EtherCAT

The
Fieldbus.
EtherCATEthernet
is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology

Oliver
Easier toFels
configure
Technology
Marketing
Cost effective
Easier to
implement

EtherCAT Technology Group

Well proven
ETG Headquarters, Germany
Open

Conformance
Safety
Redundancy
Versatile

September 2016

EtherCAT The Ethernet Fieldbus.

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Ethernet is a great technology

But it is challenging to use it on the fieldbus level:
Switch + Router Configuration (+ Costs)
MAC + IP-Address Handling
Router
Star Topology
Complex Protocols
Diagnostics
Performance
Comprehensive
IT Know-How
Required

Ethernet for Real-Time Communication

EtherCAT is:

Faster

Main Performance Problems:

Synchronization
Industrial
Ethernet

Flexible Topology

1. Bandwidth Utilization

Easier to
configure

Cost effective
Easier to
implement

2. Stack Delays

Well proven
Open

Conformance
Safety
Redundancy

3. Switch Delays

Versatile

September 2016

1. Industrial Ethernet Bandwidth Utilization

EtherCAT is:

Minimum Ethernet Frame: 84 Bytes

Faster
Example: with 4 Bytes Process Data (32 I/O): 4/84 =
Synchronization
% Application Data Ratio
4.75
Industrial
Ethernet
Flexible Topology
Easier to
configure
14 Bytes
Cost effective
Easier to
implement

Ethernet HDR

Well proven

84 Bytes, regardless which Protocol

4 Bytes

Process Data, e.g. 1..4 Bytes

14 Bytes

FCS
Interpacket Gap
CRC

Process

Ethernet Frame Payload: min. 46 Bytes

Data

Open
Conformance

84 Bytes, e.g. with

Safety
Redundancy
14 Bytes
Versatile

Ethernet HDR

September 2016

20 Bytes

IP HDR

8 Bytes

UDP
HDR

20 Bytes

Ethernet/IP
CIP HDR

Payload,
e.g. 4 Bytes 4 Bytes 14 Bytes

FCS
Interpacket Gap
Data CRC
Process

1. Industrial Ethernet Bandwidth Utilization

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

2. Industrial Ethernet Stack Delays

EtherCAT is:

I/O Ports
Faster
Device
Synchronization
Profile
Application
Industrial
Objects
Ethernet(e.g. I/O)

Industrial Ethernet Protocol Stacks are

BIG

Network
&
CIP
Flexible
Topology
Transport
Easier to
configure Explicit
Implicit
Msg
Msg
Cost effective
Message
CIP
Easier
to
Encapsulation
implement

Encapsulation
Well proven
Open
TCP
UDP
Conformance
IP
Safety
Redundancy

Ethernet
Versatile
MAC

September 2016

Processing them needs

TIME

2. Industrial Ethernet Stack Delays

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

EtherCAT is

LEAN

Stack Performance Comparison (I)

is:
EtherCAT
Stack
performances of the Ethernet technologies differ substantially,
Faster
due to the different complexity of the stacks
Synchronization
Industrial
Softing, a German specialist for field bus technology published*
the following comparison of the stack delay times:
Ethernet
Flexible Topology
Easier to
configure
Stack
Cost effective
Time

Profinet IO

Ethernet/IP

EtherCAT

Easier to
Average
implement

0.58 ms

1.89 ms

0.11 ms

Max.
Well proven

0.74 ms

2.96 ms

0.18 ms

0.54 ms

1.23 ms

0.05 ms

Open

Min.

Conformance

Safety
All three protocols were implemented on the same hardware
Redundancy
(interface board with FPGA + Softcore CPU) and by the same team,
Versatile
so they are indeed comparable
* Source: Einer fr alle; Flexible Real-Time-Ethernet Anschaltung mit FPGA, messtec drives Automation Real-Time Ethernet
Sonderheft 2010, by Frank Iwanitz, Business Development Manager Real-Time Ethernet at Softing GmbH, Munich, Germany
September 2016

3. Industrial Ethernet Switch Delays

EtherCAT is:

Switch Buffer Delay:

Faster
Unpredictable by Nature
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Buffer delay depends

on buffer load @ frame
arrival.
QoS (Quality of
Service) eases the
pain by introducing
multiple priorities (and
buffers), but does not
resolve the issue.

3. Industrial Ethernet Switch Delays

Almost all Switches use Store & Forward
Faster
Line Topology means cascaded Switches
Synchronization
EtherCAT is:

Industrial
Ethernet
Flexible Topologyaccumulated delay and jitter even without buffer delay
Substantial
Easier
to
(if
switches
are idle)
configure

Cost effective

Typical
Easier to Store & Forward Delay per switch: Frame length (7122 s) + 3 s
implement
Example:
Full frame, 20 nodes in line topology: 2.5 ms
Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Ethernet for Real-Time Communication?

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure

20ms

Cost effective
Cycle
times
Easier
to can be realized in the range of 5 to 10 ms
implement

Quote: RT in Profinet provides

similar
Open
Real-Time properties
like
Conformance
Profibus
Well proven

Safety
Redundancy
Versatile

Source: Profibus International

http://www.profibus.org.pl/index.php?option=com_docman&task=doc_view&gid=28

September 2016

8ms

Quote: When tested up to

80 percent network bandwidth
utilization, using both managed
and unmanaged switches, the
system managed 16 position
configured axes with an 8 ms
coarse update rate.
Source: Rockwell Automation, White Paper: Scalability-The
Best Approach to Change, Aug 2012
http://literature.rockwellautomation.com/idc/groups/literature/
documents/wp/ia-wp002_-en-p.pdf

EtherCAT: Performance Breakthrough

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

EtherCAT: highest Performance

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

The fastest Industrial

Ethernet Technology

1000 distributed digital I/O in 30 s

100 Servo-Axis every 100 s
EtherCAT directly to the I/O Slice, no Sub-Bus
Optimal Usage of the Standard Ethernet Port in the
Controls, no extra hardware
Reason for this Unique Performance:
The EtherCAT Functional Principle
(Ethernet on the Fly)

Functional Principle: Ethernet on the fly

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology

Car
27

Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Analogy Fast Train:

Train (Ethernet Frame) does not stop
Even when watching Train through narrow window
one sees the entire Train
Car (Sub-Telegram) has variable length
One can extract or insert single persons (Bits) or
entire groups (Bytes) even multiple groups per
train

Functional Principle: Ethernet on the fly

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open

Efficient: Typically only one

Ethernet Frame per Cycle
Safety
Ideal Bandwidth Utilization for
Redundancy
maximum Performance
Versatile
Conformance

September 2016

Functional Principle: Ethernet on the fly

EtherCAT is:

Slave Device

Slave Device

Faster
Synchronization
Industrial
Ethernet
Flexible Topology

EtherCAT Slave
Controller

EtherCAT Slave
Controller

Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Process data is extracted and inserted on the fly:

Process data size per slave almost unlimited
(1 Bit60 Kbyte, if needed using several frames)
Compilation of process data can change in each
cycle, e.g. ultra short cycle time for axis, and longer
cycles for I/O update possible
in addition asynchronous, event triggered
communication

Functional Principle: Ethernet on the fly

EtherCAT is:

Master

Faster
Synchronization
Industrial
Ethernet
Flexible Topology

Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

ECAT HDR

PLC Data 1

NC Data

HDR 3

Ethernet Header

HDR 2

Cost effective

HDR 1

Easier to
configure
PLC Data 2

CRC

Minimal protocol overhead via implicit addressing

Optimized telegram structure for decentralized I/O
Communication completely in hardware: maximum
(+ predictable!) performance
No switches needed if only EtherCAT devices in the
network
Outstanding diagnostic features
Ethernet-compatibility maintained

EtherCAT resolves the Performance Problems

EtherCAT is:

Faster

Main Performance Problems:

Synchronization
Industrial
Ethernet

Flexible Topology

1.
Bandwidth Utilization
Resolved!

Easier to
configure

Cost effective
Easier to
implement

2.
Stack Delays
Resolved!

Well proven
Open

Conformance
Safety

3.
Switch Delays
Resolved!

Redundancy
Versatile

September 2016

EtherCAT The Ethernet Fieldbus.

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

EtherCAT is real time down to the I/O level

No underlying sub-systems any more

EtherCAT The Ethernet Fieldbus.

EtherCAT is:
Faster

Other technologies need local I/O cycles + gateways

Synchronization

Well proven
Open
Conformance

RAM

CPU

Flash

September 2016

I/O

Versatile

Fieldbus
Controller

Redundancy

Driver

Safety

I/O

Flash

Easier to
implement

I/O

Cost effective

I/O

CPU

I/O

Fieldbus
Controller

Easier to
configure

Driver

Flexible Topology

Master for Local

Extension Bus

RAM

Industrial
Ethernet

EtherCAT The Ethernet Fieldbus.

EtherCAT is:
Faster

EtherCAT: Real time down to the I/O

Synchronization
Industrial
Ethernet

Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

EtherCAT
Controller

EtherCAT
Controller

EtherCAT
Controller

EtherCAT
Controller

Cost effective

EtherCAT
Controller

Easier to
configure

Driver

Flexible Topology

EtherCAT The Ethernet Fieldbus.

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

EtherCAT is real time down to the I/O level

No underlying sub-systems any more
No delays in gateways
In- and outputs, sensors, actuators, drives, displays:
everything in one system!

EtherCAT is faster
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Transmission Rate:
2 x 100 Mbit/s (Fast Ethernet, Full-Duplex)

Update Times:
256 digital I/O in 11 s
1,000 digital I/O distributed to 100 nodes in 30 s
= 0.03 ms
200 analog I/O (16 bit) in 50 s, 20 kHz Sampling
Rate
100 Servo-Axis (each 8 Byte In + Out) in 100 s
= 0.1 ms
12,000 digital I/O in 350 s

Slow Control Systems benefit, too

EtherCAT is:
Faster

Reaction time with legacy fieldbus I/O:

Synchronization
I

Industrial
Ethernet

PLC Task O

PLC Task O

PLC Task O

PLC Task O

PLC Task O

Bus Cycle

Bus Cycle

Tmpd

Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven

Bus Cycle

TI/O

TI/O

Bus Cycle

TI/O

TI/O

TI/O

TI/O

Bus Cycle

TI/O

TI/O

Bus Cycle

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

Best case reaction time

Worst case reaction time

Open
Conformance
Safety

TI/O

Bus Cycle

Input (worst case)

Input (best case)

Output

Redundancy
Versatile

Tmpd: Master Processing Delay

TI/O: Local I/O Update Time
(Local Extension Bus + Firmware)
Emoji provided free by EmojiOne

September 2016

Slow Control Systems benefit, too

EtherCAT is:
Faster

System Architecture with EtherCAT:

Synchronization
Industrial
Ethernet

PLC Task O

PLC Task O

PLC Task O

PLC Task O

PLC Task O

Bus Cycle

Bus Cycle

no dedicated Master Device any more

Tmpd

Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Bus Cycle

TI/O

TI/O

Bus Cycle

TI/O

TI/O

Bus Cycle

TI/O

TI/O

Bus Cycle

TI/O

no underlying extension bus any more

TI/O

TI/O

Bus Cycle

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

TI/O

Slow Control Systems benefit, too

EtherCAT is:
Faster

System Architecture with EtherCAT:

Synchronization
Industrial
Ethernet

PLC Task O

PLC Task O

PLC Task O

PLC Task O

PLC Task O

Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

TDMA (NIC)

Well proven
Open
Conformance

TEtherCAT Cycle

Safety
Redundancy
Versatile

September 2016

TDMA = Time for Data Transfer

from/to Ethernet Controller via
Direct Memory Access:
neglectible

EtherCAT: Mapping moved into Slave Devices

EtherCAT is:

Master

Faster
Synchronization
Industrial
Ethernet
Flexible Topology

Easier to
implement

Well proven
Open

Data n

Redundancy

PLC Data

Versatile

NC Data

September 2016

PLC Data

NC Data

Data n

Enet FCS

logical
process
images up
to 4 Gbyte

Conformance
Safety

ECAT HDR

HDR 3

Ethernet Header

HDR 2

Cost effective

HDR 1

Easier to
configure

Datagram 1

Datagram 2

Datagram n

Control System is unburdened, master

becomes very simple
Data is transmitted according to the
application requirements: extremely
fast, flexibly and efficiently

Synchronization
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Source: konflikty.pl

Versatile

September 2016

EtherCAT Propagation Delay Measurement (1)

EtherCAT is:
Faster
Synchronization

EtherCAT Node measures time difference between

leaving and returning frame

Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

EtherCAT Frame
Processing Direction

EtherCAT Frame
Forwarding Direction

EtherCAT Propagation Delay Measurement (2)

EtherCAT is:
Faster
Synchronization

EtherCAT Node measures time difference between

leaving and returning frame

Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Master

Distributed Clocks
EtherCAT is:
Faster
Synchronization

Precise Synchronization (<< 1 s!) by exact adjustment

of Distributed Clocks

Industrial
Ethernet
Flexible Topology

Master

Easier to
configure
S

Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Distributed Clocks
EtherCAT is:
Faster
Synchronization

Long Term Scope View of two separated devices

300 Nodes in between, 120 m Cable Length

Industrial
Ethernet
Flexible Topology

Interrupt
Node 1

Easier to
configure
Cost effective
Easier to
implement

Simultaneousness:
~15 ns

Well proven

Jitter: ~ +/-20 ns

Open
Conformance
Safety
Redundancy
Versatile

September 2016

Interrupt
Node 300

Synchronization with Distributed Clocks

EtherCAT is:
Faster
Synchronization
Position
Signal
Industrial
= xEthernet
Flexible Topology
Easier to
configure
Cost effective

Sample
Easier to
Point

implement

DC
Sync
100 s

100 s

equidistant

Well proven
Open

100 s

100 s

100 s Cycle Time

No sampling
Error

Conformance
Safety
Velocity
x
Redundancy
=
Versatile
Sync In

EtherCAT

Calc. Out

In
D/A
A/D

September 2016

Sync Out
Calc. Out

In
D/A
A/D

Calc. Out

In
D/A
A/D

Calc. Out

In
D/A
A/D

Synchronization of multiple Networks

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet

EtherCAT networks can be coupled via EtherCAT Bridge

Bridge provides hardware synchronization of several
networks
1

Flexible Topology
Easier to
configure
Cost effective

MASTER

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

Easier to
implement

Well proven

SLAVE

MASTER

SLAVE

Open

Conformance
Safety
Redundancy

MASTER

SLAVE

Versatile

September 2016

Synchronization of multiple Networks

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet

EtherCAT networks can be coupled via EtherCAT Bridge

Bridge provides hardware synchronization of several
networks
1

Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy

S
Y
N
C
H
R
O
N
O
U
S

MASTER

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

SLAVE

1
SLAVE

MASTER

SLAVE

1
SLAVE

MASTER

SLAVE

Versatile

September 2016

S
Y
N
C
H
R
O
N
O
U
S

External Clock Synchronization: IEEE 1588

EtherCAT is:
Faster

Switchport with integrated IEEE 1588 Boundary Clock

Synchronization

IEEE 1588
Grandmaster

Industrial
Ethernet
Flexible Topology
Easier to
configure

Boundary
Clock

Master

Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

EtherCAT is Industrial Ethernet!

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet

EtherCAT uses Standard Ethernet Frames: IEEE 802.3

Alternatively via UDP/IP (if IP Routing is needed)
no shortened frames

Flexible Topology

MTU: max. 1514 Byte

Easier to
configure
Cost effective
Easier to
implement

Well proven

48 Bit
Destination

48 Bit
Source

16 Bit

16 Bit

EtherType

Header

Embedded in Standard Ethernet

Frame, EtherType 0x88A4

48 -1498 Byte
EtherCAT Datagrams

32 Bit
CRC

1n EtherCAT Datagrams

Open
Conformance
Safety
Redundancy
Versatile

September 2016

160 Bit
Ethernet Header
Or: via UDP/IP
UDP Port 0x88A4

IP Header

48 -1470 Byte

64 Bit

16 Bit

UDP H.

Header

EtherCAT Datagrams

11 Bit

1 Bit

4 Bit

Length

Res.

Type

CRC

EtherCAT is Industrial Ethernet!

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet

fully transparent for TCP/IP

all Internet technologies (HTTP, FTP, Webserver,)
available without restricting the real time capabilities!

Flexible Topology

EtherCAT Slave Device

Easier to
configure
Cost effective
Easier to
implement

Well proven
Open

Standard
TCP/IP
Stack

Ethernet
Application
TCP

Real Time Application

UCP

Conformance
Safety

IP

Acyclic Data

Redundancy
Versatile

Mailbox

Process Data

EtherCAT MAC / DLL

Ethernet PHY
September 2016

Ethernet PHY

EtherCAT is Industrial Ethernet!

EtherCAT is:
Faster
Synchronization

Any Ethernet Device can be connected to Switchport

Access to Webserver with Standard Browser

Industrial
Ethernet
Flexible Topology

Virtual Ethernet Switch

Functionality

Webserver

Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Master

Switchport

EtherCAT is Industrial Ethernet!

EtherCAT is:
Faster
Synchronization

Any Ethernet Device can be connected to Switchport

Access to Webserver with Standard Browser

Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Master TCP/IP Stack

provides access to Mailbox
protocol

Master

Online access to
device

Switchport

Switchport: Any Ethernet Protocol

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology

Interface to any Ethernet Device or Network

Ethernet Frames are inserted into EtherCAT Protocol:
Ethernet over EtherCAT
EtherCAT Switchport

Easier to
configure

Ethernet MAC

PHY

Cost effective
Easier to
implement

RX1RX2RX3RX4
TX
C
Fragmentation

Well proven
Open
Conformance
Safety
Redundancy
Versatile

PHY

Mailbox

Process Data

EtherCAT MAC / DLL

September 2016

PHY

EtherCAT wiring is more flexible

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Standard Ethernet Topology: Star

Your Selling Point: Expandability

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure

Flexible tree structures arbitrarily extendable

Topology variants like Line, Star, Tree, Daisy Chain
+ Drop Lines possible; can be used in any combination!
Up to 65,535 nodes for each EtherCAT segment
Standard Ethernet cabling
Line

Cost effective
Easier to
implement

Well proven

Master

Open
Conformance
Safety
Redundancy
Versatile

Star/Tree

September 2016

Drop Line

EtherCAT Extra Large System Test

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

10.056
EtherCAT Nodes

EtherCAT wiring is more flexible

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure

Ethernet Signal Variants of EtherCAT:

100BASE-TX (up to 100 m between 2 nodes)
100BASE-FX (up to 20 km between 2 nodes
with single mode fibre)
LVDS (for modular devices)
100 m

LVDS*

Cost effective
Easier to
implement

Well proven

20 km

Master

Open
Conformance
Safety
Redundancy
Versatile

Ethernet on
100BASE-TX up
to 100 m with
transformer
coupling

Ethernet on LVDS*
physical layer:
for modular devices

Ethernet on
100BASE-FX
(fibre optics)
up to 20 km

Any number of physical layer changes allowed

*LVDS: Low Voltage Differential Signaling according to ANSI/TIA/EIA-644,
also used in IEEE 802.3ae (10 Gigabit Ethernet)
September 2016

EtherCAT P:
Communication & Power combined
EtherCAT
Lessis:Cabling on the field level
Faster
Synchronization
Cascadable in all topologies
(star, line, tree)
Industrial
Ethernet
100 % EtherCAT-compatible
Flexible Topology
100 Mbit/s full duplex,
Easier to
Processing on the Fly,
configure
Distributed Clocks etc.
Cost effective
Easier
Dualto power supply: US (system and
implement
sensors) and UP (peripheral voltage
Well
forproven
actuators) = 24 V DC/3 A
Open
Daisy-chained power supply
Conformance
through EtherCAT P devices
Safety

TX-US
RX+
GNDP
RX- TX+
UP GNDS

Redundancy
Versatile

Communication & Power combined:

EtherCAT P
September 2016

EtherCAT P: Connectors and cables

EtherCAT is:
EtherCAT
P connectors
Faster
Synchronization
M8, EtherCAT-P-coded
Industrial
Symmetrical connector design
Ethernet
Mechanical keying: Sockets and
Flexible Topology
plugs are polarized to prevent
Easier to
improper connection.
configure
Cost
Easy
field assembly
effective

Black and red

EtherCAT P cable
Red EtherCAT P
plugs and
sockets

EtherCAT
Power

Easier to
implement

Cables
Well proven
Open
Standard: industrial CAT5 cables in
AWG22/7
Conformance
Safety
AWG24/7 cables for short distances
available
Redundancy
Versatile
Ultrathin cables for short distances
are in consideration

September 2016

Mechanical
EtherCAT P
keying
4 poles:
EtherCAT
+ 2 x 24 V DC/3 A

EtherCAT P: Makes EtherCAT even simpler!

EtherCAT
EtherCAT is: master
Faster
Synchronization
Industrial
Ethernet
Flexible Topology

24 V DC

Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile P
EtherCAT
for actuators
AC and DC motors
Actuators
Valve terminals
September 2016

for sensors
Proximity switches
Light barriers
Shaft encoders

for vision
Cameras
Barcode scanners
3-D scanners

for I/O components

IP 67
IP 20

EtherCAT P:
The sensor, actuator and measurement bus
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Optimized for direct connection of EtherCAT P devices in

the field
Time savings through reduced wiring requirements
Reduced number of error sources
Smaller sensors and actuators through the elimination of
separate supply cables
Simplified connection of components

Outlook: From 24 V sensors to 600 V drives

is:
EtherCAT
Trapezoidal
EtherCAT P element
Faster
enables high packing density
Synchronization
Industrial
Resulting in improved currentcarrying capacity and dielectric
Ethernet
strength
of the power pins
Flexible
Topology
to
Easier
Seamless
and consistent 360
configure
shielding of the connector
Cost effective
Easier
Uniform
EtherCAT P element for all
to
implement
sizes, from B12B36

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

M8
EtherCAT
2 x 24 V DC, 3 A

EtherCAT P: Matching connectors

for every performance class
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology

B36
630 V AC/
850 V DC,
64 A

M8
2 x 24 V DC,
je 3 A

B12
90 V DC,
10 A

Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

B23
630 V AC/
850 V DC,
30 A
September 2016

B17
630 V AC/
850 V DC,
16 A

EtherCAT P: Communication & Power

combined
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

US: 24 V DC,
UP: 24 V DC
400 V AC

September 2016

EtherCAT P: Timeline
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

March 2016:
ETG Technical Committee accepts EtherCAT P as
Extension to the EtherCAT Technology Portfolio
September 2016:
First Draft Specification (M8 Variant) will be presented at
ETG Technical Committee Meeting

EtherCAT is easier to configure

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure

Topology:
Automatic Topology Expected/Actual Comparison

Diagnosis:
Diagnosis with exact Localization

Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

Bit errors are

detected and
localized

Even Timing Errors (e.g. Time Window for Actual Values

missed) are detected and stored locally in the chip
September 2016

Every node
constantly
monitors
checksum

EtherCAT is easier to configure

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure

Network planning:
Performance independent of:
Slave implementation
(no Stacks involved in Process Data
Communication)
Topology (no Switches/Hubs)

Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Addressing:
No manual address setting required
No IP- or MAC-Address Handling
required
Addresses can be assigned automatically
Addresses can be kept
no new addressing if nodes are added

EtherCAT is lower costs (1): Engineering

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Less effort for Network planning:

Simplified configuration
Default settings will work, no network tuning
Improved Diagnosis:
Faster error handling leads to less downtime
Faster Setup:
No address setting required
Implementation / Tools:
Standard Network Monitor Tools, e.g. MS Network
Monitor or Wireshark: free of charge
Parser Software: free of charge

EtherCAT is lower costs (2): Hardware

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven

Master:
no dedicated plug in card (co-processor)
on-board Ethernet Port is fine
Slave:
low cost Slave Controller
FPGA or ASIC
for simple devices: no C needed at all
no powerful C + lots of memory needed

Open
Conformance
Safety
Redundancy
Versatile

September 2016

Infrastructure:
no Switches/Hubs required
Standard Ethernet Cabling + Connectors

32 Bit
C

EtherCAT is easier to implement

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Slave Implementation:
All time critical functions implemented on ASIC or FPGA
ESC handles Real-time Protocol in Hardware
Integrated Communication State Machine
Network Performance independent of
Slave-C Performance
Protocol Stack
For usage with or without C (Host CPU)
Integrated DPRAM (18 kByte)
Integrated Distributed Clock Handling
Ultra precise interrupts to C

EtherCAT Chips from Multiple Sources

ASIC

TI Sitara

Faster

AM335x

EtherCAT is:

ARM

Synchronization

A8

Renesas

Renesas TI Sitara

R-IN32M3-EC

RZ/T1

C, P

ARM Cortex
A9 AM435x

Infineon

Beckhoff

ARM Cortex-M

ET1100

Industrial
Ethernet

Hilscher
netX 50

Microchip

HMS

Hilscher

Flexible Topology
Easier to
Hilscher
configure

Cortex

LAN9252

Anybus
NP40

netX 51/52/6

Innovasic
Fido5000

Beckhoff

netX 100/500 ET1200

Cost effective
Easier to
implement

Well proven
Open

IP-Core
for FPGA
of
IP-Core for

Conformance

Safety
Redundancy

IP-Core for

Altera Max10

Xilinx

Altera Stratix -IV Spartan -6

IP-Core for

IP-Core

Xilinx

Spartan -3

IP-Core for

Xilinx Kintex -7

IP-Core for

ESC10/20:

Altera Stratix -V

Altera Cyclone -I

IP-Core for

Altera Cyclone -II

September 2016

Altera

Cyclone -V

IP-Core for

Versatile

Intel Atom
E6x5C

IP-Core for

IP-Core for

Altera Cyclone -III

Altera Cyclone -IV

IP-Core for

Xilinx Artix -7 + Zync

FPGA84

EtherCAT Slave Controller

with Host Controller
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open

8/16-bit C Interface
Demultiplexed
Intel Signal Types
Polarity configurable (BUSY,
INT)
Typical C:
Intel 80x86, Infineon
80C16x, Hitachi SH1,
ST10, ARM, TI TMS320
Series,

Conformance
Safety
Redundancy
Versatile

September 2016

SPI
Up to 10 MBaud
C is SPI Master
Typical C:
Microchip PIC, DSPic, Intel 80C51,

EtherCAT is an open technology

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet

Protocol is disclosed completely:

EtherCAT is IEC, ISO and SEMI Standard
(IEC 61158, IEC 61784, ISO 15745, SEMI E54.20)

Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Slave Controller from several sources available

Slave Controller provides interoperability
ETG organizes Interoperability Testing (Plug Fests),
Workshops and Seminars
Conformance Testing + Certificates

EtherCAT is an open technology

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

Foundation: November 2003

Tasks: Support, Advancement and Promotion of
EtherCAT
The worlds largest fieldbus organization
More than 3900* member companies from 62 countries
in 6 continents:
Device Manufacturers
End Users
Technology Providers
Membership is open to everybody

* as of Sept 2016
September 2016

ETG Membership Development

4000
EtherCAT
is:

Faster
3500
Synchronization
Industrial
Ethernet
3000

Flexible Topology
Easier to
configure
2500
Cost effective
2000
Easier to
implement

Well proven
1500
Open
Conformance
1000
Safety
Redundancy
500
Versatile

September 2016

ETG Membership Development

4000
EtherCAT
is:

2016: exceeding
500 new members/year

Faster
3500
Synchronization
Industrial
Ethernet
3000

2013:
1 new Member every
calendar day

Flexible Topology

500

400

Easier to
configure
2500
Cost effective
300

2000
Easier12
to months
implement
Growth

Well proven
1500
Open
Conformance
1000
Safety
Redundancy

200

2008:
1 new Member every
business day

100

500
Versatile

September 2016

ETG Members worldwide

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet

As
of Sept 6th, 2016:
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

ETG members from

62* countries and 6 continents
September 2016

62 Countries, 6 Continents
EtherCAT is:
Faster
Argentina

Australia

Synchronization

Austria

Belarus

Belgium

Bosnia and
Herzegovina

Brazil

Bulgaria

Canada

Croatia

Czech Rep

Denmark

Finland

Estonia

France

Germany

India

Indonesia

Iran

Ireland

Israel

Italy

Japan

Latvia

Liechtenstein

Lithuania

Luxemburg

Macedonia

Malaysia

Malta

New Zealand

Norway

Poland

Portugal

Qatar

Romania

Russia

Switzerland

Industrial
Ethernet
Columbia
China
Flexible Topology

Easier to
configure
Greece
Cost effective
Hungary
Easier to
implement

Well proven
Korea

Lebanon

Open
Conformance
Mexico
Safety

Netherlands

Redundancy
Versatile
San Marino

Serbia

Singapore

Slovakia

Slovenia

South Africa

Spain

Sweden

Taiwan

Thailand

Turkey

UAE

Ukraine

United Kingdom

USA

Vietnam

September 2016

ETG Membership Distribution

100%

EtherCAT is:
Faster

90%

>3900 members

33 members

Synchronization

Industrial
Ethernet
80%
Flexible Topology
70%

60%

Easier to
configure
Cost effective

Asia

EtherCAT Technology Group:

a truly Global Organization!
America

Easier to
implement
50%

40%

Well proven
Open

Europe

Conformance

w/o Germany

Safety
30%

Redundancy
Versatile

20%

10%

September 2016

Germany

Most important EtherCAT Country

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Liechtenstein!
13.9 ETG members
per 100,000 inhabitants
The equivalent of 180,000
Chinese members

ETG Team Worldwide

EtherCAT is:
Faster
Synchronization
Thomas
Industrial
Rettig,
GER
Ethernet

Martin Rostan,
GER

Joseph P. Stubbs,
USA

Dr. Karl Weber,

GER

Key Yoo,
KOR

Dr. Guido
Beckmann, GER

Andrea Bock,
GER

Geng Cheng,
CHN

Bin (Beryl) Fan,

CHN

Flexible Topology
Easier to
configure
Cost effective
Dr. Yong-Seon
ProfEasier
to
Moon, KOR
implement

Emma Lee,
KOR

Well proven
Open
Conformance
Safety
Dr. YanQiang Liu,

Burkart Lingner,

CHNRedundancyGER

Alessandro Figini,
GER

Florian Hammel,
GER

Liliane Hgel,
GER

Florian Hfele,
GER

Versatile

Fengjiao (Jojo) Fu
CHN

September 2016

Oliver Fels,
GER

Masanori Obata,
JPN

Michele Beers,
USA

Christiane Heubusch, Rainer Hoffmann,

GER
GER

Makiko Hori,
JPN

EtherCAT Technology Group Structure

EtherCAT is:
Faster

ETG Membership Assembly

ETG Members

Synchronization
Industrial
Ethernet
Flexible Topology

Board of Directors
Executive

EtherCAT Test Center

(ETC)
Kyoto, Japan

EtherCAT Test Center

(ETC)
Beijing, China

EtherCAT Test Center

(ETC)
Nuremberg, Germany

EtherCAT Test Center

(ETC)
Savage, USA

Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

ETG Headquarters
Germany

Marketing Committee
(MC)

ETG Office
North America

ETG Regional
Committee Japan

ETG Office
China

ETG Regional
Committee Korea

ETG Office
Japan

ETG Office
Korea

Technical Advisory
Board (TAB)

Technical Working
Groups (TWG)

Task Forces (TF)

Semiconductor

CiA402 Drive
Profile

Conformance

Device & Network

Description

EAP

FDT/DTM

Master Classes

Safety

Vision Sensor

September 2016

Technical Committee
(TC)

EtherCAT Versioning
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

There is only one

EtherCAT Version,
not one every year

How many members

invest in the technology?

Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Avnet
Beck IPC
Deutschmann
EBV Elektronik
Hilscher
Infineon Technologies
Microchip Technology
Red one technologies
Renesas
Soft Servo Systems
Softing Industrial Automation
Spansion
STMicroelectronics
Terasic Technologies
Texas Instruments
TRINAMIC Motion Control
Xilinx

Master

Faster

One indicator: implementation kits sold.

Until now, Beckhoff alone has sold over 2000 kits
(80% slave kits, 20%(!) master kits)
+ there are slave implementation kits + master stacks
from many other vendors*, such as
Slave

EtherCAT is:

acontis
esd
HMS Industrial Networks
igH
Kithara
Koenig-pa
MicroSys Electronics
Profimatics
Sybera

* Only those listed that have entered their

offering in the EtherCAT Product Guide at
www.ethercat.org/products

EtherCAT Adoption Rate

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

EtherCAT Master Vendors

EtherCAT Drive Vendors
EtherCAT I/O Vendors

EtherCAT Master OS Technology Variety

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

33

EtherCAT Masters implemented on wide range of RTOS*

eCos
FreeRTOS
INTEGRITY
INtime
Linux (with RT-Preempt)
Microware OS-9
MQXTM
On Time RTOS-32
Oracle Solaris (SunOS)
PikeOS
Proconos OS
QNX
RMOS
ROS (Robot Operating
System)
RTKernel
RTLinux
RTX
RTXC

RTAI-Linux
SCALE-RT
TKernel
VxWin + CeWin+
RTOS32Win+LxWin
VxWorks
Windows CE
Windows Embedded
with IntervalZero RTX
Windows XP/XPE with
CoDeSys SP RTE
Windows XPE/WES7/
WES8 with TwinCAT RTExtension
Windows NT/2000/XP/
Vista/7/8 with TwinCAT
RT-Extension
XOberon
XENOMAI Linux
C/OS-IITM
ITRON

* as of March 2014

EtherCAT Master (Controller) Vendors

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

193

EtherCAT Drive Vendors

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

156

EtherCAT I/O Vendors

ABB
EtherCAT

is:

ectronic

Kolektor Synatec

Schaeffler Engineering

Ackermann

elobau

Kollmorgen

ACS Motion Control

esd

Kuhnke

Schweitzer
Engineering
Laboratories / SEL

Faster

ADDI-DATA
SynchronizationFesto
Adlink

Lenze

Foshan Shunde
M-System
Industrial
Gather Win Information
AFT Fahrzeugtechnik
MaVi
Tech.
Ethernet
Algo System
Messung
Galil Motion Control
Flexible
Topology
Amoy
Dynamics
NEXCOM
Gantner
Anca Motion
MicroControl
GE Intelligent
Easier to
Platforms
AutomationX
Microinnovations/
configure
Eaton
Gefran
B&R
Mikrap
Cost effective Grossenbacher
Balluff
MKS Instruments
HBM
Baumller
Easier to
MKT Systemtechnik
Helmholz
BBH
implement
MSC
Hitachi
Beckhoff
MTT
Well proven
IDS
Belden
Murrelektronik
Imc/Additive
Berghof
Open
M-System
IPC DAS
Brunner Elektronik
National Instruments
Conformance
ISAC
Bosch
Rexroth
NCT
IXXAT
CEC
Safety
Omron
Jger Messtechnik
Cosworth
Panasonic SUNX
Redundancy Jetter
CREVIS
Parker Hannifin
Jumo
CSM
Versatile
Pilz
KEB
Deif
Phoenix Contact
KEBA
DEWESoft
Power Instruments
Keyence
Dina Elektronik
Prima Electro
kk-electronic
dSPACE
Renesas
Knestel
Eckelmann

September 2016

SERAD
SEW Eurodrive
SIPRO

Shanghai Xinhua
SHF
SMC
SOFTLINK
Sontheim Industrie
Elektronik
TETRA
TexComputer
TR Elektronik
Turck
UFG Elettronica
Unidor
Unitro
VIPA

Wachendorff
WAGO
Watlow
Weidmller
Wenglor
Wieland Electric

105

EtherCAT: Largest Product Selection

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

I/O, Controller, HMI, Servo Drives, Variable Speed Drives

Sensors, Slave + Master Development Kits
Control Panels, Hydraulic Valves
and Pneumatic Valves,

Conformance and Interoperability

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Conformance and interoperability are very important

factors for the success of a communication technology
Conformity to the specification is an obligation to all
users of the EtherCAT technology
Therefore the EtherCAT Conformance Test Tool
(CTT) is used
Test Cases for the CTT are provided by the Working
Group Conformance within the ETG community
The EtherCAT Conformance Test proves
conformance with issuing a certificate after passing
the test at an official EtherCAT Test Center (ETC)

Safety over EtherCAT

EtherCAT is:
Faster

Material feeding
Muting

Synchronization

Two-Hand control

Industrial
Ethernet

Protection of workspace
e.g. with Laser scanner

Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open

Emergency
stop
Operator
Diagnosis

Conformance
Safety
Redundancy
Versatile

Safely-limited
Position / Speed

Door guarding with

Interlocking

September 2016

Setup /
Maintenance
Safety guard

Safety by safety I/O-Connections

EtherCAT is:

SPS

Standard fieldbus

Faster

Standard
I/O

Synchronization
Industrial
Ethernet

..
..

DVI

Flexible Topology

RelaisLogic

Easier to
configure

Safe
Inputs

Cost effective
Easier to
implement

Well proven

Safe
Logic

Open
Conformance

Safe
Outputs

Safety

Redundancy
Versatile

M M
September 2016

Standard
Drives

Modern Machine Safety Concepts

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Safety over EtherCAT: Software Architecture

EtherCAT is:

Device 1

Device 2

Faster
Synchronization
Industrial
Ethernet

Safety
Application

Flexible Topology

Standard
Application

Easier to
configure
Cost effective
Easier to
implement

Well proven
Open

Safety
Application

Standard
Application
Safety over
EtherCAT
Protocol

Safety over
EtherCAT
Protocol
EtherCAT
Communication Interface

EtherCAT
Communication Interface

Conformance
Safety

EtherCAT Telegram

Redundancy
Versatile

Safety data container (FSoE Frame)

EtherCAT is used as a black channel

It contains safety and standard information
September 2016

Safety over
EtherCAT

EtherCAT
DLL and AL

Safety over EtherCAT: Software Architecture

EtherCAT is:

FSoE Frame

Device 1

Faster
Safety
Application

Synchronization
Industrial
Ethernet

Standard
Application

Flexible Topology
Safety over
EtherCAT
Protocol

Easier to
configure
Cost effective

EtherCAT
Communication Interface

Easier to
implement

Conformance

Ethernet
Header

EtherCAT 1. DataHeader gram

FSoE

Open

EtherCAT Frame
HDR

Well proven

2. Datagram
Process Data FCS

Safety

FSoE Frame

Redundancy
Versatile

CMD

September 2016

Safe
Data 0

CRC_0

Safe
Data 1

CRC_1

Safe
Data n

CRC_n Conn ID

The FSoE Frame is

embedded as a
Container in the
process data of the
device.
Each device detects a
new FSoE Frame, if at
least one Bit in the
FSoE Frame is
changed.
Every 2 Byte SafeData
are checked by a
2 Byte CRC
The maximum number
of SafeData is therefore
not restricted by the
protocol.

Safety over EtherCAT: Advantages

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Fully integrated solution:

safe and standard communication in one channel
Reduction of fieldbuses and interfaces
Central configuration, diagnosis and maintenance for
safe and unsafe I/O in one tool
Safety application makes full use of EtherCAT
advantages:
Short reaction times
Almost unlimited number of nodes
Large network extensions
Cable redundancy options
High Flexibility with Hot Connect

Safety over EtherCAT: Implementation Example

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet

Decentralized Safety-Logic
Standard PLC routes the safety messages
Standard
PLC

Safety Inputs

Safety Sensors

Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Safety Outputs

Well proven
Open
Conformance
Safety
Redundancy
Versatile

Safety Drives
September 2016

Safety Logic

Safety over EtherCAT Vendors

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

27

Without Redundancy: Normal Operation

EtherCAT is:

EtherCAT Master

Faster
Synchronization

RX Unit

TX Unit

RX

TX

Industrial
Ethernet
Flexible Topology
Easier to
configure

MAC 1
RX TX

Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Slave 1
RX

TX

TX

RX

Slave 2

RX

TX

TX

RX

Slave N

RX

TX

TX

RX

Without Redundancy: Cable Failure

EtherCAT is:

EtherCAT Master

Faster
Synchronization

RX Unit

TX Unit

RX

TX

Industrial
Ethernet
Flexible Topology
Easier to
configure

MAC 1
RX TX

Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Slave 1
RX

TX

TX

RX

Slave 2

Slave N-1

RX

TX

RX

TX

TX

RX

TX

RX

Slave N

RX

TX

TX

RX

Without Redundancy: Node or Cable Failure

EtherCAT is:

EtherCAT Master

Faster
Synchronization

RX Unit

TX Unit

RX

TX

Industrial
Ethernet
Flexible Topology
Easier to
configure

MAC 1
RX TX

Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Slave 1
RX

TX

TX

RX

Slave 2

Slave N-2

Slave N-1

RX

TX

RX

TX

RX

TX

TX

RX

TX

RX

TX

RX

Slave N

RX

TX

TX

RX

With Redundancy: Normal Operation

EtherCAT is:

EtherCAT Master

Faster
Synchronization

RX Unit

TX Unit

RX

TX

MAC 1

MAC 2

RX TX

RX TX

Industrial
Ethernet

Only 2nd Ethernet

Port required no
special Interface Card

Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Slave 1
RX

TX

TX

RX

Slave 2

RX

TX

TX

RX

Slave N

RX

TX

TX

RX

With Redundancy: Cable Failure

EtherCAT is:

EtherCAT Master

Faster
Synchronization

RX Unit

TX Unit

RX

TX

MAC 1

MAC 2

RX TX

RX TX

Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Slave 1
RX

TX

TX

RX

Slave 2

Slave N-1

RX

TX

RX

TX

TX

RX

TX

RX

Slave N

RX

TX

TX

RX

With Redundancy: Node or Cable Failure

EtherCAT is:

EtherCAT Master

Faster
Synchronization

RX Unit

TX Unit

RX

TX

MAC 1

MAC 2

RX TX

RX TX

Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Slave 1
RX

TX

TX

RX

Slave 2

Slave N-2

Slave N-1

RX

TX

RX

TX

RX

TX

TX

RX

TX

RX

TX

RX

Slave N

RX

TX

TX

RX

Your Selling Point: Availability

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure

Cabling redundancy
2nd Ethernet port needed on master side only
Hot Swap of devices
Hot Connect of network segments
Hot Connect
Master Redundancy with Hot Stand By
Group

Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Master

EtherCAT: versatile system architecture

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet

Master to Slave
Slave to Slave
Master to Master

Flexible Topology

M2S

Easier to
configure
Switchports

Cost effective
Easier to
implement

Well proven
Open

Master

M2M

Conformance
Gateways

Safety
Redundancy
Versatile

September 2016

M2S
Master

S2S

EtherCAT Automation Protocol

EtherCAT is:

EtherCAT Automation Protocol

Faster
MES

Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective

Factory-Network

Synchronization

Remote
Access

WiFi

SCADA

Central Computer

HMI

Configuration/
Diagnosis
Handheld

Easier to
implement
Automated
Guided Vehicle
(AGV)

Well proven
Open
Safety
Redundancy
Versatile

PLC

Fieldbus-Network

Conformance

PLC

EtherCAT Device Protocol (processed on the fly)

September 2016

PLC

EtherCAT Automation Protocol: Application

EtherCAT is:
MES

Faster
Synchronization
Industrial
Ethernet

OPC

Controller

Flexible Topology
Easier to
configure

Je Verbindung:
10ms cycle
IN 1kByte
OUT 1kByte

Cost effective
IN 600 Byte
OUT 600 Byte

IN 600 Byte
OUT 600 Byte

IN 600 Byte
OUT 600 Byte

Visu

zum Controller und

allen Stationen

IN 600 Byte
OUT 600 Byte

IN 600 Byte
OUT 600 Byte

IN 600 Byte
OUT 600 Byte

IN 600 Byte
OUT 600 Byte

IN 600 Byte
OUT 600 Byte

IN 600 Byte
OUT 600 Byte

StationsMaster

StationsMaster

StationsMaster

StationsMaster

StationsMaster

StationsMaster

10 ms cycle

Easier to
Stationsimplement
Master

StationsMaster

StationsMaster

StationsMaster

Well proven
Open
Conformance
Safety
Redundancy
Versatile
Einschleusen

Einschleusen

ProzessKammer

ProzessKammer

ProzessKammer

Ethernet Connection

EtherCAT Automation Protocol

EtherCAT Segment

OPC

September 2016

ProzessKammer

ProzessKammer

Ausschleusen

Ausschleusen

Ausschleusen

EtherCAT and Wireless Communication

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Wireless Devices can be connected via Switchport

Wireless segment does not slow down EtherCAT
communication
Protocol: EtherCAT Automation Protocol
Pushed and/or Pulled Process Data Exchange
Wireless Segment transparent for Master Device
Master

Switchport

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

e.g. Card or RFID Reader

EtherCAT and Wireless Communication

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Wireless Devices can be connected via Switchport

Wireless segment does not slow down EtherCAT
communication
Protocol: EtherCAT Automation Protocol
Pushed and/or Pulled Process Data Exchange
Wireless Segment transparent for Master Device
Switchport

Master

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

e.g. Card or RFID Reader

Master sees
process data of
underlying system
as local I/O data

Master with or
without control
application

Why do Companies choose EtherCAT?

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

High Performance
EtherCAT is the fastest Industrial Ethernet
technology
Flexible Topology
Benefit not only for widely distributed applications
Ease of Use
Easy configuration and maintenance
Low Cost
Inexpensive implementation & infrastructure
Functional Safety
Safety communication integrated
Product Variety
Great variety of available EtherCAT products

Crucial for Dynamics: Performance of

Control- and Communication System
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure

Example:
Humanoid Robots
MARLO, bipedal robot build by
Jonathan Hurst at Oregon State
University for Prof. Jessy Grizzle,
University of Michigan

Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Medulla microcontroller board

It provides an interface between the varied
input and output protocols used on the
robot and the unified EtherCAT interface
used by the control computer.

Walking EtherCAT Robot MARLO

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Decisive Factors: Performance, Topology

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Example:
Radio
Telescope
Robert C. Byrd
Green Bank
Telescope, VA:
Retrofit of
Positioning
System of the
world's largest
fully steerable
single aperture
antenna.

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Decisive Factors:
Fieldbus Integration, Performance
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Example: Robotics
DLR, Germany: Rollin Justin

Decisive Factors:
Fieldbus Integration, Performance
EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Decisive Factors: Robustness

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet

EtherCAT in
Space:
RJo Joystick by
DLR

Flexible Topology
Easier to
configure

2 Slave Devices,
1 ms Cycle Time

Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Beckhoff EtherCAT
Chip passed
extensive
irradiation tests

Decisive Factors: Performance

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Example:
European XFEL X-Ray Laser,
Hamburg, Germany
91 EtherCAT controlled
magnet assemblies
(undulators)
in the accelerator

Decisive Factors: Performance

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open

Dr.
Suren Karabekyan, XFEL:
Conformance
EtherCAT
communication is a key component of our facility. It enables us to
Safety
configure
a very robust and reliable control system with redundant ring topology,
Redundancy
even
in a large installation such as ours. Overall, it is a very cost-effective solution,
Versatile
which is particularly important in the context of research projects funded via public
institutions.

September 2016

Decisive Factors: Performance

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

Control Configuration for an Undulator Section

September 2016

EtherCAT The Ethernet Fieldbus.

EtherCAT is:
Faster
Synchronization
Industrial
Ethernet
Flexible Topology
Easier to
configure
Cost effective
Easier to
implement

Well proven
Open
Conformance
Safety
Redundancy
Versatile

September 2016

Why go for something slower,

just because it is more
expensive?