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Embedded TechCon Synchronizing mechatronic systems in real-time using FPGAs and Industrial Ethernet. Sari Germanos sari.germanos@ethernet-powerlink.org Technology Marketing Ethernet POWERLINK Standardization Group. Video. Video Example. Everything Connected to one network.

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  1. Embedded TechConSynchronizing mechatronic systems in real-time using FPGAs and Industrial Ethernet Sari Germanossari.germanos@ethernet-powerlink.orgTechnology MarketingEthernet POWERLINK Standardization Group

  2. Video • Video Example

  3. Everything Connected to one network • Integrated System Architecture Controller Robotics Visualization Vision Pneumatics Sensor remote I/Os Safety Logic Robotics Motion Systems

  4. 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

  5. Fieldbus Technology • Traditional fieldbuses • RS485 or CAN based • Reliable, field proven • Cheap • Very limited bandwidth • Need a faster solution: Industrial Ethernet

  6. 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!

  7. Ideal Machine Network Requirements • Real-time performance, high efficiency • Large asynchronous bandwidth • One single Network for all automation • Flexible network topology • Hot pluggable • High availability • Electromagnetic Compatibility (EMC) • Easy commissioning, maintenance and diagnostic

  8. Ideal Network Requirements • Real-time performance, high efficiency • Large asynchronous bandwidth • One single Network for all automation • Flexible network topology • Hot pluggable • High availability • Electromagnetic Compatibility (EMC) • Easy commissioning, maintenance and diagnostic

  9. POWERLINK Technology • Network master • 1 Managing Node (MN) • Network slaves • Up to 239 Controlled Nodes (CN)

  10. POWERLINK Technology Synchronization and communication during each cycle SoA PReqCNn SoC PReq CN1 PReq CN2 Synchronous phase Asynchronous phase CYCLE TIME PLC I/O I/O Axis Async. data PRes CN1 PRes CN2 PResCNn No complex time synchronization All on one medium Easy and robust functionality

  11. POWERLINK Technology • Cross communication SoC SoC SoC PReq CN1 PReq CN1 PReq CN1 PReq CN1 SoC Encoder Axis Axis PLC Encoder PRes CN1 PRes CN1 PRes CN1 PRes CN1 Extremely fast axis synchronization Centralized and decentralized architectures

  12. Ideal Network Requirements • Real-time performance, high efficiency • Large asynchronous bandwidth • One single Network for all automation • Flexible network topology • Hot pluggable • High availability • Electromagnetic Compatibility (EMC) • Easy commissioning, maintenance and diagnostics

  13. Requirement 3 • Multiplexed slot assignment • No need to exchange all data at fastest cycle time • Ideal for Integrated Automation

  14. More Efficient Mechanism • Poll Response Chaining • Position Control Loop • Current Control Loop

  15. Ideal Network Requirements • Real-time performance, high efficiency • Large asynchronous bandwidth • One single Network for all automation • Flexible network topology • Hot pluggable • High availability • Electromagnetic Compatibility (EMC) • Easy commissioning, maintenance and diagnostic

  16. 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

  17. Ideal Network Requirements • Real-time performance, high efficiency • Large asynchronous bandwidth • One single Network for all automation • Flexible network topology • Hot pluggable • High availability • Electromagnetic Compatibility (EMC) • Easy commissioning, maintenance and diagnostic

  18. Requirement 6 • High Availability • Ring redundancy • Full medium redundancy • Redundant master

  19. Ideal Network Requirements • Real-time performance, high efficiency • Large asynchronous bandwidth • One single Network for all automation • Flexible network topology • Hot pluggable • High availability • Electromagnetic Compatibility (EMC) • Easy commissioning, maintenance and diagnostic

  20. Requirement 7 • Electromagnetic Compatibility • New machines include noisy electric power components

  21. Ideal Network Requirements • Real-time performance, high efficiency • Large asynchronous bandwidth • One single Network for all automation • Flexible network topology • Hot pluggable • High availability • Electromagnetic Compatibility (EMC) • Easy commissioning, maintenance and diagnostic

  22. 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.

  23. 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

  24. POWERLINK implementation • Hardware Choices • Operating Systems

  25. POWERLINK Frame Structure • POWERLINK frame • Fully compliant with IEEE 802.3 • Ether Type = 0x88AB

  26. POWERLINK OSI model • POWERLINK OSI model • POWERLINK sits on top of the standard Ethernet MAC layer • Full integration with TCP/IP

  27. CANopen Reference Model • POWERLINK interface is CANopen over Ethernet • Same device profiles • CANopen application layer • Same mechanisms (PDO, SDO, Object Dictionary…)

  28. The fastest network in the world! • 728 axes in 400µs

  29. Topology comparison - Conventional structure <1ms jitter Bus 1 Bus 2 Vision PLC Sensor Sensor I/O I/O Motioncontroller Drive Drive Drive Drive <5ms cycle time Bus 3 >100 bytes Bus 4 <10$ Bus 5 >1Mbits/s Complex diagnostics and maintenance Many bus systems Different engineering tools

  30. Topology comparison - Integrated automation • 100ns jitter • 100µs cycle time • 1 to 1490 bytes • 100 Mbit/s • <10$ I/O I/O Sensor Sensor PLC Vision Drive Drive Drive Drive Unlimited freedom in machine design One technology Unmatched performance Easy diagnostics and maintenance

  31. 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

  32. 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/

  33. Market Share • 3,100 OEMs developing POWERLINK systems • More than oneMillion POWERLINK systems deployed Source IMS Research 2013

  34. Government Recommended Standard • Industrial Ethernet National Standard GB/T-27960

  35. openSAFETY TÜV certification IEC 61508 SIL3, PL e Certified safe motion profiles IEC 61800-5-2 International safety standard IEC 61784-3 certifiedproduct

  36. POWERLINK news www.ethernet-powerlink.org/ www.linkedin.com/groups?about=&gid=2331103

  37. Embedded TechCon Thank you for your attention! Sari Germanossari.germanos@ethernet-powerlink.orgTechnology MarketingEthernet POWERLINK Standardization Group

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