Introduction to EtherCAT:

EtherCAT (Ethernet for Control Automation Technology) is an open, real-time

industrial Ethernet protocol designed for automation and motion control applications. It
operates as a master-slave architecture, where the EtherCAT master communicates with
multiple EtherCAT slaves in a daisy-chain topology.

Brief history and development of EtherCAT:

EtherCAT is a high-performance, low-cost, easy to use Industrial Ethernet technology

with a flexible topology. It was introduced in 2003 and has been an international standard
since 2007. The EtherCAT Technology Group promotes EtherCAT and is responsible for its
continued development. EtherCAT is an open technology: anyone is allowed to implement or
use it.

EtherCAT: Based on Ethernet technology:

EtherCAT is Industrial Ethernet and utilizes standard frames and the physical layer as
defined in the Ethernet Standard IEEE 802.3. However, it also addresses the specific
demands faced in the automation industry, where: there are hardline real-time
requirements with deterministic response times the system is usually made up of many
nodes, and each node only has a small amount of cyclic process data hardware costs play an
even bigger role here than they do in IT and office applications. The above requirements
make it practically impossible to use a standard Ethernet network at field level. If an
individual Ethernet datagram is used for each node, the effective data rate sinks significantly
for just a few bytes of cyclic process data: the shortest Ethernet datagram is 84 bytes long
(including the interpacket gap), of which 46 bytes can be used for process data.

For example, if a drive sends 4 bytes of process data for the actual position and
status information and receives 4 bytes of data for the target position and control
information, the effective data rate for both datagrams sink to 4/84 = 4.8%. Additionally, the
drive usually has a reaction time that triggers the transmission of the actual values after the
target values have been received. At the end, not much of the 100 Mb/s transfer rate
remains. Protocol stacks, such as those used in the IT world for routing (IP) connection (TCP),
require additional overhead for each node and create further delays through the stack
runtimes

Advantages of EtherCAT:

Real-Time Communication:

EtherCAT achieves near real-time communication by processing data on the fly as it

passes through each slave device. This minimizes communication delays and ensures precise
synchronization.
Ethernet Compatibility:

EtherCAT delivers all of the advantages of Industrial Ethernet at fieldbus prices. How?
Firstly, EtherCAT doesn’t require any active infrastructure components. The controlling
device doesn’t require a special interface card and the connected devices use highly
integrated, cost-effective chips available from a variety of suppliers. Furthermore, there’s no
need for costly IT experts to commission or maintain the system

Flexible topology:

In addition, it its speed, an EtherCAT network can support up to 65,535 devices

without placing restrictions on their topology: line, bus, tree, star – or any combination
thereof. Fast Ethernet physics allows two devices to be up to 100 m (330 ft) apart, and
greater distance scan be achieved with fiber optics. EtherCAT also has additional features
that offer further topological flexibility, such as Hot Connect and Hot Swap for devices, and
added redundancy through a ring topology.

Functional Safety:

Safety over EtherCAT is just like EtherCAT itself – lean and fast. Functional safety is
built directly into the bus with options for both centralized and decentralized safety logic.
Thanks to the Black Channel approach, it is also available for other bus systems.

Companies Preferring EtherCAT:

1. Beckhoff Automation:

Drive Series: AX8000, AX5000

 Beckhoff Automation has been at the forefront of EtherCAT adoption. Their

AX8000 and AX5000 servo drives utilize EtherCAT for real-time communication.

 TwinCAT Integration: Beckhoff’s TwinCAT software seamlessly integrates with

EtherCAT networks. TwinCAT acts as the EtherCAT master, coordinating
communication between the controller and servo drives.

 Real-Time Performance: EtherCAT’s unique processing-on-the-fly approach

minimizes communication delays. Data is processed as it passes through each slave
device, ensuring precise synchronization and high-speed communication.

 Efficient Data Transmission: EtherCAT minimizes data overhead by embedding

data directly into the Ethernet frame. This efficient approach maximizes bandwidth
utilization.

 Compatibility with Standard Ethernet Hardware: Beckhoff benefits from

EtherCAT’s compatibility with standard Network Interface Cards (NICs), reducing
costs and simplifying implementation.
2. Bosch Rexroth:

Drive Series: IndraDrive Cs

 Bosch Rexroth’s IndraDrive Cs series relies on EtherCAT for critical motion control
applications.

 High-Speed Communication: EtherCAT ensures rapid communication between the

controller and servo drives. This is essential for applications like CNC machining
and printing.

 Deterministic Control: EtherCAT’s deterministic behavior guarantees consistent

timing, allowing precise coordination of motion profiles.

 Synchronization: EtherCAT’s distributed clock mechanism ensures synchronized

operation across multiple drives, even in complex multi-axis systems.

3. Siemens:

Drive Series: SINAMICS V90

 Siemens chooses EtherCAT for their SINAMICS V90 servo drives.

 Efficient Motion Control: EtherCAT provides efficient communication, allowing

precise control of motor movements. Siemens appreciates its compatibility with
standard Ethernet hardware.

 Real-Time Capabilities: EtherCAT’s real-time communication ensures minimal

latency, critical for applications where synchronization matters.

 Scalability: EtherCAT scales well from simple single-axis drives to complex multi-
axis systems, making it suitable for Siemens’ diverse automation solutions.

4. Kollmorgen:

Drive Series: AKD2G

 Kollmorgen’s AKD2G servo drives benefit from EtherCAT’s real-time capabilities.

 Robust Design: EtherCAT ensures robust communication, even in harsh industrial

environments. Kollmorgen’s drives can handle demanding applications with
precision.

 Seamless Integration: EtherCAT seamlessly integrates into modern fieldbus

systems. Kollmorgen leverages this for high-performance motion control across
their product range.

5. Lenze:

Drive Series: 9400 HighLine, i750

  Lenze relies on EtherCAT for their 9400 HighLine and i750 drives.

 Flexible Functionality: EtherCAT allows Lenze to implement flexible motion

profiles, adapt to changing requirements, and optimize performance.

 Safety Features: EtherCAT supports distributed safety functions, enhancing

6. Yaskawa:

Drive Series: SGD7S EtherCAT Servo Drive:

 Yaskawa’s SGD7S EtherCAT servo drive is designed for automation systems

standardized on EtherCAT industrial networks.

 Plug-and-Play Compatibility: Immediate compatibility, faster refresh rates, and

minimal system infrastructure make it cost-effective.

 Real-Time Communication: EtherCAT ensures high-speed communication and

synchronization.

 Advanced Tuning Algorithms: Yaskawa’s servo tuning algorithms include vibration

suppression, ripple compensation, and advanced autotuning.

 overall system safety. Lenze prioritizes safety in their drive solutions.

7. FANUC:

Drive Series: Digital Servo Adapter-MODEL B (DSA-B):

 Allows using FANUC servo motors with a customer’s controller.

 EtherCAT Compatibility: Supports CAN application protocol over EtherCAT (CoE)
and IEC61800-7 CiA402 drive profile.
 One-Touch Auto-Tuning™: Fast, trouble-free servo tuning without user
adjustment.
 High-Speed Update Rates: Communication cycles as fast as 250 µs.
 Short Settling Times: Industry-leading performance with 2.5 kHz speed frequency
response.
8. EPSON:

Driver Series: EtherCAT-Compatible Servo Amplifiers:

 Enhanced functions available for higher-performance MR-J5 servo amplifiers with

EtherCAT.
 Touch Probe Support: The servo amplifiers also support touch probe functionality
9. Mitsubishi Electric:

Drive Series: MR-J4-TM Multi-Network Servo with EtherCAT®:

  Combines high fidelity response with ease of use and EtherCAT integration.
 One-Touch Auto-Tuning™: Fast, trouble-free servo tuning.
 High-Speed Update Rates: Communication cycles as fast as 250 µs.
 Short Settling Times: Industry-leading performance with 2.5 kHz speed frequency
response.
 Machine Diagnosis Function: Detects changes in machine parts and system
vibration for preventative maintenance scheduling

Application Areas:

Explore specific sectors where EtherCAT excels:

Robotics: EtherCAT enables precise and synchronized motion control in robotic arms and
manipulators.

Packaging Machines: EtherCAT ensures efficient communication between drives, sensors,

and actuators in packaging lines.

Automated Assembly Lines: EtherCAT’s real-time capabilities enhance production line

efficiency.

Safety Applications: EtherCAT supports distributed safety functions, critical for safeguarding
operators and equipment.

Comparison with Other Protocols:

1. Comparison with ProfiNet:

Real-Time Performance:

 EtherCAT: EtherCAT operates as close to real-time as possible. It processes data on

the fly, minimizing communication delays. Devices can be synchronized with sub-
microsecond accuracy.
 ProfiNet: ProfiNet also offers real-time capabilities but may not achieve the same
level of precision as EtherCAT. Its performance depends on the specific
implementation and network configuration.

Scalability:
  EtherCAT: EtherCAT scales well from simple single-axis drives to complex multi-axis
systems. Its daisy-chain topology allows easy expansion.
 ProfiNet: ProfiNet supports various topologies (line, star, ring), but scalability may
be limited in certain scenarios.

Efficiency:

 EtherCAT: EtherCAT minimizes data overhead by embedding data directly into the
Ethernet frame. This efficient approach maximizes bandwidth utilization.
 ProfiNet: ProfiNet uses standard Ethernet frames, which may introduce more
overhead. However, it offers flexibility in terms of data types and services.
2. Comparison with CANopen:

Data Transmission Efficiency:

 EtherCAT: EtherCAT surpasses CANopen in terms of data transmission efficiency.

EtherCAT frames are processed on the fly, reducing latency.
 CANopen: CANopen uses the Controller Area Network (CAN) bus, which introduces
more overhead due to its message-based nature.

Deterministic Behaviour:

 EtherCAT: EtherCAT ensures deterministic communication, critical for synchronized

motion control. Devices are tightly synchronized.
 CANopen: CANopen lacks strict determinism. It relies on message priorities and
may not guarantee precise timing.

Complexity and Flexibility:

 EtherCAT: EtherCAT is simpler to implement due to its streamlined approach. It

offers flexibility in topology and device types.
 CANopen: CANopen is more complex, supporting various profiles and services. It
allows customization but requires more effort during setup.
3. Comparison with Modbus:

Real-Time Capabilities:

 EtherCAT: EtherCAT excels in real-time communication. It processes data on the fly,

achieving sub-microsecond synchronization.
 Modbus: Modbus is not inherently real-time. It operates over serial or Ethernet
connections, but timing is less predictable.

Traditional vs. Modern Approach:

 EtherCAT: EtherCAT’s streamlined design focuses on efficiency and performance. It
minimizes protocol layers.
 Modbus: Modbus follows a more traditional approach with multiple protocol layers
(application, transport, data link). It lacks the efficiency of EtherCAT.

Applications:

 EtherCAT: Widely used in robotics, CNC machines, and high-speed production lines.
 Modbus: Commonly used for SCADA systems, industrial automation, and
monitoring applications.