Kollmorgen EtherCat

1. Kollmorgen EtherCat December 19, 2019 Carroll Wontrop – System Engineer

2. EtherCAT - Topics • Why Use Kollmorgen Ethercat ? • Basic Principles and Capabilities • Communication Overview • AKD Implementation • PDMM Implementation

3. Why Use Kollmorgen Ethercat ?

4. EtherCAT – Overview • What is Ethercat? • Why would I use EtherCAT? • Why would I use EtherCAT verses other networks

5. Ethercat – What is it ? • High performance Ethernet based Fieldbus Network • Allows transferring information quickly and deterministically • between Controller and Drive • between Controller and I/O • Uses standard Ethernet components to keep implementation cost low • Open Standard (non proprietary), Designed for the Factory

6. Why would I use EtherCAT ? • Improve Machine Performance • Higher Production Rates • Higher Quality Parts and products • Gets information quickly across the network • Accuracy - Low jitter and distributed clocks node synchronization • Fast Communication times • Now: down to 250 usec (with Kollmorgen product) • Future: ability to go to 10 usec • Supported in all Kollmorgen Servo Drive Lines

7. Why would I use EtherCAT • Real-time Information • Allows monitoring of many drive parameters • Machine Diagnostic - know when a machine problem is about to occur • Get information if the machine faults • Allows changing many drive and I/O parameters • Change parameters on the fly • Can have Remote I/O on the same network • Analog and Digital I/O, Thermocouple • Third party modules

8. Why would I use EtherCAT • Reliability • Transport information reliably, Proven in thousands of applications • Interface Flexibility • Supports many different drive opmode and interface types to fit many different customer machine control schemes and the available interfaces on other products

9. Why would I use EtherCAT • Easy Integration into the Network • Easy integration of third party products • Easy learning curve and product implementation • Special hardware chips not require as with some Networks • COE – Can Over Ethercat use COE utilizing the well known CanOpen Protocol • Less Wiring – More reliable, less wiring cost • Processing on the fly – Faster communications • Strong users group. Wide industry acceptance

10. Why would I use EtherCAT verses other networks • More Component Vendor Options • Not tied to a particular vendor • Wide I/O support • Many Vendors Support • Not a separate SW to configure - Setup is integrated right into the KAS IDE • No need for expensive Ethernet switches • Comes with Kollmorgen’ s excellent tech support (usually not needed) • Includes a distributed clock mechanism • Low jitter that meets IEEE 1588 (Precision Time Protocol standard) without additional hardware • May be the only bus needed

11. The Kollmorgen Ethercat Advantage • Combines precision transfer of information w/ Kollmorgen’ s: • Precision servo loops • High performance motors • Easy to use controllers • Tight integration between motion and machine control Result: Industry Setting Machine Performance

12. Ethercat Basic Principles and Capabilities

13. EtherCAT – Capabilities • Processing on the fly • Deterministic for high performance motion control • Digital control – not susceptible to noise • Precise motion control between axis (Master slaving, gearing coordinated motion) • Quick sensor pickup in registration applications • Lower installation cost by eliminating both Ethernet start topology and all switches routers and hubs.

14. EtherCAT – Design Goals • Ethernet for Control Automation Technology • First developed in early 2000’s • Design Goals • Apply Ethernet to applications with quick update times • Cycle times down to 100usec • Precise Synchronization – low jitter • Low HW cost • Fast deterministic update • One cable for many signals

15. Governing Standard • IEC 61158 – Defines how Ethercat adapts the OSI seven layer communication model • Ethercat FieldBus Network • IEC 61784-2 - (Industrial communication network spec • IEEE 802.3 - standards for 100Base-TX, the physical layer of Ethernet.

16. Fit in 7 Layer communication Model • Ethernet communication optimized for Precision machine control • The EtherCAT Frame replaces the Ethernet standard stackData portion of an Ethernet Packet

17. Ethercat Protocol Overview • Physical layer is based on IEEE 802.3 standards for 100Base-TX, the physical layer of Ethernet. • Data link and application layers are specifically designed for motion control applications. • The 100BASE-TX media system is based on specifications published in the ANSI TP-PMD physical media standard. • The 100BASE-TX system operates over two pairs of wires, one pair for 'receive' data signals and the other pair for 'transmit' data signals.

18. Ethercat Protocol Overview • Automatic network configuration and integrity check • Cabling over 100 Meters between each node • Electrical isolation for robust noise immunity • Motion bus - Deterministic • Data update rates down to 250 usec • Bus connection and bus Medium: 100BASE-T media system • Transmission Rate: 100 mhz, • Connector and Cables: RJ-45 • Physical Media: CAT5 cable • Topology: Line

19. Network Operation - On the fly • Process data is extracted and inserted on the fly Slave Device AKD 1 Slave Device EtherCAT Slave Controller EtherCAT Slave Controller • A single messagewith data for all nodes • Each node reads its inputs and adds its outputs to the message • Without messages targeted to specific devices, maximum bandwidth is achieved • An EtherCAT network is like a railway and at each train cars are unloaded and loaded while the train moves

20. Network Operation – Distributed Clocks • Packet Routing provides precision motion command synchronization • Each receiving node uses advanced digital time-correction techniques to minimize skew and jitter to provide precise control • EtherCAT Node measures time difference between leaving and returning frame • Propagation delays between any nodes can be computed • Precise Synchronisation (<< 1 µs!) by exact adjustment of distributed clocks EtherCAT Frame vom Master

21. Communication Overview

22. EtherCAT Type Kollmorgen Supports • COE (CanOverEthercat) • It is the CanOpen Network run over a Ethernet foundation • Supported by Kollmorgen KAS, S700, and AKD product lines • Parameters Supported for Standards: • CiA301 - CanOpen Communication Profile for Industrial Systems • CiA402 – Drive Profile Interface

23. Ethercat COE Communication • Process Data (PDO) Communication • Deterministic, Real Time Communication - FAST • Limited parameter set • Mailbox Communication • Non-Deterministic • Service Data Objects (SDO) and ACSII Communication • Fuller parameter set • Network Startup (COE Init) • Non-Deterministic • Sent once during Ethercat Network Initialization • Service Data Objects (SDO) setup by the Ethercat Master Device

24. Information Passed over EtherCAT • Setup up parameters • Diagnostics parameters • Operation parameters • Status parameters • Motion command parameters (Servo Drives) • Servo Tuning and limit parameters (Servo Drives) • Other Operational Parameters Ethercat Master

25. Ethercat Communication – Initialization • Steps up to full Synchronization

26. Network Operation - Ethercat Telegram • Efficient Transmission of Data • Low overhead Ethernet Ethernet Header ECAT EtherCAT Telegram Pad. FCS DA SA Type Frame HDR EtherCAT HDR Data CTR (0…32) (4) (6) (6) (2) (2) (10) (0….1486) (2) constant Header completely sorted (mapped) process data WorkingCounter:constant Padding Bytes and CRC generated by Ethernet Controller (MAC)

27. Network Operation - Slave Implementation Definitions • ESC = Ethercat slave controller • Trafo = Transformer • PHY = Physical Layer (Layer 1 in OSI model)

28. Product Configuration File

29. ESI Vendor Files • Also called Ethercat XML Device Description • Defines the communications and what objects will be passed through Cyclicly • Required by the Master to setup the ECAT Network

30. AKD Implementation

31. Network Operation - AKD Ethercat Connection

32. Architecture • Typical Ethercat Configuration 1 • Path Generation in Controller PLC PLC or PAC PLC or PC PLC or PC Machine Control I/O Field Bus Motion Programming Standalone Multi Axis Control SingleAxis Controller PDMM Field Bus Digital Drive AKD or S700 Path Generation Motion Bus Position Control Digital Drive AKD or S700 +/- 10V Velocity / Torque Control Analog Drive

33. Architecture • Typical Ethercat Configuration 2 • Path Generation in Drive PLC PLC or PAC PLC or PC PLC or PC Machine Control I/O Field Bus Motion Programming Standalone Multi Axis Control SingleAxis Controller PDMM Field Bus Digital Drive Path Generation Motion Bus Position Control Digital Drive +/- 10V AKD or S700 Velocity / Torque Control Analog Drive

34. Network Operation -Drive Addressing • No drive manual address setting required • Addresses assigned automatically • Addresses can be kept – no new addressing if nodes are added

35. AKD Drive Modes • AKD drive models that support Ethercat • AKD-P00xxx-NAEC-0000: Ethercat bus only • AKD-P00606-NACC-0000: Configurable to Ethercat or CanOpen bus

36. AKD COE Communication • Network Startup (COE Init) • Non-Deterministic – Initial Setup ( related to initial drive setup) • Sent only one time during Ethercat Network Initialization • Service Data Objects (SDO) setup by the Ethercat Master Device • Process Data (PDO) Communication • Deterministic - Operational (Realtime) • Limited parameter set • Mailbox Communication • Non-Deterministic - Operational (Non-realtime) • Service Data (SDO) and ACSII Communication • Fuller parameter set

37. AKD Opmodes supported • Set by Object 0x6060 • 1 to 8 : ECAT Standard Opmodes • -1 to -3 : Additional Kollmorgen specific Opmodes

38. AKD Support Parameters • Most AKD Parameters are linked to Ethercat Objects • Example: Velocity Loop Proportional Gain is linked to object 0x3548

39. Control and Status Objects • Bit Wise Objects not connected to a specific AKD Parameter • Drive Control Word: 0x6040 (Master Controller to AKD) • Drive Status Word: 0x6041 (AKD to Master Controller) Status Word Control Word

40. Network Startup (COE Init) Communications • Sent by master to the AKD during ECAT network startup • Used to configure the drive for ECAT communications. Can in parameters to set up: opmode, high speed capture engine, network synchronization, Units scaling, Enable/Disable coordination with tthe controller, and others: • Example : Beckhodff TwinCat (Ethercat Master) ECAT Startup

41. AKD PDO Communications (Fixed) • Some combination of the PDO‘s below is possible • Parameters transmitted at the ECAT update rate • The following are standard (Fixed) options Options: AKD to Controller Options: Controller to AKD

42. AKD PDO Communications (Other options- Flexible PDOs) • Some other AKD parameters can be mapped into the PDO communication (Requires removing some Fixed PDOs) • Check the Appendix to the AKD Ethercat Manual to determine PDO mappable objects

43. AKD Mailbox communications • Non time critical transmission of Parameters. Example: Change Tuning gains, Limits, Scalings • Many AKD parameters can be mapped into the PDO communication (Requires removing some Fixed PDOs) • See the Appendix to the AKD Ethercat Manual for complete list

44. AKD Ethercat Notes • Position Feedback Object • 0x6064 is for interpolated position • 0x6063 is for everything else. • PDO mapping • When free mapping PDO , turn off the PDOs you don’t intend to use.  • Individual PDOs limited to 8 bytes.  Some masters only will map one TX-PDO and one RX-PDO. • Ethercat Network Run-up • Often when Starting up Ethercat network via the Control Word (0x6040), will need to monitor the status word (0x6041) for the step completion before using the control Word to move on to the next step. • Monitor the bus voltage bit in the status word, plus 300mS, for the bus voltage to be present before starting the run up. • Resetting Home • AKD firmware 1.10.x.x and up: homing will reset 0x6064 and 0x6063.  Set HOME.MODE to 13 and set FB1.OFFSET.

45. AKD Ethercat Notes • Over Travel Limit • May need to defeat Over travel limit setup in AKD to work with certain master • Position Jump • If position “jump” occurs in interpolated position mode, caused by the position update arriving at the drive when the drive is calculating the next set of position points set FBUS.PARAM02 and FBUS.PARAM04 = 1 • AKD XML file • Use new XML file for TwinCat3 and other controllers • There are some clerical errors in the “optional” parts of the AKD’s XML files and some Ethercat masters don’t like it.  Will not allow configuration.  (Delta Tau, Omron).

46. KAS PDMM/PCMM Implementation

47. Architecture • Default KAS Ethercat Configuration PLC PLC or PAC PLC or PC PLC or PC Machine Control I/O Field Bus Motion Programming Standalone Multi Axis Control SingleAxis Controller Field Bus Digital Drive AKD or S700 Path Generation Motion Bus Position Control Digital Drive AKD or S700 +/- 10V Velocity / Torque Control Analog Drive

48. Architecture • KAS Ethercat Configuration Machine Controller PCMM or PDMM Servo Drive (AKD or S700) Motor Machine I/O Position Control Velocity Control Current Control Application Program Profile Generator Feedback Network Interface HMI Interface Feedback Interface EtherCAT HMI

49. Network Operation - Drive Addressing • No drive manual address setting required • Addresses assigned automatically • Addresses can be kept – no new addressing if nodes are added

50. PDO Execution Time • Each Ethercat cycle • 250, 500, 1000 or 2000 microsecond