This document discusses choosing between Ethernet and EtherCAT networks for motion control applications. It provides an overview of centralized vs distributed control systems, describes the key differences between Ethernet and EtherCAT at the hardware level, and gives examples of Galil motion controllers and I/O modules that support both network types. A decision tree is presented outlining considerations for determining whether EtherCAT or Ethernet is best for a given application.

1. January 26, 2016
Ethernet or EtherCAT for Motion Control
Choosing the Right Network for Your Applications
Matt Klint
Applications Engineer
Galil Motion Control

2. Speakers
Texas Instruments & Ethernet POWERLINK Standardization Group
Matt Klint
Applications Engineer
Galil Motion Control
mattk@galil.com
Meet The Presenter

3. Thank You To Our Exclusive Sponsors

4. Agenda
• Introduction
• About Galil
• Solutions
• Motion Control Systems
• Centralized vs. Distributed
• Ethernet
• EtherCAT
• Examples
• Galil EtherCAT Hardware
• DMC-500x0 EtherCAT Master
• RIO-574x0 EtherCAT IO
• Summary
• Decision points for EtherCAT or Ethernet
• Q&A

5. About Galil
Established Reputation and long History of Success
• Founded in 1983 by Dr. Jacob Tal and Wayne Baron
• Introduced the 1st microprocessor based servo controller
• Profitable for over 120 consecutive quarters
• Over 750,000 motion controllers and PLCs delivered
Excellent Engineering Support and Service
• Worldwide network of factory trained reps & distributors
• Support team with over 100 years combined motion control experience
• Online support tools at www.galil.com

6. Motion Control System
Component Function
Command Position An ideal reference generated by the Motion Controller
Actual Position Encoder feedback position
Error Difference between the commanded and actual positions
Kp, Kd, Ki PID Filter gains that translate measured error into a control signal
Control Signal Works to correct the measured error via negative feedback

7. Centralized Control
• All components in close proximity
• Servo control, IO are all monitored and
controlled from the same hardware
• Motion can be synchronized and
coordinated with changes in IO states
• Examples:
o CNC Machine
o Semiconductor Inspection
o Pick and Place Machine
HMI/PC
Motion
Controller
Servo
Drives
PLC

8. Distributed Control
• Coordination (motion or triggering
IO) is left to each node to manage
and report back to the central
‘master’ node
• Communication delays between
nodes and the master can lead to
race conditions, indeterminate states
etc.
• Best for plant/process control and
monitoring
PLC
PLC
PLC
Switch
Motion
Controller
Servo
Drives

9. EtherCAT and Ethernet
• Ethernet
• Designed to move large amounts of data through many different nodes
• Able to route data to and from billions of separate addresses allowing
communication across vast networks
• Large overhead involved in encapsulating, routing and formatting data
• Software handles extraction and processing of data
• EtherCAT
• Uses standard Ethernet hardware, CAT5 cabling and Network Interface Cards
(NIC)
• Streamlines Ethernet communication at the hardware level
• Data processing on slave devices is handled “on the fly” via FPGA or ASIC,
minimizing latency
• Initial setup and configuration required

10. Ethernet – What’s on the Wire?
An Ethernet frame contains:
• Ethernet Header
• Destination Address: 6 bytes
• Source Address: 6 bytes
• EtherType: 2 bytes, 0x0800 specifies IPv4.
• Ethernet Data
• Payload: 46 – 1500 bytes
• CRC (Checksum): 4 bytes
Standard Ethernet Frame (Packet)

11. Ethernet Physical Layout
Host PC or HMI
Motor
+
EncoderCAT5
Ethernet Cable
Drive
Drive
Motion
Controller
Motor
+
Encoder
Motor
+
Encoder
Drive
• Communication between
motion controller and PC is
over Ethernet
• Motion Commands are
relayed to the drives analog
signals

12. EtherCAT Communication
• Based on CANopen, specifically COE (CAN
Over Ethernet)
• Standard CAT5 Cabling
• FPGAs for fast data processing
• Data formatting must be configured prior
to operation
• Multiple modes of operation
• IO Supported
• Distributed Clock allows for tightly
coordinated actions
• Likened to a ‘data train’, each drive takes
data off the train, places data on the train
Slave 1 Slave 2 Slave 3 Slave 4
Master

13. EtherCAT – What’s on the Wire?
An EtherCAT frame is very similar to an Ethernet frame:
• Ethernet Header
• EtherType 0x08A4 specifies EtherCAT
• EtherCAT Header
• Data Length: 11 bits
• Reserved: 1 bit
• Protocol type: 4 bits (0x01 indicates CoE, CAN over EtherCAT)
• EtherCAT Data: 46 – 1496 bytes
• Working Counter: 2 bytes
• CRC (Checksum): 4 bytes
EtherCAT Frame (Packet)

14. EtherCAT Network Layout
I/O
Module
EtherCAT Master
EtherCAT
Drive 1
EtherCAT
Drive 2
EtherCAT
Drive 3
Motor/
Encoder
Motor/
Encoder
Motor/
Encoder
CAT5
Ethernet Cable

15. The DMC-500x0 EtherCAT Master
• Includes all the features of our flagship
DMC-40x0 series controller with the
addition of EtherCAT drive support for up
to 8 axes in Cyclic Synchronous Position
and Torque Modes
• Only motion controller in the industry
with the ability to mix and match local
and EtherCAT drives
• Easily configurable and designed with
compatibility and flexibility in mind
• Multiple drive vendors supported
• Compatible with Galil’s entire line of
internal servo and stepper motor
amplifiers

16. The RIO-574x0 EtherCAT I/O Slave
Features
• 16 high power, 500mA sourcing,
optoisolated digital outputs
• 16 Optoisolated digital inputs
• 8 x Programmable analog inputs
• 8 x Programmable analog outputs
Fully Functional EtherCAT Slave
• EtherCAT Conformance Tested
• Supports Distributed Clock
• Programmable Analog IO ranges
• Field Upgradeable Firmware
Conformance Tested

17. DMC Code Examples
Commanding movement on a local axis
Commanding movement on an EtherCAT axis
and reading EtherCAT IO

18. Why Choose?
• The DMC-500x0 can accommodate a multitude of interfaces and
communication buses:
o EtherCAT
o Ethernet
o TCP Modbus
o RS-232/USB
• This versatility makes selecting the best drives and IO for your application a
much simpler process. If design considerations change down stream,
developers are not locked into a particular hardware platform. This is in stark
contrast to many EtherCAT only controllers on the market.

19. DMC-500x0 Hardware Layout
DMC-50070
EtherCAT
Drive 1
EtherCAT
Drive 2
EtherCAT
Drive 3
Servo
Motor
Servo
Motor
Servo
Motor
RIO-57420
Analog &
Digital IO
Stepper
Motor
Servo
Motor
Servo
Motor
Stepper
Motor
Stepper
Driver
Stepper
Driver

20. Compatible EtherCAT Drives
Currently Supported Drives & IO
• AMC DZEANTU Series
• Copley XenusPLUS XEL-230-36
• LS Mecapion Pegasus and L7NA Series
• Panasonic Minas A5B
• Sanyo-Denki SANMOTION RS2A01A0KA4
• Yaskawa Sigma-5 Series
• Delta Electronics ASD-A2 Series
• Galil RIO-574x0 IO
• VIPA IO
For devices not listed, please contact a Galil
Applications Engineer to discuss your application

21. Summary
• The EtherCAT protocol is gaining traction as a robust and efficient solution to
demanding, large scale automation applications
• The higher cost of EtherCAT controllers and drives is partly offset by the use of
pre existing, easily attainable hardware and simplified wiring
• Although Ethernet control can not technically be referred to as ‘real time’, for
many applications it is more than sufficient
• For centralized control schemes, analog servo control signals will continue to be
the most cost effective option

22. Please submit your questions regarding any part of this presentation or about
EtherCAT in general at this time
Additionally, please contact Galil’s dedicated Applications Engineering team anytime
with additional questions or comments:
Q & A
1 (916) 626-0101
support@galil.com
www.galil.com

23. Questions?
Joanna Keel
Marketing & Membership Manager
Motion Control &
Motor Association
jkeel@motioncontrolonline.org
+1-734-994-6088
www.MotionControlOnline.org
Thank you to our exclusive sponsors:
Matt Klint
Applications Engineer
Galil Motion Control
mattk@galil.com
Galil Engineering Support
1-800-377-6329
support@galilmc.com
Electromate Contact
1-877-737-8698
sales@electromate.com
www.electromate.com