real-time ethernet for machine control
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1 © Omron
Real-time Ethernet for
Machine Control
Educational Webcast
Moderated by David Greenfield, Director,
Media & Events at Automation World
2 © Omron
Real-time Ethernet for Machine Control
• Wide acceptance in IT and Manufacturing
• Enterprise connectivity
• Growing integration with field devices
• Remote diagnostics
• Determinism/True Real-time?
3 © Omron
Real-time Ethernet for Machine Control
• A comparative look at industrial automation networks,
assessing speed, performance and precision for machine
control applications
• Real-world applications and the benefits associated with
real-time Ethernet
• How can be applied in design, development,
deployment, production and maintenance on the factory floor
• How Omron Industrial Automation uses
to integrate Servos, AC drives, I/O, Vision, as well as
PLC-based and stand-alone controllers
Webcast Objectives
4 © Omron
Real-time Ethernet for Machine Control
Bill Faber, Commercial Marketing Manager –
Motion, Drives, Vision
Omron Industrial Automation
Dennis Hydock, President –
High-end Motion/Robot/Vision Integration
Integrated Industrial Technologies
Keith Grey, Strategic Account Manager –
Automotive
Omron Industrial Automation
5 © Omron
Bill Faber
Commercial Marketing Manager – Motion, Drives, Vision
Omron Industrial Automation
Real-time Ethernet for
Machine Control
6 © Omron
What is Real-time?
Real-Time
Computing
Operational Deadlines from Event to
system response. Real-time
programs must guarantee response
within strict time guidelines.
Example Application Response Time
Temperature PID Loops Seconds
Feed-To-Length Indexing with PLS* outputs Milliseconds
Servo Line Shafting – Master/Slave Gearing Microseconds
*PLS = Programmable Limit Switch
7 © Omron
Context of Machine Control
Device I/O
Layer
Motion
Controller
HMI
SCADA
PLC PLC
Vision Servo Inverter I/O
Motion
Layer
Control
Layer
Information
Layer
Database
Safety Inte
rco
nn
ec
tio
n
Visualization
Control
Sensing Actuation
RFID
Temperature
Sensors
8 © Omron
Applications that Require Real-time
Application: • Rotary Knife
• Linear Flying Cutoff
Problems: • Large inertia knife loads can
cause overshoot inaccuracies
Use electronic CAM with
registration adjust
• Cost of hardwiring multiple cutter
stations can be high
Use a network
• Cutter axis is slaved off of the
master which may be irregular
unsynchronized cycles
Use a real-time network
9 © Omron
Applications that Require Real-time
• Contouring
• Pattern Cutting
• Robotic
• Other multi-axis
coordinated motion
control applications
Application: • 4-Color Printing
• Line Shafting
• Converting
10 © Omron
Architecture Trends – Real-time Ethernet
• Ethernet Networks are Expanding to Device Level
ARC: ―Industrial Ethernet—already
established at the factory level of industrial
automation hierarchies—is now becoming a
viable networking protocol at the I/O or field
level.‖ 30% CAGR thru 2012
To achieve
synchronous
motion control,
the network must
be real-time
Motion
Controller
Vision Servo Inverter I/O
RFID
Temperature
Sensors
Device
I/O
Layer
11 © Omron
Architecture Trends – Converging Controls
• Ethernet Networks are Expanding to Device Level
• Control Technology Platforms are Converging
PMMI: ―There is a growing trend towards
integrated controllers that perform more than one
function… this eliminates the need to create
communications between two controllers,
simplifying programming and maintenance.‖
Motion Logic
(PLC) Motion
Layer
12 © Omron
Architecture Trends – Converging Controls
• When logic converges with Motion & Vision
it becomes a MOVi application
Motion Logic
Vision
Application Examples:
– Move – Inspect – Reject
– Move – Inspect – Orient
– Inspection in Motion
– Vision Servo-ing
– Storage & Retrieval
13 © Omron
• Time to Market
• Complexity of Design/Development
Driving Factors for Real-time Ethernet
Landscape of
Automation Pain:
OEMs Drive Toward
Efficiencies of:
Machine
Development
• Setup, Configuration, Programming
• Field Expansion Options
Machine
Deployment
• Bottlenecks in Throughput & Yield
• Data Exchange (C2C, Enterprise)
Machine
Production
• Troubleshoot & Error Reporting
• Uptime
Machine
Maintenance
Converging platforms
require real-time
networks to eliminate
system level latencies
and bottlenecks
At the same time,
networks allow for
smarter machines
14 © Omron
What Makes a Network Real-time?
Real-time
• Network is faster than the
control system
• Deterministic (Repeatable)
• Synchronization across
the platform
• Must meet data throughput
requirements for the intended
application
Not Real-time
• Node control and feedback
data updates slower than
control system
• Update jitter exceeds node
synchronization requirements at
maximum machine speed
• Controller, Network and Slave
nodes updating at different times
• Data volume exceeds network
transport capacity
15 © Omron
Comparative Look at Ethernet Networks
EtherCAT <<1 usec ** Distributed Clocks
Branch Slave Line, star,
ring, tree,
On-the-fly frame
Processing
Slave map
PowerLink 1 usec ** Depends on frames
Hub Line, star,
ring, tree
Polling (half duplex)
Sercos III 1 usec ** IEEE1588
Line, ring Polling
Profinet IRT 1 usec * IEEE1588
Switch Line, branch,
tree
Polling
EtherNet/IP Switch Star, ring Polling (producer
consumer)
EtherNet/IP CIP
Synch
~1 usec IEEE1588
Managed
Switch
Star, ring Polling (producer
consumer)
Modbus TCP/IP Switch Star Polling & master map
* Depends on number of cascaded switches, practical limit around 20 nodes
** Depends on communication jitter of frames from the master
16 © Omron
Ethernet Optimized for Machine Control
• Fast & Efficient
• Open & Accepted
• Deterministic & Repeatable
• 40 axis + 2200 I/O Test
17 © Omron
Ethernet Optimized for Machine Control
Deterministic & Repeatable
• Distributed Clock
• <<1usec jitter (repeatability)
• Learns the topology & delays
Distributed Clock
Synchronization
18 © Omron
One Real-time Network for Machine Control
One physical layer
Two Protocols
One Machine Network
For Real-time Control
Fastest open network
One Factory Network
For Information
Most accepted open network
One Real-time Network enables
Faster, Simpler, Smarter Machines
One Purpose for
Machine Automation
19 © Omron
Dennis Hydock
High-end Motion/Robot/Vision Integration
Integrated Industrial Technologies
Dial Table Vision Inspection
20 © Omron
Customer Requirements
Challenge:
• High-speed bolt inspection for automotive
• Achieve 500 inspections per minute
• Two cameras to inspect top and side of bolt
• Another camera to inspect threads while rotating
• Control the rest of the machine (14 other axis)
• Control 150 points of process I/O
• Display machine status, setup, machine faults,
common rejects, etc. on a networked HMI
21 © Omron
Camera 1
Camera 2 Camera 3
Servo Motor 1 Servo Motor 2
Servo Motor 3
Linear Feed Conveyor
Dial Index Table
Head Inspection
Length, Diameter,
& Thread Inspection
Rotate Thread Inspection
From Bowl
Feeder
Bolt Inspection Dial Table Indexing Machine
22 © Omron
Previous Solution
PLC
Frame
Grabber
Frame
Grabber
Stepper
Indexer
PC with Imaging
Software
Rotate Frame
Grabber
Index
Table
HMI
Complex Solution • Different protocols
• Different hardware
• Noise issues
• Slow!!!
Stepper
Amp Stepper
Amp
Camera
Camera
Camera
Programming
Software
23 © Omron
Motion & Vision on .
Latest EtherCAT Solution: • Trajexia TJ2-64 motion controller
• FZM1 camera & controller
• 16-Axes G5 Servo Motors
• NS HMI via Ethernet
• EtherCAT Network
• EtherCAT I/O
• Single Program
24 © Omron
Motion & Vision on .
EtherCAT Solution Advantages • No Noise Issues
• Easier Maintenance
• Reduced Wiring
• Single Supplier
• Standard Hardware
• Fast Changeover
• Saves Time
• Saves Money
25 © Omron
Quicker Setup with One Integrated Network
Camera Setting
Communication Setting
Select Motion Control Type
Robot – XY, XYӨ
Stage – XYӨ,UVW,UVWR
Sampling position
Automatic setting of Calibration
Parameters
Easy Setup
Slave Configuration
Camera Image Calibration Screen
26 © Omron
Application Example
Simple Program Configuration
IF NOT ETHERCAT($66,0,1000,1000,5,1010,12) THEN
27 © Omron
Faster Performance with Real-time Network
Operation EtherCAT
System
Time
(msec)
Previous
System
Time
(msec)
Network cycle (capture command)
1 17
Capture image and
process 50 50
Network cycle (send 4 read 12)
1 17
TOTAL vision cycle 52 84
Motion controller Scan 1 1
Initiate Motion 0.5 0.5
9 degree move 50 50
Settling time 2 2
TOTAL motion cycle 53.5 53.5
TOTAL CYCLE TIME 105.5 137.5
Does Real-time Matter?
• YES: Separate non-real-time
network scan is almost as
high as the motion cycle
(37msec)
• YES: Simple setup and
configuration on one Ethernet
PHY network is simple
• YES: Real-time is needed for
the motion axis, required if
everything is on the same
network
Bottleneck is a System Issue.
Network is not the bottleneck.
28 © Omron
Summary – Dial Table Vision Inspection
• Ethernet wiring is common and easy
• One real-time network and integrated
motion/vision platform provides:
• Quicker setup without sacrificing performance
• Synchronization amongst slaves (vision, motion, I/O)
• Reduced overall latencies and higher throughput
• Less time commissioning
• High noise immunity
• Initial and long term savings
29 © Omron
Keith Grey
Strategic Account Manager – Automotive
Omron Industrial Automation
Preventive Maintenance for Automotive
30 © Omron
Preventive Maintenance with
Challenge
– Automotive Plant Downtime (average
servo issue takes 45 minutes to fix)
– Maintenance – must be easy enough for
3rd shift to use without training
Solution
– CJ2H PLC with NC882 ECAT Module
– NS15 HMI with Template Screens
– S8VS power supply with indicator
– 2 axis G5 Servo
– EtherCAT Network for machine control
– EtherNet/IP Network for information
AUTOMOTIVE
31 © Omron
Benefit
• Servo, Drive, Vision, I/O slave devices
on one real-time EtherCAT Network
(no sacrificing performance)
• HMI on EtherNet/IP information
network tunnels into EtherCAT
• No additional engineering time setting
up slave monitoring - Pre-Programmed
HMI Screens
– Servo utility screen
– Inverter utility screen
– Vision utility screen
– Network health
One Network – One HMI
32 © Omron
Benefit
• EtherCAT allows
preventive maintenance
• View speed/torque data
real-time, +/- values
• View all parameters
real-time
• Instant for the user
4msec deterministic
data update rate
View Data Real-time on
<torque/speed curve
here>
33 © Omron
Benefit
• Don’t need an expert to
replace an absolute encoder
motor or servo drive
– Just push buttons, follow
step-by-step procedure
with pictures
– No additional training
required
• Easily change motion profile
(teach profile)
Simple to Use on
34 © Omron
Summary – Preventive Maintenance
• One real-time network and integrated
motion/vision platform provides:
– Centralized error reporting via operator interfaces
– Simplified maintenance
– Quick updates of time critical data
• Preventive maintenance is possible without
sacrificing performance
• Pre-programmed solutions give confidence and
quicker commissioning
35 © Omron
Summary & Key Takeaways
• Machine builders face constant demands for:
– More efficient machine design/development
– Faster deployment
– Higher throughput and yield
– Simpler maintenance
• Real-time networks are required to achieve true complete
machine automation without sacrificing performance
• Converging technology platforms are putting higher
demands on real-time networks and control systems
• Putting all real-time devices on one network protocol
ensures performance and simplicity
36 © Omron
Call to Action
• Learn for yourself about
Real-time Ethernet
– www.ethercat.org
– Come to EtherCAT Technology
Group Roadshow – 6 U.S. locations
• Evaluate your machine control
platform for bottlenecks
– Is it in the interconnection?
– Is it in the network?
Date Location
10/11/2011
(Tues)
Boston
10/12/2011
(Wed)
Chicago
10/13/2011
(Thurs)
Milwaukee
10/18/2011
(Tues)
San Diego
10/19/2011
(Wed)
Phoenix
10/20/2011
(Thurs)
Denver
37 © Omron
Questions
Bill Faber, Commercial Marketing Manager – Motion, Drives, Vision
Omron Industrial Automation, bill.faber@omron.com
www.Omron247.com
Dennis Hydock, President – High-end Motion/Robot/Vision Integration
Integrated Industrial Technologies, dhydock@isquaredt.com
www.isquaredt.com
Keith Grey, Strategic Account Manager – Automotive
Omron Industrial Automation, keith.grey@omron.com
www.Omron247.com
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