slave N
RX TX RX TX RX TX RX TX
... ...
TX RX TX RX TX RX TX RX
Switchover time: < 15s

With Redundancy: Node or Cable Failure
EtherCAT is:
- Synchronization
RX TX RX TX
- Well proven
- Open
- Conformance
- Safety
J J
- Redundancy
- Versatile J J
Slave 1 Slave 2 Slave N-2 Slave N-1 Slave N
RX TX RX TX RX TX RX TX RX TX
... ...
TX RX TX RX TX RX TX RX TX RX

EtherCAT: High availability
EtherCAT is: Cabling redundancy

- Faster 2nd Ethernet port needed on master side only
- Synchronization
Hot Swap of devices
- Flexible Topology Hot Connect of network segments
Hot Connect
- Easier to configure Master Redundancy with Hot Stand By Group
- Cost effective
Master
- Well proven
- Open
- Conformance
- Safety
- Redundancy
- Versatile

EtherCAT: versatile system architecture
EtherCAT is: Master to Slave

- Faster Slave to Slave
- Synchronization Master to Master
M2S
- Flexible Topology
Switchports
- Cost effective
- Well proven Master
- Open
M2M
- Conformance
- Safety
Gateways
- Redundancy

- Versatile M2S
Master
S2S

EtherCAT Automation Protocol
EtherCAT is:
- Faster
- Synchronization
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy

- Versatile

EtherCAT Automation Protocol: Application
MES
OPC
Controller Visu
zum Controller und
allen Stationen
Je Verbindung:
10ms cycle
IN 1kByte
OUT 1kByte
IN 600 Byte IN 600 Byte IN 600 Byte IN 600 Byte IN 600 Byte IN 600 Byte IN 600 Byte IN 600 Byte IN 600 Byte
OUT 600 Byte OUT 600 Byte OUT 600 Byte OUT 600 Byte OUT 600 Byte OUT 600 Byte OUT 600 Byte OUT 600 Byte OUT 600 Byte
10 ms cycle
Stations- Stations- Stations- Stations- Stations- Stations- Stations- Stations- Stations- Stations-
Master Master Master Master Master Master Master Master Master Master
Einschleusen Einschleusen Prozess- Prozess- Prozess- Prozess- Prozess- Ausschleusen Ausschleusen Ausschleusen
Kammer Kammer Kammer Kammer Kammer
Ethernet Connection EtherCAT Automation Protocol
EtherCAT Segment OPC

EtherCAT and Wireless Communication
EtherCAT is: Wireless Devices can be connected via Switchport

- Faster Wireless segment does not slow down EtherCAT
- Synchronization communication
- Industrial Ethernet Protocol: EtherCAT Automation Protocol
- Flexible Topology Pushed and/or Polled Process Data Exchange
Wireless Segment transparent for Master Device
- Cost effective
Master Switchport
- Well proven
- Open
- Conformance
- Safety
- Redundancy

- Versatile
e.g. Card or RFID Reader

Master sees
process data of
underlying system
Master with or
as local I/O data without control
application

EtherCAT is:
- Faster
- Synchronization
- Flexible Topology

Why go for something slower,
- Cost effective

just because it is more
- Well proven
- Open

expensive?
- Conformance
- Safety
- Redundancy

- Versatile

EtherCAT is: Please visit

- Faster www.ethercat.org
- Synchronization for more information
- Flexible Topology
- Cost effective
- Well proven
- Open
- Conformance
- Safety
- Redundancy

- Versatile
EtherCAT Technology Group
ETG Headquarters
Ostendstr. 196
90482 Nuremberg, Germany
Phone: +49 911 54056 20
info@ethercat.org

EtherCAT WorkshopCERN 120920

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EtherCAT WorkshopCERN 120920

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EtherCAT Workshop @ CERN Sept 20, 2012

How to implement an EtherCAT Slave Device

Q&A, Open discussion

EtherCAT is: EtherCAT is real time down to the I/O level

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: Other technologies need local I/O cycles + gateways

Master for Local

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: EtherCAT: Real time down to the I/O

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: EtherCAT is real time down to the I/O level

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: Transmission Rate:

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: Bandwidth Usage of Ethernet for I/O and Drives:

- Well proven Node

with 4 Byte input + 4 Byte output per node:

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: Bandwidth Usage Comparison:

September 2012 EtherCAT Technology Group, 2012

September 2012 EtherCAT Technology Group, 2012

Efficient: Typically only one Ethernet Frame per Cycle

September 2012 EtherCAT Technology Group, 2012

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: Reaction time with legacy fieldbus I/O:

Input Input Output

Tmpd: Master Processing Delay

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: System Architecture with EtherCAT:

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: System Architecture with EtherCAT:

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: Reaction Time with EtherCAT:

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: Traditional fieldbus system generate physical process image

- Open PLC Data

September 2012 EtherCAT Technology Group, 2012

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: Master

- Open PLC Data

Control System is unburdened, master becomes very

EtherCAT is: Fieldbus cards: PC Control with Fieldbus cards

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: EtherCAT Node measures time difference between

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: EtherCAT Node measures time difference between

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: Precise Synchronization (<< 1 s!) by exact adjustment

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: Long Term Scope View of two separated devices

- Conformance Jitter: ~ +/-20ns

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: EtherCAT networks can be coupled via EtherCAT Bridge

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: EtherCAT networks can be coupled via EtherCAT Bridge

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: Switchport with integrated IEEE 1588 Boundary Clock

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: EtherCAT uses Standard Ethernet Frames: IEEE 802.3

September 2012 EtherCAT Technology Group, 2012

EtherCAT is: fully transparent for TCP/IP

Ethernet PHY Ethernet PHY

September 2012 EtherCAT Technology Group, 2012