ethercat benefits production of green energy

EtherCAT Benefits Production of Green Energy

Lester Shaw, Elmo Motion Control, Inc.

Elmo and Green Energy Applications

Aim of New Generation Machinery

Application Challenges

System Diagram

Environmental Benefits of Efficient Power Use

Any Motor, Any Feedback

Advanced Servo Calibration & Gain Scheduling

Compliance with Standard Protocols

© Elmo Motion Control, Inc.October 2011


• Pioneers in green energy• Photovoltaics characterized by long production lines• Elmo servo controllers are installed in hundreds of

production lines of this type.




System Diagram







• Much higher throughput• Improved yield• Greater efficiency• Migration from CANopen to EtherCAT• Highest density of power and intelligence• Install the servo drive anywhere• Modular build and test of subsystems• Scalability • Flexibility




System Diagram







• Operating in harmony• Richness of motion control and programming

capabilities• Compliance with standard communication protocols• Interface with a large number of motor types• Support wide range of power ratings (50 W to 7 kW)• Support for different operating voltages• Support for wide variety of feedback types• Installing the servo drives anywhere• Advanced networking capabilities• Electromagnetic compliance• Reliability• Throughput




System Diagram





© Elmo Motion Control, Inc.

• Gold Whistle: PCB-mounted, extremely lightweight. The Gold Whistle is the smallest and lightest EtherCAT servo drive available.

• Gold Solo Whistle: Integrated solution for applications that require a small footprint, high efficiency, and without the need to integrate it on a specific PCB.

• Gold DC Whistle: A closed and protected case (IP42) in an industrial enclosure, with full size connectors. It is “ready for use”.

• Gold Duo: An industrial enclosure that that integrates two Gold Whistle drives in a single product. The case is closed and protected (IP42) and the drive is economical.

• Customized Gold Duo: A dual axis solution tailored to the customer’s specifications. It enables a simple and quick interface to the additional control units in the system. It is an ideal solution for multi-axis machines.

October 2011

Elmo Servo Drives Incorporated in the Application I




System Diagram






Elmo Servo Drives Incorporated in the Application II

• Gold Trombone: PCB-mounted for integrating directly into an application. It is very compact and economical.

• Gold DC Trombone: A closed and protected case (IP42) in an industrial enclosure, with full size connectors. It is “ready for use”.

• Elmo Duet: An intelligent motor that combines a servo controller in one integral unit. The servo unit is super compact and full of advanced features. It is an ideal solution for multi-axis applications that require high levels of synchronization in a deterministic communications network. The Duet is closed and protected (IP65) in an industrial enclosure, and it can withstand extreme environmental conditions including vibrations and temperature. It saves the need for electricity boxes and extra wiring.




System Diagram






System Diagram




System Diagram






Gold Line Servo Drive Performance

• The servo drives in the Gold Line have very impressive loop performance ratings:– Current loop: up to 40 µs– Velocity loop: up to 80 µs– Position loop: up to 80 µs– Advanced filtering for performance optimization.

• Additional performance features are as follows:– Advanced servo tuning and gain scheduling.– High power density.– Very high efficiency (approximately 99%).– Support for many types of feedback.– Compliant with standard communication protocols.




System Diagram





© Elmo Motion Control, Inc.

Elmo Gold Drive

Industrial

Medical

October 2011


• High efficiency: negligible heat• High electromagnetic immunity: negligible disturbance• Proprietary FASST Technology (Fast and Soft Switching

Technology)• Minimizes the need for heat sinks




System Diagram







• The FASSTechnolgy:

– Provides fast and highly efficient switching

– Keeps process “soft” with no stress on power device with very low EMI

– The FASSTechnology is realized in Elmo’s fully customized analog/digital IC designed for the “Optimum Drive” of power for MosFets and IGBTs.




System Diagram







• The efficiency of Elmo’s servo drives is around 99% and the EMI is significantly below the regulations’ requirements. This contributes to the compactness of the overall machine, minimizes the need for bulky heat-sinks, and eliminates the need for heat dissipation using unreliable fans or cooling systems. It is also unnecessary to reduce noise that would otherwise increase the overall cost of the system.

• Thus, the Green Energy Machine is itself green, due to Elmo’s servo drives.




System Diagram







• Elmo’s highly advanced motion control algorithm allows the best solution for any motor and feedback combination, from a simple rotary and Hall-only motor up to the most precise linear motor in the sub-micrometer range.

Motor Types Feedback OptionsDC Brush Motors Incremental EncodersBrushless Motors Absolute Serial EncodersMoving Coil Digital Hall EffectsLinear Motors Analog Hall EffectsTorque Motors Encoder Sin-Cos 1V ptp

Stepper Motors ResolverTachometerPotentiometer




System Diagram







• Self tuning with the following tools:– Nichols Plot– Bode Plot– Low Pass and High Pass

filters– Notch and Anti-notch filters.

– Fixed frequency filters– Position and velocity

scheduled filters




System Diagram







• Position based addressing – eliminates the need to set switches or preload configuration

data before placing units on the network• EtherCAT permits tuning software to access the drives

while on the network using EOE and FOE– No need to connect to each drive directly




System Diagram







• Full compatibility with standard protocols• Maximum flexibility and interoperability• Easily add or switch servo drives• Fast and efficient interface with host computer

• Support for:– EtherCAT– CANopen– Ethernet (Ethernet/IP, Modbus, TCP/IP, UDP, Telnet)– USB




System Diagram






Intelligent Use of Network Efficiency

• The EtherCAT protocol allows for the following network features:– Remotely download firmware (FoE)– Automatically download configuration files (FoE)– Automatically set the EtherCAT address after a drive has

been replaced on the network.– Synchronization level is H/W controlled, down to < 1 µs– Flexible network topology. You can combine star and loop

topologies, mixed– Daisy chained networks can be made redundant by

connecting the last drive’s EtherCAT out port back to the EtherCAT master

– Many data objects can be mapped from each drive• Remote access is possible while the system is operating:

– Monitor and change axis parameters (EoE)– Update settings on the-the-fly (EoE)– Evaluate diagnostic variables (EoE).




System Diagram






Summary I

Elmo’s Gold drives have allowed the OEM to achieve their goals:– Much higher throughput– Improved yield– Greater efficiency– Modular build and test of subsystems– Scalability – Flexibility

Elmo’s Gold drives have the highest density of power and intelligence of any drive in the market. Their compact size and flexible packaging options permit the installation of the servo drive anywhere on the machine. In long production machines such as these, a significant reduction in the size of the machine, the saving in cooling factors, heat dissipation and EMC compliance, together with the simplicity of installation, lead to a great reduction in the machine’s hardware infrastructure.




System Diagram






Summary II

Utilizing a networked solution allowed the OEM to construct the machine in a modular fashion. The ability to build and test subsystems increases the efficiency of manufacturing. The modular nature of the machine also permits scalability and flexibility. More modules can be added to increase capacity or modules can be exchanged or added for new processing methods.

The green energy machine is an exception in terms of its size and complexity, however, it is very representative of the multiple advantages that Elmo’s servo drives offer in a network setting.

When using the right servo drives, any machine that has more than four axes can be implemented much more effectively when using our distributed network topology.

ethercat benefits production of green energy

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