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Synchronizing mechatronic systems in real-time using FPGAs and Industrial Ethernet
Sari [email protected]
Technology MarketingEthernet POWERLINK Standardization Group
Everything Connected to one network• Integrated System Architecture
remote I/Os Safety Logic
Motion Systems
Vision
Robotics
Pneumatics
Controller
Visualization
Robotics
Sensor
CSMA/CD• Ethernet Medium access: CSMA/CD
– Carrier-Sense Multiple Access with Collision Detection– Collisions generate repeat after random delay – Induces unpredictable delays
• Standard Ethernet is not deterministic– Designed for office applications
Fieldbus Technology
• Traditional fieldbuses– RS485 or CAN based– Reliable, field proven– Cheap– Very limited bandwidth
• Need a faster solution: Industrial Ethernet
Switched Ethernet• Switched Ethernet networks
– Traffic separation in collision domains– Messages managed in queues– Collisions are moved from network to queues– Queues generate delay– Packets are dropped in case of congestion – Switches introduce latency thus not deterministic!
Ideal Machine Network Requirements
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostic
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostic
Ideal Network Requirements
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostic
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostic
POWERLINK Technology• Network master
– 1 Managing Node (MN)
• Network slaves– Up to 239 Controlled Nodes (CN)
CYCLE TIME
POWERLINK TechnologySynchronization and communication during each cycle
Async. data
Synchronous phase Asynchronous phase
SoCPReq CN1PReq CN2PReq CNnSoA
Easy and robust functionality
No complex time synchronizationAll on one medium
I/O Axis I/O
PRes CN1 PRes CN2 PRes CNn
PLC
POWERLINK Technology• Cross communication
PRes CN1
SoCSoCSoCPReq CN1PReq CN1PReq CN1PReq CN1
PRes CN1PRes CN1PRes CN1
SoC
Encoder Axis Encoder
PLC
Axis
Extremely fast axis synchronizationCentralized and decentralized architectures
Ideal Network Requirements
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostics
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostics
Requirement 3
• Multiplexed slot assignment–No need to exchange all data at fastest cycle time–Ideal for Integrated Automation
More Efficient Mechanism• Poll Response Chaining
– Position Control Loop– Current Control Loop
Ideal Network Requirements
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostic
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostic
Requirements 4 & 5• Hot Plug
– Higher productivity, modular system concepts
• Topology flexibility– 100% free choice of star, tree, ring, or daisy chain – No limits on system extensions
Ideal Network Requirements
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostic
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostic
Requirement 6• High Availability
– Ring redundancy– Full medium redundancy– Redundant master
Ideal Network Requirements
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostic
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostic
Requirement 7• Electromagnetic Compatibility
– New machines include noisy electric power components
Ideal Network Requirements
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostic
1. Real-time performance, high efficiency
2. Large asynchronous bandwidth
3. One single Network for all automation
4. Flexible network topology
5. Hot pluggable
6. High availability
7. Electromagnetic Compatibility (EMC)
8. Easy commissioning, maintenance and diagnostic
Requirement 8• Network Diagnostics
– Unambiguous diagnostics – Total view of the network– No data manipulation on path-transmission– Standard office diagnostic-tools– PC with on-board Ethernet interface using Wireshark, Omnipeak, etc.
Performance• Timing characteristics
– 0.1 µs system synchronization– 100 µs cycle time
• High capacity– High data throughput– 239 Controlled Nodes– 480 synchronized axes– 460,000 digital I/O data points
• Exceptional performance– Example : 17 stations, 800 digital I/O, 180 analog I/O, 24 axes -> cycle
time of 200 µs
POWERLINK implementation• Hardware Choices
• Operating Systems
POWERLINK Frame Structure• POWERLINK frame
– Fully compliant with IEEE 802.3– Ether Type = 0x88AB
POWERLINK OSI model• POWERLINK OSI model
– POWERLINK sits on top of the standard Ethernet MAC layer– Full integration with TCP/IP
CANopen Reference Model • POWERLINK interface is CANopen over Ethernet
– Same device profiles– CANopen application layer– Same mechanisms (PDO, SDO, Object Dictionary…)
The fastest network in the world!• 728 axes in 400µs
Topology comparison - Conventional structure
Different engineering toolsMany bus systems
Complex diagnostics and maintenance
Bus 1 Bus 2
Bus 3
Motioncontroller
I/O I/O
SensorSensor
PLC
Bus 4
VisionBus 5
<1ms jitter<1ms jitter
>100 bytes>100 bytes
<10$<10$
>1Mbits/s
<5ms cycle time<5ms cycle time
Topology comparison - Integrated automation
I/O I/O
SensorSensor
PLC
Vision
One technologyUnmatched performanceUnlimited freedom in machine design
• 100ns jitter• 100µs cycle time• 1 to 1490 bytes• 100 Mbit/s• <10$
• 100ns jitter• 100µs cycle time• 1 to 1490 bytes• 100 Mbit/s• <10$
Easy diagnostics and maintenance
Standards• EPSG is an open vendor group
– Maintaining openPOWERLINK– openSAFETY
• POWERLINK is an open protocol– No license fees– No patents– Free specification:
• http://www.ethernet-powerlink.org/– Open-source protocol stack available for download on SourceForge
• Open standards– IEEE 802.3– IEC 61784-2
openPOWERLINK• Open-source POWERLINK stack (MN and CN)
– BSD license– Developed for Linux– Ported to Windows and VxWorks– Other platforms under development
• Project hosted at SourceForge.net:– http://sourceforge.net/projects/openpowerlink/
Market Share
• 3,100 OEMs developing POWERLINK systems
• More than one Million POWERLINK systems deployed
Source IMS Research 2013
Government Recommended Standard
Industrial Ethernet National Standard GB/T-27960
openSAFETY
TÜV certificationIEC 61508 SIL3, PL e
Certified safe motion profiles IEC 61800-5-2
International safety standard IEC 61784-3
TÜV certificationIEC 61508 SIL3, PL e
Certified safe motion profiles IEC 61800-5-2
International safety standard IEC 61784-3
certified product
POWERLINK news
www.ethernet-powerlink.org/
www.linkedin.com/groups?about=&gid=2331103
Embedded TechCon
Thank you for your attention!
Sari [email protected]
Technology MarketingEthernet POWERLINK Standardization Group