real-time ethernet for machine control
DESCRIPTION
View this webinar to learn how to apply industrial networks for real-time machine control. The webinar will highlight: • A comparative look at industrial automation networks, assessing speed, performance and precision for machine control applications • Real-world applications and the benefits that result from using a real-time Ethernet-based solution • An in-depth examination of how the EtherCAT industrial Ethernet network can be applied to all aspects of production – from design, development and deployment through to production and maintenance on the factory floor • How Omron uses EtherCAT to integrate HMIs, servos, AC drives, I/O, vision, and PLC-based or stand-alone controllersTRANSCRIPT
![Page 1: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/1.jpg)
1 © Omron
Real-time Ethernet for
Machine Control
Educational Webcast
Moderated by David Greenfield, Director,
Media & Events at Automation World
![Page 2: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/2.jpg)
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?
![Page 3: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/3.jpg)
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
![Page 4: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/4.jpg)
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
![Page 5: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/5.jpg)
5 © Omron
Bill Faber
Commercial Marketing Manager – Motion, Drives, Vision
Omron Industrial Automation
Real-time Ethernet for
Machine Control
![Page 6: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/6.jpg)
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
![Page 7: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/7.jpg)
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
![Page 8: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/8.jpg)
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
![Page 9: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/9.jpg)
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
![Page 10: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/10.jpg)
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
![Page 11: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/11.jpg)
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
![Page 12: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/12.jpg)
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
![Page 13: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/13.jpg)
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
![Page 14: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/14.jpg)
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
![Page 15: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/15.jpg)
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
![Page 16: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/16.jpg)
16 © Omron
Ethernet Optimized for Machine Control
• Fast & Efficient
• Open & Accepted
• Deterministic & Repeatable
• 40 axis + 2200 I/O Test
![Page 17: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/17.jpg)
17 © Omron
Ethernet Optimized for Machine Control
Deterministic & Repeatable
• Distributed Clock
• <<1usec jitter (repeatability)
• Learns the topology & delays
Distributed Clock
Synchronization
![Page 18: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/18.jpg)
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
![Page 19: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/19.jpg)
19 © Omron
Dennis Hydock
High-end Motion/Robot/Vision Integration
Integrated Industrial Technologies
Dial Table Vision Inspection
![Page 20: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/20.jpg)
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
![Page 21: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/21.jpg)
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
![Page 22: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/22.jpg)
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
![Page 23: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/23.jpg)
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
![Page 24: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/24.jpg)
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
![Page 25: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/25.jpg)
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
![Page 26: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/26.jpg)
26 © Omron
Application Example
Simple Program Configuration
IF NOT ETHERCAT($66,0,1000,1000,5,1010,12) THEN
![Page 27: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/27.jpg)
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.
![Page 28: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/28.jpg)
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
![Page 29: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/29.jpg)
29 © Omron
Keith Grey
Strategic Account Manager – Automotive
Omron Industrial Automation
Preventive Maintenance for Automotive
![Page 30: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/30.jpg)
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
![Page 31: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/31.jpg)
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
![Page 32: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/32.jpg)
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>
![Page 33: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/33.jpg)
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
![Page 34: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/34.jpg)
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
![Page 35: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/35.jpg)
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
![Page 36: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/36.jpg)
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
![Page 37: Real-time Ethernet for Machine Control](https://reader033.vdocuments.us/reader033/viewer/2022042614/555ecdb6d8b42af67f8b5576/html5/thumbnails/37.jpg)
37 © Omron
Questions
Bill Faber, Commercial Marketing Manager – Motion, Drives, Vision
Omron Industrial Automation, [email protected]
www.Omron247.com
Dennis Hydock, President – High-end Motion/Robot/Vision Integration
Integrated Industrial Technologies, [email protected]
www.isquaredt.com
Keith Grey, Strategic Account Manager – Automotive
Omron Industrial Automation, [email protected]
www.Omron247.com