Xilinx Smarter Connected Control SolutionsIndustry Mega Trends Page 2 Cyber-Physical Systems Communicating Devices Cloud, Connected ... Market Enterprises Strategy Talents The 4 Advantages

Xilinx Smarter Connected Control Solutions

XILINX CONFIDENTIAL.

Industry Mega Trends

Page 2

Cyber-Physical

Systems

Communicating

Devices

Cloud, Connected

Everything

Machine 2 Machine Industry 4.0 Internet of Things


Market Enterprises Strategy Talents

The 4

Advantages

New Info

Technology

Numerical

Control Tools

Aerospace

Equipment

High-Tech

Ships

Railway

Equipment

Energy

Saving

New

Materials

Medical

Devices

Agricultural

Machinery

Power

Equipment

The 10 Key

Sectors

Source – People’s Daily Online, 05/22/2015

Made in China 2025


Smart Factory B

Merging of Virtual

and Physical Worlds

– Cyber-Physical Systems CPS

Give Birth to the “Smart Factory”

concept

– Real-time quality, time, resource

cost advantages

• Flexible

• Self-adaptable

• Learning

• Fault tolerance

Services provide added Values

Page 4

Industry 4.0 Smart Factory PipelineCloud-based Secure Networks

Smart Factory A

Smart

Machine

Smart

Machine

M2M –

Communication

Cyber-Physical Production Systems

Smart

Materials

Smart

Products

Secure

Cloud Networks

Source: DFKI 2012

Services


Page 5

Attributes of Smarter Factories

Dynamically Adaptable Machines

Smarter Sensors Smarter Controls Smarter Connectivity


An Example of Smart Factory


Scores of Industrial Networks...

Page 7

Enterprise LAN

GigE

Fieldbus

devices

Historic Data

OPC Server

Workstation

PLCPACMotion Controller

Fieldbus

Master

HMI

Servo

Drives

I/Os

Light

Curtain

Sensor

Drive

Machine Vision

Camera Many optimized

networks

None is compatible

to the other!

but


consequently

... and you must support them all!

I/O Drive Sensor

Controller

Different Factories

use equivalent equipment in different networks

must support Many ProtocolsYour Product


S

Program-

mable

Logic

Controller

(PLC)

Industrial EthernetIndustrial Network is the Backbone

Sensors

Actuators

S

SS

No automation without real-time Network

Modern Industrial Networks are on Ethernet

S

M

S

= Master

= Slave (e.g. IO module)

Photoelectric

Sensor Pressure

Sensor

Motor

M I n d u s t r i a l N e t w o r k o n E t h e r n e t


Industrial EthernetMarket Share by installed nodes

other, 3%Ethernet,

8%Discrete Machine

Safety, 7%

Industrial Ethernet,

9%

Fieldbuses, 74%

Industrial Ethernet

and Fieldbuses,

780 millions of nodes

connected in 2014

(installed base)

Profinet25%

EtherNet/IP24%

Modbus-TCP13%

Powerlink7%

EtherCAT6%

Sercos III1%

other24%

54 millions of Industrial Ethernet

nodes connected in 2014 (installed base)

Based on forecast data for 2014 from http://www.imsresearch.vom

"The World Market for Industrial Ethernet & Fieldbus Technologies(...) - 2013 edition", Chapter 2

http://www.imsresearch.vom/


Industrial EthernetChoices are growing

Sponsor Siemens Rockwell Schneider El. Beckhoff B&R Bosch

Consortia

Profibus User

Organization

(PNO)

Open DeviceNet

Vendors

Association

(ODVA)

Modbus

Organization

EtherCAT

Technology

Group (ETG)

Ethernet

Powerlink

Standardization

Group (EPSG)

Sercos

International

e.V.

Installed base

(nodes) 2014*24,600k 23,900k 13,200k 6,000k 6,400k 1,200k

New nodes

connected

2014*

(CAGR 2011-

16)*

6,700k

(CAGR 17%)

6,200k

(CAGR 15%)

3,300k

(CAGR 16%)

1,700k

(CAGR 18%)

1,500k

(CAGR 12%)

260k

(CAGR 13%)

Max. nodes in a

network**

Almost

Unlimited

Almost

Unlimited

Almost

Unlimited65,536 240 511

Sub millisecond

cyclesYes No No Yes Yes Yes

Focus Industrial I/O Industrial I/O UniversalAutomation,

PLC to Device

Machine

Building

Automation,

Drives

* Source: Based on 2012 data from http://www.imsresearch.com/, "The World Market for Industrial Ethernet & Fieldbus Technologies (...) - 2013 edition, chapter 2".

** Source: Wikipedia, Definition of Industrial Ethernet

http://www.imsresearch.com/


Protocol Differentiators

• Different classes with different complexity (Conformance Class A, B and C)

• Seamless integration with Profibus available

• Optimized for cyclic traffic (cycles down to 12.5 µs)

• With optimized MAC layer in hardware

• 100% standard 802.3 MAC Layer and Data Link Layer.

• Half-duplex - all information is boradcasted.

• Open protocol (BSD license)

• Short cycle times, ideal for drive applications

• Slave-to-slave communication

• Can runs on standard UDP/IP

• Optional DLR for lower latency and enhanced synchronoization

• Software based, uses TCP/IP port 502

• Open protocol

• No hard real-time

Industrial EthernetDifferentiators of the most important protocols


Industrial Ethernet Generic Architecture and Building Blocks (1/2)

Communi-

cation

Processor

HALSwitch + MAC +

Synchronization

Direct I/O

Process Data Interface (PDI)

Host

Processor

Protocol Stack Application

PHY

PHY

IE Network

Hardware

Software

General Purpose

(internal or

external)

AMS

Function in PL

Xilinx

AXI

xMII

GPIO

Legend:

Analog in


Communication ProcessorRuns protocol stack.

Forwards information between network and Process Data Interface.

Can be a hard core, soft core or dedicated logic.

Switch+MAC+Sync

Provides two network ports

Functionality for filtering and fast forwarding with interrupt and sync signal

Time-stamping

HALHW Abstraction Layer as a shim between and (typically with AXI slave).

Gateway between two clock domains, optionally with DMA

Direct I/OLatch or sample/hold functionality.

Can built AMS functionality with access to XADCs.

Process Data Interface

Communication with the user application on host processor.

Provides µC specific interface (often AXI, sometimes (Q)SPI or other).

Interrupt request control

Host ProcessorFor user application and higher layer services

Industrial Ethernet Generic Architecture and Building Blocks (2/2)

Full diagram: see slide before


Introducing Anybus embedded

– one solution for all

networks


• Multi-Protocol suite for Industrial Ethernet on Zynq

• From HMSProduct

• FPGA IP + Protocol Stack

• License = Security Chip from HMSDelivery

• No NRE *), charge per Security Chip

• MoQ = 500 + One-time low quantity option for ramp upPricing

• HMS's established support structures for Anybus

• Documentation, Reference System on ZedboardSupport

Anybus IP on Xilinx

*) unless features beyond standard model are ordered

Page 17

Industrial NetworkingIP Cores from Alliance Partner Program


Xilinx Alliance Partner Program

customer-specific

adaptations possible

flexible licensing models

Main model:

Source code buyout

Alternative:

One-time-fee for binaries

Xilinx Alliance

Partner Program

Multi protocol Single Protocol

Profinet IRT

EtherCAT

sercos III(Spartan-6)

Powerlink

EtherNet/IP,

Modbus-TCP,

Powerlink(SW porting upon customer

request as design service)

Note: is also multi protocol

supplier for Xilinx. Focus: SW stacks for

Zynq

Mechatrolink-III

CC-Link IE


Example 1: Xilinx Partner Beckhoff - EtherCAT

Zynq-7000 EtherCAT System

EtherCAT with 31.25 µs on Zynq

ISM-NET


Example 2: Xilinx partner Enclustra

Functional Safety with Profinet IRT in Zynq


Protocol Type Features / Conditions ProviderGeneral

Availability

Device Family

Support

Profinet RT/IRT Device

- Conformance class C

- Proven SDK from Molex

- Application in A9 or MicroBlaze

- Source code buyout option

- Volume independent license

Enclustra

ZHAW InES

available (RT)

Q2/2015 (IRT)

Zynq-7000, Artix-7

Profinet IO Device

- Conformance Class A

- Pure Software solution

- Very small stack size


port GmbH availableZynq-7000,

Spartan-6

Profinet RT/IRT Device

- Conformance class C

- with integrated soft core

processor for the protocol stack

- Royalty model

Softing available Zynq-7000, Artix-7

Ethernet/IP Adapter

- Proven SDK from Molex

- 3 port switch in FPGA fabric

- Linux driver support for real-time

and non-real-time traffic


Enclustra

ZHAW InESQ2/2015 Zynq-7000, Artix-7

Industrial Ethernet from Xilinx Alliance Program Partners (1/3)


Protocol TypeFeatures / Conditions

Provider AvailabilityDevice Family

Support

EtherCAT Slave

- Ethernet Slave Controller

- Comprehensive configuration

options supported by GUI

- Source code for slave stack

development available for ETG

members

- Volume independent model or

mixed annual fee/royalty model

available

Beckhoff availableZynq-7000, Artix-7,

Spartan-6

EtherCAT Master

- Based on proven stack from

acontis

- Compliant to the EtherCAT Master

Class Directive according to

ETG.1500

- Independent from operating

system

- Royalty model

IXXAT available Zynq-7000

Ethernet

POWERLINK

Controlled

Node

- OpenPOWERLINK with openMac

- Implemented in uBlaze for cross

platform compatibility and to free

up A9s for application use

B&R availableZynq-7000, Artix-7,

Spartan-6

Ethernet

POWERLINK

Controlled

Node +

Managing

Node

- openPOWERLINK for Cortex A9

- software solution for standard

Ethernet infrastructure

B&R availableZynq-7000, Artix-7,

Spartan-6



Protocol Type Features / Conditions Provider AvailabilityDevice Family

Support

Modbus-TCP Slave

- OS-independent software

- Runs as an application on a

socket

API on TCP layer

- Compatible with all Ethernet

hardware

Ixxat on requestZynq-7000, Artix-7,

Spartan-6

Sercos IIISlave +

Master

- Self-contained and lean FPGA IP

core

- Less than 5.000 LUTs

Sercos International

e.V.available Spartan-6

CC-Link IE Slave- Annual license fee (volume

independent)inrevium on request Zynq-7000

Mechatrolink IIISlave +

Master

- Annual license fee (volume

independent)inrevium available Zynq-7000



– Avnet Supported Kit

– EtherCAT slave TRD

– LX150T base board +

ISMNET card

– Phasing out!

Industrial Ethernet Kits

– Positioned as “platform”

– Customer buys

hardware pieces

individually

– Qdesys MC reference

design with EtherCAT

– Go to Qdesys for D/L

and support

– Various boards for CC-Link, Powerlink, Mechatrolink, EtherCAT

– Sold as kits or individual boards that can be assembled for complete network evaluation

– Expanding to global presence

Inrevium Boards For Industrial Networking

Avnet Spartan-6

IEK

$1,895

Zynq Intelligent

Drives

$1,145+

– Spartan-6 LX75T

– Basis for S6 Motor Control Kit

– Can add ISMNET

– Larger device good for

EtherCAT, bridging apps

– Driving ref. designs towards

this

Avnet LX75T Board

$425

$250

ISMNET

+

$TBD

FMC

+

Avnet ZedBoard

– Produced by Avnet

– Zynq 7Z020

– New FMC with motor

control and dual

Ethernet

– Driving all new IE ref.

designs on Zynq to this

Industrial Ethernet Switches for High AvailabilityHSR/PRP switches, IEEE1588-2008 solutions


Problem: Network outage can impact whole plants

Solution: Recovery with HSR and PRP protects the networks

Ethernet High Availability (1/2)

PRP(Parallel Redundancy Protocol)

HSR(High Availability Seamless Redundancy Ring)

Node

#1

Node

#3

Node

#2

Node

#4

Node

X

Node

Y

Network

A

Network

B

Protection in a RING Protection via PARALLEL paths

Widely used for communication between substation networks

SoCe has solution with lowest latency - exclusively for Xilinx!


Ethernet High Availability (2/2)

HSR / PRP

Switch

IEE

E1

58

8

Tra

nsp

are

nt C

lock

A B

uplink

PHYPHY

PHY

Xilinx Alliance Partner:

Protection with zero packet loss

3 port switch for Ethernet

IEEE1588 for synchronization over network

Target markets

– Energy (i.e. IEC 62439)

– Industrial

– Transportation

For Zynq and Spartan-6


Ethernet High AvailabilityHSR/PRP Switch IP-Core

Differentiators

Cut through mode

– Constant and Low latency times:

– <3 µs for FE / <500 ns for GE

– (Competitor: 106 µs @ 1280 byte frame)

No need for CPU or software stack

– 1588 and Supervision Frames managed by hardware

– (Competitor: always need a CPU)

1GE HSR - Forwarding Time Latency

Comparison

0

2000

4000

6000

8000

10000

12000

14000

16000

256 512 1024 1280

Payload Size (Bytes)

La

ten

cy (

ns)

- L

ow

er

is b

ette

r

Theoretical Min.

HSR/PRP Switch-Xilinx

FRS-Alteracompetition

HSR/PRP Switch is a HDL IP Core for the implementation of both the HSR (IEC 62439-3-

Clause 5) and PRP (IEC 62439-3-Clause 4) protocols in a single device.


Ethernet High AvailabilityHSR/PRP Switch IP-Core

100M / 1GE / Copper - Fiber

Full IEEE 1588-2008 V2 support

Fully scalable in number of ports and features

RSTP, VLAN, SNMP, DAN, RedBox, Quadbox

Reference Designs for Spartan-6 and Zynq devices

Single flag switches between PRP and HSR modes

Area optimized for low cost FPGA devices

– Example: RedBox with Transparent Clock

– 5.250 slices (15.000 LUTs, 11.300 registers), 64 RAMB16, 20 RAMB8

Commercial conditions

– Project license with netlist: 34K€, +6K€ annual support and maintenance

– Site license with encrypted HDL and royalty-based model: on request

Contact:

– [email protected]

HSR/PRP Switch, further information


Ethernet High AvailabilityNETBox (Development Kit)

NETbox is an all-in-one solution to develop FPGA based

Industrial Networking Solutions. It includes the NEToem

pluggable OEM module and a NETcarrier board.

– On-board LAN9303 Ethernet Switch to combine

Reliable Ethernet with regular Ethernet

– UART/GPIO/GPS Clock/JTAG/PMOD connectors

for versatile connectivity

– User programmable OLED Graphic Display

– EHIZtari PC HSR/PRP Network Analysis and

Testing tool availableRJ45

RJ45

RJ45

RJ45

RJ45

RJ45

NEToemModule

(FPGA)

I2C

SDA SCL

Fast Ethernet Switch

SERIAL

JTAGOLED

PMOD GPIO

LPDDR

FLASH

Tº Sensor

Board-to-board connector

Debug Connector

F.E PHY F.E PHY F.E PHY F.E PHY

GPIOS

x40

MII x5


Individual Products – Many CPU variants, OS and API

Lack of Security, Reliability

Smart Grid Automation – Current Generation Architecture

Power Supply CPU

Backplane

MCUNo OS

CPLD

CPU

OS a

FPGASwitch

CPU

OS b

FPGA

Protection

Relay

DSP b

FPGA

Measurement

Unit

DSP a

FPGA

I/O

MCU

FPGA


IIoT Factors Contributing to Smart Grid

– New Feature >> Highest Reliability - HSR/PRP

» Lowest latency

» Sub 4 ms recovery time IED to IED

– New Requirements >> Robust Security

>> Functional Safety

Smart Grid Automation – Next Generation Architecture

Power Supply

HSR/PRP, IEEE1588 IP

+

+

CPU

HSR/PRP

EtherCAT

Module nModule 2

EtherCATEtherCAT

DSP

I/O

EtherCAT

DSP

I/O

Module 1

EtherCAT

DSP

I/O

Multi-axis Motion Control for CNC & Robotics


Page 37

Worldwide Industrial Robots Shipment

CAGR (2012-17)

6.5%

34.2%

2.2%

6.0%

3.7%

The actual number

by CRIA is 57,000


Two Categories of Industrial Machines

Small size, small power

Large size, high power

Collaborative Robot

6-axis Industrial Robot CNC

Laser Cutting Machine

SCARA Robot Delta Robot


Robot Controller Architecture Consideration

Motor Drivers

Integrated

Discrete

Motor Drivers

Main

CPU

2nd CPU Servo Ctrlr

CPU

Typically DSP/PowerPC

Position control

Axis computing

Typically X86 Typically FPGA

CPUServo

Ctrlr

- Multiple chips

- Single chip like Zynq/MPSoC

- Suitable for

Desktop collaborative robot

Mobile Robot

Robot ARM

- Suitable for

Traditional industrial robot

High-end collaborative robot


Single Chip for multi-axis servo drive + network

Processing System

Programmable Logic

Drive12%

ZC-7010

Processing System

Programmable Logic

ZC-7020

Drive4%

Processing System

Programmable Logic

Drive22%

ZC-7010

Processing System

Programmable Logic

ZC-7020

Drive7%

TWO MOTORS

ONE MOTOR

Drive12%Processing

System

Programmable Logic

ZC-7020

4 FULL DRIVES + EtherCAT®

60%


Basic building blocks

– Fifteen control functions, all modular

– DSP48 centric

– Dynamic operation with minimum footprint

– CLARKE, PARK, PID, ATAN2, SIN/COS, SMO, SVM,

RPFM, filters, etc.

High precision

– 48bit operations, 18bit precision

30...40 times faster than µC

– Freescale: 55 µs @ 96MHz for torque control loop

– QDESYS IP: 1.6 µs @ 50MHz

Low EMI– innovative RPFM power modulation algorithm

All Motor data and parameters via XML descriptors– scalable, wide range motor current measurement

Available today

– One-time fee @ 5K USD

Motor Control IP for Xilinx FPGA

...

Xilinx-exclusive Motor Control IP for Performance and Extensibility


Model-based Design for Motor Control

MATLAB and Simulink

Algorithm and System Design

HDL IP Core

Generation

Embedded System

Integration

SW Interface

Model Generation

FPGA Bitstream SW Build

Processor-

in-the-loop

Code Generation with Mathworks

System Design

– Simulink for model based design

HDL Worflow Advisor with

– HDL Coder for RTL code

– Embedded Coder

– Mathworks support packages for Xilinx

platform

Bitstream compilation and

programming from within Simulink

– using Xilinx design suite

Processor-in-the-loop for fast

iterations

More information:

– www.mathworks.com/xilinx

– www.mathworks.com/zynq

Lo

ng

-liv

ing

P

latf

orm

Ec

on

om

ica

l S

olu

tio

nH

igh

Pro

du

cti

vit

y

Code Generation for fastest optimization


Page 43

Industrial Robot Controller Software Architecture

Hardware

OS

RT Extension

Libraries

Applications

Motion Ctrl NetworkingUI

Processor Memory Sensor I/O

SMP -

Non Hard RT: Windows, Linux

Hard RT: Vxworks, QNX

AMP –

Linux + Baremetal/RTOS

INTime for Windows

RTAI/Xenomai for Linux

X86

ARM

PPC

…

Force

Camera

Anti-collision

…

Sensor

Encoder

Ethernet

CAN

Serial

USB

Operation 1 Operation N…

Safety

SoftPLC OPC UA

Operation 2

…Security


Zynq-based Motion Controller Solution by B&R

Page 44

Z7010

Linux

XenomaiPowerlink

Eclipse-based IDE

Core board

CNC & Robotics


Zynq-based SoftPLC/SoftMotion Solution from Phoenix Contact SW


Page 46

Integrated Control & Drive System Partition

Field

Bus

Access

High-

level

Control

Trajectory

Planning

IO

Trajectory

Integration

P/V/I

ControllerPWM

Drive

Non-Real-Time Real-Time

Motion Control Drive Control

High-level Control

Trajectory Planning

Trajectory Integration

Position Control

Velocity Control

Current Control FPGA

CPU

FPGA

CPU

FPGA

CPU

FPGA

CPU A

CPU B

FPGA

CPU A

CPU B

FPGA

DSP

CPU

A B C D E F G

Flexibility

Performance


Page 47

Zynq-based Integrated Control & Drive Solution


Time Division Multiplexing in PL for Multi-axis


Implemented utilization

Resource Utilization


Co-Simulation


Collaborative Robots

Collaborative Robots going to reach >40.000 units in 2020

– ASP of $25,000 each

– $1B market

– Make production more feasible – lower cost

Use mode is in collaboration with humans

– Space becomes an issue

• Controls and power supplies need high degree of integration

– Sensors are attached and deeply embedded into control

Functional Safety is critical


Collaborative Robot Platform with Integrated Drive

A53 A53

R5

R5

TC

M

OCM

Peripherals

Cache

FPGA

Region 1

Safety

Ind. Ethernet

FPGA Region 2

SDSoC accel

FPGA Region 3

Communication

Sensor Preprocessing

Mvision accel

A53 A53

Zynq® – Smart MV Camera

A9 A9

FPGA


A9 A9

FPGA


A9 A9

FPGA

FPGA

Region 1

MOSFET MOSFET MOSFET MOSFET MOSFET

Ax

is 1

Ax

is 2

Ax

is 3

Ax

is 4

Axis

20

Motion Control for multi axis

Embedded Safe Motion

EtherCAT Master stack with Safety

Layer

Safety Requirements: Ple CAT 4

HMI

Display

FPGA

Region 1

FPGA

Region 1

FPGA

Region 1

FPGA

Region 1

Multi Axis power stage with min. drive

capabilities and safety

MOS FET or SiC driver stage

Digital Encoder

Safety requirements: Ple CAT 4

Sensors

Robotics Control

Meta data processing from

- Sensors

- Vision Sensors

Robot Motion Planning & Safe Motion

Motion controller

Sensor bus management

Camera bus management, GigE Vision etc. or

Ind.Ethernet like EtherCAT, Profinet, Powerlink

HMI

Safe motion safety requirements: PLd CAT3

…


Xilinx Functional Safety Value Proposition

Page 53

Zynq

Sa

fety

A9

Spartan-6/

Artix-7

Cost & Profitability Compliance & Reliability Flexibility &

Innovation

Integration of Safe and

Non-Safety functions

Certified Tools,

Methodologies, Reports

Isolation Design Flow

Updates to Non-Safety

Integration of Cortex A9

and FPGA

Safety Manual, Reliability

Report

Highest availability

through lowest SEU

failure rates

IEC61508

ISO26262

Certified by

Isolation Design Flow

Sa

fety

A9


Page 54

4 Devices 3 Devices 2 Devices$$ 1 Device $

Customer Time To Revenue depends on

completeness of the certified solution

Zynq and Zynq MPSoC

Functional Safety Reference Design

Accelerates customer TTR by 12 to 18 month

Unique Xilinx Functional Safety Solution we have a strong value proposition

Documents

Xilinx Smarter Connected Control SolutionsIndustry Mega Trends Page 2 Cyber-Physical Systems Communicating Devices Cloud, Connected ... Market Enterprises Strategy Talents The 4 Advantages