1. 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

2. Video Video Example

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

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 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

8. 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

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

10. CYCLE TIME POWERLINK Technology Synchronization and communication during each cycle Async. data Synchronous phase Asynchronous phase SoCPReq CN1PReq CN2 PReq CNn SoA Easy and robust functionality No complex time synchronization All on one medium I/OAxisI/O PRes CN1PRes CN2 PRes CNn PLC

11. POWERLINK Technology Cross communication PRes CN1 SoC PReq CN1 PRes CN1 SoC EncoderAxisEncoder PLC Axis Extremely fast axis synchronizationCentralized and decentralized architectures

12. 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

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 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

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 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

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

19. 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

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

21. 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

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 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 Different engineering tools Many bus systems Complex diagnostics and maintenance Bus 1Bus 2 Bus 3 Motion controller Drive I/O Sensor PLC Bus 4 Vision Bus 5 <1ms jitter >100 bytes <10$ >1Mbits/s <5ms cycle time

30. Topology comparison - Integrated automation Drive I/O Sensor PLC Vision One technologyUnmatched performance Unlimited 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

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/ http://sourceforge.net/projects/openpowerlink/

33. Market Share 3,100 OEMs developing POWERLINK systems More than one Million 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 certified product

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

37. Embedded TechCon Thank you for your attention! Sari Germanos sari.germanos@ethernet-powerlink.org Technology Marketing Ethernet POWERLINK Standardization Group