EtherCAT G: Merging Ethernet and Fieldbus Advantages

Click blue words to followServo and Motion Control

EtherCAT G: Merging Ethernet and Fieldbus Advantages
The above is an advertisement
Author | Sree Swarna Gutta
“
In industrial environments, the determinism and real-time nature of data transmission are crucial. EtherCAT G provides more reliable communication for industrial applications through its unique functional principles and industrial-grade hardware.
”
Both in terms of functionality and quantity, industrial application network technologies have made significant progress. The fieldbus, launched in the late 1980s, was a digital replacement for the analog 4-20mA relay systems used in programmable logic controllers (PLCs), but the emerging PC-based machine control has a faster scanning cycle, leaving fieldbus systems far behind.
In the subsequent fieldbus wars, engineers and plant managers began to favor Ethernet-based real-time bus systems, which not only offer high-speed transmission but also help promote the integration of Information Technology/Operational Technology (IT/OT).
Since many of the functions currently in use have been validated, Ethernet-based system applications are widespread. However, the current question is not which type of system a factory should choose, but whether a factory needs to choose one at all. Ethernet, compliant with the IEEE 802.3 communication standard, has been in use for a long time, and many new components support communication without needing to bundle with traditional fieldbus systems. Does this help factories escape expensive managed switches and other shortcomings of popular fieldbus systems? Can it free them from vendor-specific communication protocols?
Despite some limitations of certain industrial Ethernet systems, directly applying standard Ethernet in critical manufacturing, packaging, and material handling scenarios can pose risks.
The real-time performance, time synchronization, and independence sought by engineers in different applications have been achieved in open technologies (such as EtherCAT industrial Ethernet systems). EtherCAT can provide the determinism, robust hardware suitable for industrial environments, flexibility in system architecture, and built-in security to protect machines and enterprise networks without IT department intervention.
EtherCAT G: Merging Ethernet and Fieldbus Advantages
▎Industrial applications require industrial-grade devices, and EtherCAT provides IP67-rated I/O modules that can be installed in industrial sites.

Determinism and Reliability

Using Ethernet in a home environment rarely results in severe consequences due to system failures. Generally, it just means a web page fails to load, an email fails to send, or the system crashes, none of which are mission-critical. Waiting an additional 2 seconds or even a minute does not meet the definition of mission-critical. Most consumers do not care much about the shortcomings of standard Ethernet, such as poor bandwidth utilization, stack delays, switch delays, and star topology.
However, in industrial environments, reliable data transmission is crucial. If the command from the device controller cannot be transmitted timely to various components, or if the controller does not receive sufficient feedback, it can lead to severe consequences. Compared to standard Ethernet and other industrial Ethernet protocols, EtherCAT offers the reliability and determinism required for cross-industry applications. Even at a speed of 100Mbit/s, industrial Ethernet systems can ensure reliable and synchronized sending and receiving of data frames between machines and factories of different scales.
EtherCAT G and G10, with transmission speeds of 1Gbit/s and 10 Gbit/s respectively, can provide the necessary bandwidth for applications such as high-resolution machine vision, high-end measurement, advanced motion control, robotics, and complex electromechanical systems. Combined with the newly introduced branch controller mode, EtherCAT G can reduce industrial communication time by 2-7 times and increase bandwidth by 10 times (depending on the application). EtherCAT G10 can even increase bandwidth by 100 times.
The unique branch controller mode allows a 100Mbit/s EtherCAT network to be integrated into EtherCAT G branches and vice versa, simply by adding a coupler. This ensures system scalability, allowing for upgrades to application systems without a complete overhaul or replacement.
EtherCAT G technology was introduced by Beckhoff Automation in Germany in 2018 as an extension of the EtherCAT technology protocol. In 2019, the technical committee of the EtherCAT Technology Group (ETG) officially supported this technology after review. Currently, ETG is working to add EtherCAT G technology to the technical specifications.

Industrial-Grade Ethernet Hardware

Manufacturing environments require technologies that can withstand extreme conditions. Industrial-grade I/O terminals offer more form factors and functionalities compared to consumer-grade routers and switches that IT departments might use in offices. These may include: IP20-rated cards for mass production equipment, IP67 and IP69K-rated I/O modules installed on-site, and plug-in modules mounted on PCBs. Even standard Ethernet cables should be equipped with appropriate shielding and use connectors designed for industrial applications; otherwise, communication issues may arise.
As an open solution, EtherCAT can connect with “regular Ethernet” as well as over 25 other fieldbus and industrial Ethernet systems, simply by adding couplers or gateways without causing transmission delays. Using multiple couplers, EoE (Ethernet over EtherCAT) with TCP/IP communication capabilities can ensure interoperability of EtherCAT networks.
EtherCAT G: Merging Ethernet and Fieldbus Advantages
▎EtherCAT plug-in modules mounted on PCBs help achieve optimal mass production of devices.

Providing Synchronization Functions

A single EtherCAT network can support 65,535 devices, automatically configuring hardware without the need for MAC or IP addresses. Built-in free topology selection allows for star, line, tree, or other types without performance loss. Improved diagnostic interfaces can collect existing diagnostic information from the network, enhancing an already robust diagnostic capability and making troubleshooting easier.
Through dynamic processing, EtherCAT can communicate in a loop with many nodes at a rate of 100 Mbit/s within a single Ethernet frame. Using EtherCAT, 1,000 distributed digital I/Os can be polled every 30μs, and 100 servo axes can be polled every 100μs.
EtherCAT ASIC or FPGA hardware is integrated into slaves and can be accessed directly from the master station’s network card. The communication protocol processing is independent of CPU performance, protocol stack, or software implementation.
EtherCAT network devices are synchronized through a distributed clock. All EtherCAT devices have built-in local clocks to continuously maintain a standard time base, with clock deviations of less than 100 ns, representing different communication runtimes. This ensures precise synchronization between all devices. It also allows for deterministic actual value acquisition and deterministic setpoint output, achieving absolutely precise response times.

Functional Safety

EtherCAT also provides FSoE (Safety over EtherCAT), a function safety protocol certified by TüV. All other redundant safety devices use FSoE, which provides necessary safety communication redundancy through the same Ethernet cable used for machine control, employing a “black channel” method. FSoE offers both digital and analog safety for numerous discrete and process industry applications.
The functional principles of EtherCAT also help protect factories from network threats. The EtherCAT master controls all slaves, rendering man-in-the-middle attacks ineffective. Since the system is not based on Internet protocols, malware cannot propagate through EtherCAT. The network only forwards EtherCAT frames, filtering out any other Ethernet frames, including those with corrupted data or infected frames from the controller chip. These features, combined with the non-use of managed switches, eliminate the need for IT department intervention in production systems.
– END –

Popular Articles

EtherCAT G: Merging Ethernet and Fieldbus Advantages

Chairman Su Meiping of Transmission Network: Twenty Years of Motion Control

EtherCAT G: Merging Ethernet and Fieldbus Advantages
Stone Motion Control Micro Servo
EtherCAT G: Merging Ethernet and Fieldbus Advantages

China Motion Control/Direct Drive Industry Summit Forum

EtherCAT G: Merging Ethernet and Fieldbus Advantages

Professor Yang Ming: Thoughts on Three Issues of Servo Positioning Systems

EtherCAT G: Merging Ethernet and Fieldbus Advantages

“Paying Tribute to the Original Intention, Paying Tribute to Twenty Years of Motion Control” Interview

EtherCAT G: Merging Ethernet and Fieldbus Advantages

Related posts

  1. The Localization of EtherCAT in China
  2. EtherCAT Diagnosis and Configuration Optimization
  3. Fundamentals of EtherCAT Protocol (Part 1)
  4. EtherCAT Master Development Tool: EC-Master Software Stack
  5. EtherCAT Motion Control Card Homing Motion
  6. Delta Robot Application of EtherCAT Motion Controller
  7. Custom PROFINET to EtherCAT Solutions with Siemens PLC Control
  8. How to Handle F01910 Fault in G120 Inverter with PROFIBUS DP
  9. Ovation Profibus DP Fieldbus Configuration Tutorial
  10. EtherCAT G: Merging Ethernet and Fieldbus Advantages
  11. EtherCAT – Ethernet Fieldbus Technology Overview
  12. EtherCAT Installation Guide
  13. Differences Between EtherCAT and Profinet
  14. EtherCAT vs. PROFINET and EtherNet/IP: An Overview
  15. High-Performance EtherCAT Remote I/O Module Design
  16. Understanding the Evolution of EtherCAT Technology to the G Era
  17. EtherCAT G: Elevating Ethernet Speeds to Gigabit Levels
  18. How EtherCAT Ensures High Efficiency, Real-Time, and Flexibility in Fieldbus Communication
  19. EtherCAT: The Speed and Passion of Industrial Communication

Leave a Comment