High-Performance EtherCAT Remote I/O Module Design

EtherCAT is a high-performance, low-cost, easy-to-use, topologically flexible, and open-source deterministic industrial Ethernet technology. This technology overcomes the system limitations of other Ethernet solutions: with this technology, there is no need to receive Ethernet packets, decode them, and then copy process data to each device. Its key working principle lies in how its nodes process Ethernet data frames: during the downstream transmission of data frames, each node reads the data addressed to it and writes its data into the data frame. This transmission method improves bandwidth utilization, allowing the entire system’s data refresh to typically be accomplished with a single data frame per cycle, while the network does not require switches or hubs, ensuring real-time operation and avoiding delays.

The operational mechanism of EtherCAT gives it greater advantages over other standard Ethernet: fast response times, minimal data requirements per device, and low implementation costs. Furthermore, EtherCAT supports almost all topologies, making it possible to have pure bus or linear topologies with hundreds or thousands of nodes. Therefore, EtherCAT has become the ideal choice for high-performance distributed I/O systems. EtherCAT networks can connect up to 65,535 devices, with almost no limitations on network capacity, allowing modular I/O devices to be designed such that each I/O chip is an independent EtherCAT slave, and program data exchange with a thousand distributed digital inputs/outputs can be completed in just 30 microseconds.

The Hongke HK-MXB series is an EtherCAT industrial Ethernet bus interface, integrating digital input and output in a hybrid I/O module, providing an ideal channel for higher-level EtherCAT master controllers. The HK-MXB uses industrial 24V NPN/PNP type digital logic input signals and provides current limiting and electrical isolation for captured signals as safety protection.

At the same time, the HK-MXB can convert instruction signals sent from the master controller into NPN/PNP type industrial 24V digital logic signal outputs, with a maximum driving current of 0.5A/CH, suitable for driving relays, indicator lights, and digital logic signals.

Both the input and output channels of the HK-MXB, the EtherCAT communication interface, and the power interface are equipped with corresponding LED indicators for quick observation and diagnosis of signal and instruction status.

Key features of the Hongke HK-MXB I/O module:

1) Supports 16, 32, or 48 channels of 24V NPN/PNP type digital inputs

2) Supports 16, 32, or 48 channels of 24V NPN/PNP type digital outputs

3) Input current limiting protection

4) Output current limiting and short-circuit protection

5) Bus communication fault indicator

6) Pluggable terminal blocks

7) DIN35 rail mounting

The Hongke HK-MXB I/O module is based on the concept of PCB wiring, integrating I/O signal channels, RJ45 communication ports, power signal terminals, etc., related to EtherCAT remote I/O on the PCB, eliminating the need for extra wiring boards and couplers, facilitating on-site installation and wiring.

1) When the module is the first slave device connected to the master station, it must use the IN port on the module to connect to the master station.

2) When the module is a middle slave device, it must use the IN port to connect to the previous slave device and the OUT port to connect to the next slave device.

3) When the module is the last slave device, it must use the IN port to connect to the previous slave device and leave the OUT port empty.

1) When using for the first time, the slave XML configuration file needs to be imported into the master station; please refer to the respective manufacturer’s master station user manual for specific procedures.

2) Connect the power supply and use a shielded CAT5e Ethernet cable to connect the module to the master station.

4) Wiring for DO digital signal output.

The HK-MXB I/O module can associate I/O signals with some special functions of robotic systems, used for controlling robots and monitoring the status of robotic systems. At the same time, the MXB module can be installed in remote rack cabinets, placing remote I/O sites in suitable locations. Signals from an area can all be routed to this site, which then communicates with the main control PLC.

Due to its high communication speed, good communication quality, and flexible network topology, EtherCAT can be applied in high safety level hazardous environments. In semiconductor manufacturing, there are often many valve islands, actuators, sensors, and pneumatic or electric devices, and the HK-MXB I/O module can achieve signal acquisition, control, or remote maintenance of the corresponding signals.

The photovoltaic industry is a rising sun industry based on semiconductor technology and the demand for new energy, and it is also a high ground for future global advanced industry competition. In photovoltaic tracking control, the control center receives various data uploaded from multiple photovoltaic tracking devices and sends tracking control signals based on the results of data processing. The HK-MXB I/O module can undertake the functions of detecting position signals from sensors within the equipment and driving relays and other related devices to upload data to the control center and receive instructions.