'EtherCAT As A Master Machine Control Tool' Galil Webinar

Galil Motion Control
EtherCAT as a Master Machine Control Tool

Matt Klint
Applications Engineer
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Introducing Your Presenter
Matt Klint
Applications Engineer,
mattk@galilmc.com
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Agenda
About
Introduction to EtherCAT
Origins
Communication Format
Ethernet vs. EtherCAT
Hardware and Physical Layout
Galils DMC-500x0 EtherCAT Master
Features
Configuration and Setup
Setup Example
Summary
Cost and advantages of an EtherCAT control network
Q&A
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About Galil
Established Reputation and long History of Success
Founded in 1983 by Dr. Jacob Tal and Wayne Baron
Introduced the 1st microprocessor based servo controller

Profitable for over 119 consecutive quarters
Over 750,000 motion controllers and PLCs delivered
Excellent Engineering Support and Service

Worldwide network of factory trained reps & distributors
Support team with over 100 years combined motion control experience
Online support tools at www.galil.com
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Communication Protocols
Standardization allows cross platform integration
Easily attainable infrastructure lowers costs
Modular Design
Modules are easily replaceable
Additional modules can be added as needed
Wide market with dozens of vendors per type
Galil was the first to introduce TCP/IP Ethernet communication to motion control,
since then it has become the most widely used communication protocol in the
industry
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EtherCAT Origins
Ethernet for Control Automation Technology
Invented by Beckhoff Automation in 2003
Ethernet based fieldbus, optimized for industrial automation control
Based on CANOpen, a device profile for embedded systems used in
automation
Standards defined and maintained by the EtherCAT Technology Group
(ECTG)
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EtherCAT and Ethernet

Ethernet
Designed to move large amounts of data through many different nodes
Able to route data to and from billions of separate addresses allowing
communication across vast networks
Large overhead involved in encapsulating, routing and formatting data
Software handles extraction and processing of data
EtherCAT
Uses standard Ethernet hardware, CAT5 cabling and Network Interface Cards
(NIC)
Streamlines Ethernet communication at the hardware level
Data processing on slave devices is handled on the fly via FPGA or ASIC,
minimizing latency
Initial setup and configuration required
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Ethernet Frame
An Ethernet frame contains:
Ethernet Header
Destination Address: 6 bytes
Source Address: 6 bytes
EtherType: 2 bytes, 0x0800 specifies IPv4.
Ethernet Data
Payload: 46 1500 bytes
CRC (Checksum): 4 bytes
Standard Ethernet Frame
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EtherCAT Frame
An EtherCAT frame is very similar to an Ethernet frame:
Ethernet Header
EtherType 0x08A4 specifies EtherCAT
EtherCAT Header
Data Length: 11 bits
Reserved: 1 bit
Protocol type: 4 bits (0x01 indicates CoE, CAN over EtherCAT)
EtherCAT data: 46 1496 bytes
Working counter: 2 bytes
CRC (Checksum): 4 bytes
EtherCAT Frame
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EtherCAT Communication
Each drive on the network has a unique address, set by hardware
Master/Slave configuration with the EtherCAT Master sending and
requesting data from the Slave
Data not addressed to a particular slave are forwarded along to the
network
Minimal processing time can provide cycle update rates of up to
32kHz
Network Layout size is limited only by the allowable lengths of CAT5
Ethernet cable, up to 100 m
Increased noise immunity due to reliance on Ethernet physical
components
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EtherCAT Communication Analogy

Each cubicle is an EtherCAT Slave, each engineer is told where to sit by an SDO
The boss is the EtherCAT Master, sending instructions (PDOs) out to the engineers
each morning and picking up their work at quitting time.
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EtherCAT Operation Modes

Profile Position
Master sends position commands to the Slave, slave handles profiling parameters
Profile Velocity
Master sends velocity commands to the Slave, slave handles profiling parameters
Profile Torque
Master sends torque commands to the Slave, slave handles profiling parameters
Cyclic Position
Position is continuously updated by the master, master handles profiling parameters
Cyclic Velocity
Speed is continuously updated by the master, master handles profiling parameters
Cyclic Torque
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Torque is continuously updated by the master, master handles profiling parameters
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EtherCAT Master
Can be any software and or hardware configured to assemble,
send and receive EtherCAT datagrams
Requires only standard Ethernet physical layer components for
communication
Facilitates coordination between EtherCAT slaves, writing and
receiving data from each slave in an EtherCAT frame
In motion control applications, the relevant data sent to the
drives are profiling data
The data requested are position and input status
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EtherCAT Slave
Reads and processes profiling data

Writes position, input and drive status for return to the master
Can be configured in for multiple modes of operation
All slaves contain specific spaces in memory where data can be
written
These spaces are called Objects, the entire memory space is
called the Object Dictionary
Each object has its own address, specified as an index/sub index
Example, operation mode data from the Master is written to the
x6060 Object in the slaves dictionary, position commands are
written to the x607A Object
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SDOs and PDOs

Data is moved along an EtherCAT network using two protocols, SDOs and PDOs
SDO: Service Data Object
SDOs can be sent at any time, before, after or during real time operation of
the network but require additional communication overhead
As a result SDO usage is typically only used for network setup commands
PDO: Process Data Object
PDOs contain the raw operational data with minimal overhead and thus are
used for real time processes, like motion and I/O control
PDOs can only be used once they are mapped using SDOs
Mapping sets up which byte in each PDO goes to which memory address
on
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SDO vs. PDO Summary

SDO
PDO
Transfer confirmation
No transfer confirmation
Client/server model
Peer-to-peer model
Device Configuration, PDO mapping
High priority transfer of small amounts of

data
Can be sent at any time
Can only be used after configuration using

SDOs
Significant communication overhead
No additional protocol overhead
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The EtherCAT Slave State Machine
State
Allowed Communication
Init
No User Communication
Pre-Op
SDO Communication Only
Safe-Op
SDO, PDO Communication Allowed

Output PDO info ignored
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Operational
PDO, SDO Communication Allowed
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The EtherCAT Slave Architecture
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Simple PDO Example
Slave Target Position Memory Object

x607A
Incoming PDO
Position Data
4 x 8 bits
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PDO Exchange
Incoming PDO
Location
Outgoing PDO
Location
Function
Function
x607A
Target Position
x6041
Statusword
x6060
Mode of Operation
x6062
Position Demand Value
x6040
Controlword
X6061
Mode of Operation
x6064
Position Actual Value

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x60FD
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Digital Input Status
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EtherCAT Hardware
Standard Ethernet Physical Layer components
CAT5 cabling
Network Interface Cards
FPGAs for fast command processing by

slave units
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EtherCAT Only Physical Layout

EtherCAT Master
EtherCAT
Drive 1
Motor/
Encoder
EtherCAT
Drive 2
Motor/
Encoder
EtherCAT
Drive 3
Motor/
Encoder
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The DMC-500x0 EtherCAT Master
Includes all the features of our flagship

DMC-40x0 series controller with the
addition of EtherCAT drive support for up
to 8 axes in Cyclic Position Mode*
Only motion controller in the industry

with the ability to mix and match local
and EtherCAT drives
Easily configurable and designed with

compatibility and flexibility in mind
Multiple drive vendors supported
Compatible with Galils entire line of

internal servo and stepper motor
amplifiers
*Cyclic Torque mode supported on select models
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The DMC-500x0 EtherCAT Master

Currently Supported I/O Features
Forward and reverse limit switch inputs
Home sensor input
Hardware latch/touch probe
These I/O features allow access to the DMC-500x0 commands and

subroutines specific to these inputs such as:
#LIMSWI automatic subroutine

FI/FE/HM commands
AL/RL commands
#ECATERR automatic subroutine
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DMC Code Example
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DMC-500x0 Hardware Layout

Servo
Motor
DMC-50070
EtherCAT
Drive 1
EtherCAT
Drive 2
EtherCAT
Drive 3
Servo
Motor
Servo
Motor
Servo
Motor
Servo
Motor
Analog
and
Digital
I/O
Stepper
Driver
Stepper
Motor
Stepper
Driver
Stepper
Motor
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Compatible EtherCAT Drives

Currently Supported Drives
AMC DZEANTU-020B080
Copley XenusPLUS XEL-230-36

Panasonic Minas A5B
Sanyo-Denki SANMOTION RS2A01A0KA4
Yaskawa Sigma-5 SGDV-R90FE1A
Galil is actively working to include support for additional

vendors and is seeking input from customers. Contact an
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Summary
The EtherCAT protocol is gaining traction as a robust and efficient solution to
demanding, large scale automation applications
Built on the Physical and Data Link layers of Ethernet communication, making the
technology more accessible right off the bat
Higher controller/drive cost is offset by the use of pre existing, easily attainable
hardware
Due to the EtherCAT communication protocol, networks are easily expandable,
modifiable and simple to maintain
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Q&A
Please submit your questions regarding any part of this presentation or about
EtherCAT in general at this time
Additionally, please contact Galils dedicated Applications Engineering team anytime
with additional questions or comments:
1 (916) 626-0101
support@galil.com
www.galil.com
In Canada contact:
Electromate
1 877 737 8698
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Galil Motion Control

EtherCAT as a Master Machine Control Tool

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Introducing Your Presenter

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Toll Free Phone (877) SERVO98

Thanks to Our Sponsors

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Ethernet vs. EtherCAT

Hardware and Physical Layout

Galils DMC-500x0 EtherCAT Master

Configuration and Setup

Cost and advantages of an EtherCAT control network

Sold & Serviced By:

Toll Free Phone (877) SERVO98

Introduced the 1st microprocessor based servo controller

Excellent Engineering Support and Service

Toll Free Phone (877) SERVO98

Toll Free Phone (877) SERVO98

Sold & Serviced By:

Toll Free Phone (877) SERVO98

EtherCAT and Ethernet

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Standard Ethernet Frame

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EtherCAT Communication Analogy

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EtherCAT Operation Modes

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Reads and processes profiling data

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SDOs and PDOs

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SDO vs. PDO Summary

Device Configuration, PDO mapping

High priority transfer of small amounts of

Can be sent at any time

Can only be used after configuration using

Significant communication overhead

No additional protocol overhead

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The EtherCAT Slave State Machine

SDO Communication Only

SDO, PDO Communication Allowed

PDO, SDO Communication Allowed

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The EtherCAT Slave Architecture

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Simple PDO Example

Slave Target Position Memory Object

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Position Demand Value