Real-time Ethernet for Machine Control

37
1 © Omron Real-time Ethernet for Machine Control Educational Webcast Moderated by David Greenfield, Director, Media & Events at Automation World

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 controllers

Transcript of Real-time Ethernet for Machine Control

Page 1: Real-time Ethernet for Machine Control

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

29 © Omron

Keith Grey

Strategic Account Manager – Automotive

Omron Industrial Automation

Preventive Maintenance for Automotive

Page 30: Real-time Ethernet for Machine Control

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

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

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

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

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

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

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

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