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

1. Educational Webcast
Real-time Ethernet for
Machine Control
Moderated by David Greenfield, Director,
Media & Events at Automation World
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2. 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?
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3. Real-time Ethernet for Machine Control
Webcast Objectives
• 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
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4. 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
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5. Real-time Ethernet for
Machine Control
Bill Faber
Commercial Marketing Manager – Motion, Drives, Vision
Omron Industrial Automation
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6. 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
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7. Context of Machine Control
SCADA
Information
Layer
Visualization
Database
Control
Layer
Motion
Layer
Device I/O
Layer
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Interconnection
PLC
HMI
PLC
Control
Safety
Motion
Controller
RFID
Temperature
Sensors
I/O
Vision
Sensing
Servo
Inverter
Actuation

8. 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
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9. Applications that Require Real-time
Application:
• 4-Color Printing
• Line Shafting
• Converting
• Contouring
• Pattern Cutting
• Robotic
• Other multi-axis
coordinated motion
control applications
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10. 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
Motion
Controller
Device
I/O
Layer
RFID
Temperature
Sensors
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I/O
Vision
Servo
Inverter
To achieve
synchronous
motion control,
the network must
be real-time

11. 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
Motion
Layer
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Logic
(PLC)

12. Architecture Trends – Converging Controls
• When logic converges with Motion & Vision
it becomes a MOVi application
Application Examples:
– Move – Inspect – Reject
– Move – Inspect – Orient
– Inspection in Motion
– Vision Servo-ing
– Storage & Retrieval
Motion
Vision
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Logic

13. Driving Factors for Real-time Ethernet
Landscape of
Automation Pain:
OEMs Drive Toward
Efficiencies of:
• Time to Market
• Complexity of Design/Development
Machine
Development
• Setup, Configuration, Programming
• Field Expansion Options
Machine
Deployment
• Bottlenecks in Throughput & Yield
• Data Exchange (C2C, Enterprise)
Machine
Production
• Troubleshoot & Error Reporting
• Uptime
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Machine
Maintenance
Converging platforms
require real-time
networks to eliminate
system level latencies
and bottlenecks
At the same time,
networks allow for
smarter machines

14. What Makes a Network Real-time?
Not Real-time
• Node control and feedback
data updates slower than
control system
• Network is faster than the
control system
• Update jitter exceeds node
synchronization requirements at
maximum machine speed
• Deterministic (Repeatable)
• Controller, Network and Slave
nodes updating at different times
• Synchronization across
the platform
• Data volume exceeds network
transport capacity
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Real-time
• Must meet data throughput
requirements for the intended
application
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15. Comparative Look at Ethernet Networks
EtherCAT
Line, star,
ring, tree,
On-the-fly frame
Processing
Slave map
Hub
Line, star,
ring, tree
Polling (half duplex)
Line, ring
Polling
Switch
Line, branch,
tree
Polling
Star, ring
Polling (producer
consumer)
Managed
Switch
Star, ring
Polling (producer
consumer)
Switch
**
Branch Slave
Switch
<<1 usec
Star
Polling & master map
Distributed Clocks
PowerLink
1 usec
**
Depends on frames
Sercos III
1 usec
**
IEEE1588
Profinet IRT
1 usec
*
IEEE1588
EtherNet/IP
EtherNet/IP CIP
Synch
Modbus TCP/IP
~1 usec
IEEE1588
* Depends on number of cascaded switches, practical limit around 20 nodes
** Depends on communication jitter of frames from the master
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16. Ethernet Optimized for Machine Control
• Fast & Efficient
• Open & Accepted
• Deterministic & Repeatable
• 40 axis + 2200 I/O Test
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17. Ethernet Optimized for Machine Control
Deterministic & Repeatable
• Distributed Clock
• <<1usec jitter (repeatability)
• Learns the topology & delays
Distributed Clock
Synchronization
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18. One Real-time Network for Machine Control
One Real-time Network enables
Faster, Simpler, Smarter Machines
One Factory Network
For Information
 Most accepted open network
One physical layer
Two Protocols
One Purpose for
Machine Automation
One Machine Network
For Real-time Control
 Fastest open network
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19. Dial Table Vision Inspection
Dennis Hydock
High-end Motion/Robot/Vision Integration
Integrated Industrial Technologies
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20. 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
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21. Bolt Inspection Dial Table Indexing Machine
Servo Motor 3
From Bowl
Feeder
Dial Index Table
Linear Feed Conveyor
Camera 1
Head Inspection
Length, Diameter,
& Thread Inspection
Camera 2
Servo Motor 1
Camera 3
Servo Motor 2
Rotate Thread Inspection
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22. Previous Solution
Camera
HMI
Frame
Grabber
PC with Imaging
Software
Frame
Grabber
PLC
Camera
Stepper
Indexer
Rotate
Frame
Grabber
Camera
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Index
Table
Stepper
Amp
Stepper
Amp
Programming
Software
Complex Solution
•
•
•
•
Different protocols
Different hardware
Noise issues
Slow!!!

23. Motion & Vision on
Latest EtherCAT Solution:
•
•
•
•
•
•
•
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Trajexia TJ2-64 motion controller
FZM1 camera & controller
16-Axes G5 Servo Motors
NS HMI via Ethernet
EtherCAT Network
EtherCAT I/O
Single Program
.

24. Motion & Vision on
EtherCAT Solution Advantages
•
•
•
•
•
•
•
•
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No Noise Issues
Easier Maintenance
Reduced Wiring
Single Supplier
Standard Hardware
Fast Changeover
Saves Time
Saves Money
.

25. Quicker Setup with One Integrated Network
Easy Setup
Slave Configuration
Communication Setting
Camera Setting
Select Motion Control Type
Robot – XY, XYӨ
Stage – XYӨ,UVW,UVWR
Sampling position
Automatic setting of Calibration
Parameters
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Camera Image Calibration Screen

26. Application Example
Simple Program Configuration
IF NOT ETHERCAT($66,0,1000,1000,5,1010,12) THEN
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27. Faster Performance with Real-time Network
Operation
EtherCAT
System
Time
(msec)
Previous
System
Time
(msec)
1
17
Capture image and
process
50
50
Network cycle
1
17
configuration on one Ethernet
PHY network is simple
TOTAL vision cycle
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84
• YES: Real-time is needed for
Motion controller Scan
1
1
Initiate Motion
0.5
0.5
the motion axis, required if
everything is on the same
network
9 degree move
50
50
Settling time
2
2
TOTAL motion cycle
53.5
53.5
TOTAL CYCLE TIME
105.5
137.5
Network cycle
(capture command)
(send 4 read 12)
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Does Real-time Matter?
• YES: Separate non-real-time
network scan is almost as
high as the motion cycle
(37msec)
• YES: Simple setup and
Bottleneck is a System Issue.
Network is not the bottleneck.

28. 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
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29. Preventive Maintenance for Automotive
Keith Grey
Strategic Account Manager – Automotive
Omron Industrial Automation
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30. 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
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AUTOMOTIVE

31. One Network – One HMI
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
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32. View Data Real-time on
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
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<torque/speed curve
here>

33. Simple to Use on
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)
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34. 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
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35. 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
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36. Call to Action
• Learn for yourself about
Real-time Ethernet
Date
Location
10/11/2011
(Tues)
Boston
10/12/2011
(Wed)
Chicago
10/13/2011
(Thurs)
Milwaukee
10/18/2011
(Tues)
San Diego
Phoenix
– Is it in the interconnection?
10/19/2011
(Wed)
– Is it in the network?
10/20/2011
(Thurs)
Denver
– www.ethercat.org
– Come to EtherCAT Technology
Group Roadshow – 6 U.S. locations
• Evaluate your machine control
platform for bottlenecks
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37. Questions
Bill Faber, Commercial Marketing Manager – Motion, Drives, Vision
Omron Industrial Automation, bill.faber@omron.com
www.Omron247.com
Dennis Hydock, President – High-end Motion/Robot/Vision Integration
Integrated Industrial Technologies, dhydock@isquaredt.com
www.isquaredt.com
Keith Grey, Strategic Account Manager – Automotive
Omron Industrial Automation, keith.grey@omron.com
www.Omron247.com
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