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SERCOS – Motion, Safety and I/O SERCOS Seminar Atlanta / September 16, 2009

SERCOS – Motion, Safety and I/O SERCOS Seminar Atlanta / September 16, 2009. Introduction to SERCOS SERCOS Seminar Atlanta September 16, 2009. Peter Lutz, Managing Director SERCOS International e.V. SERCOS interface History.

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SERCOS – Motion, Safety and I/O SERCOS Seminar Atlanta / September 16, 2009

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  1. SERCOS – Motion, Safety and I/OSERCOS Seminar Atlanta / September 16, 2009

  2. Introduction to SERCOSSERCOS Seminar AtlantaSeptember 16, 2009 Peter Lutz, Managing Director SERCOS International e.V.

  3. SERCOS interfaceHistory • 1985: Working Group by VDW (Association of German Machine Tool Builders) and ZVEI (Association of Electrotechnical Industry) releases an updated version of the analogue +/- 10V interface and initiates the definition of a digital drive interface for machine tools (Working Group „Digital Drive Interface“) • 1989: SERCOS interface having its premiere at EMO in Hannover / Germany • 1990: Foundation of SERCOS Organization (today: SERCOS International) • Original members: ABB, AEG, AMK, Bosch, Indramat, Siemens (c) SERCOS International 2009

  4. SERCOS International SERCOS International • Founded in 1990 • Central Office located in Suessen close to Stuttgart/Germany • Regional Organizations in North America and Japan (China in preparation) • Offices in North America, Japan and China • ~80 member companies worldwide SERCOS InternationalBoard of Directors: • Dr. Bernd-Josef Schäfer, Bosch Rexroth AG (Chairman) • Fred Cohn, Schneider Electric • Ralf Prechtel, LTi Drives GmbH • Prof. Alexander Verl, ISW/University of Stuttgart (c) SERCOS International 2009

  5. Organizational Structure SERCOS International Board of Directors / Management Task Force(s) SERCOS Steering Committee (SSC) Testing & CertificationLaboratory Technical Working Groups TWG Comm. /Hardware TWG NRT TWG Safety TWG Encoder TWG GDP TWG Installation TWG Drive TWG SCI + PG FDT TWG IO TWG SNA SERCOS Webdav / SERCOS Wiki (c) SERCOS International 2009

  6. CNC/Motion Control/PLC Fiber-optic ring Digital Intelligent Spindles Digital Intelligent Servo Drives or I/Os SERCOS I/II – Highlights • Transmission Rate up to 16 Mbit/s • Cycle time down to 62,5 µs • Sub-microsecond synchronization • Noise-free optical transmission (c) SERCOS International 2009

  7. Drive buses vs. Field buses PerformanceDriven Motion Networks(drive buses) I/O Networks(field buses) CostDriven PLCDriven NC/MCDriven (c) SERCOS International 2009

  8. Synchronization with SERCOS Machines with master drive and mechanical synchronization elements Mechanical line shafts and gears Sub-microsecond synchronization Machines with decentralized drives synchronized via motion networks Electronical line shafts and gears (c) SERCOS International 2009

  9. SERCOS interfaceInstalled base 2 Million Real-Time nodes in November 2007 More than 50 control suppliers, more than 30 drive suppliers, ~6 I/O device manufacturers (c) SERCOS International 2009

  10. Backup SERCOS I/II Device Manufacturers Controls Drives I/O devices (c) SERCOS International 2009

  11. Existing SERCOS –Selected Applications Gear Grinding Camshaft Grinding High-speed Free-form Milling Printing Machines Packaging Machines Wood working (c) SERCOS International 2009

  12. Milestones IEC Standardization • 1995: IEC Standard IEC 61491 (Ed. 1.0) • 1999: EN Standard IEC 61491 (Ed. 1.0) • 2002: IEC Standard IEC 61491 (Ed. 2.0) • 2007: • IEC Standard IEC 61800-7 Ed 1.0 (SERCOS Drive Profile) • IEC Standard IEC 61784-1 Ed 2.0 and IEC 61158 Standards (Fieldbus Profiles, SERCOS I/II) • IEC Standard IEC 61784-2 Ed 1.0 and IEC 61158 Standards (Real-Time Ethernet Profiles, SERCOS III) • IEC Standard IEC 61784-3 Ed 1.0 (Safety buses, CIP Safety) (c) SERCOS International 2009

  13. SERCOS III Conformizer Master Conformizer • Conformizer for SERCOS III developed by ISW (University of Stuttgart) • Commercialization by SERCOS International • Use as official certification tool in testing laboratory • Use as test and development tool by companies Slave Conformizer Universität Stuttgart Master driver Slave Driver Windows Windows (c) SERCOS International 2009

  14. Packaging Profile for SERCOS (c) SERCOS International 2009

  15. SERCOS III : Next Evolution Step for SERCOS Decision of SERCOS members in 2003: SERCOS III = SERCOS + Ethernet Innovation by Combining SERCOS and Ethernet • Utilization of Standard Ethernet as Motion Network • Re-use of well-defined and proven SERCOS mechanisms : • Time-slot protocol for collision avoidance • Hardware synchronization • Protocol in the real-time channel • Motion control profile (c) SERCOS International 2009

  16. Master SERCOS goes Ethernet SERCOS II SERCOS III Master Full-Duplex Ethernet (bidirectional), Fiber optic or Copper Wire Baudrate 100 Mbit/s Fiber Optic Ring (unidirectional) Baudrate up to 16 Mbit/s (c) SERCOS International 2009

  17. CAT5e SERCOS III – New Features (1) Fast Ethernet (Full-Duplex) Standard Ethernet Frames Master Line Topology Baudrate : 100 Mbit/s Ring Topology Cycle time : 31,25 µs … 65 ms Cyclic Real-time Data Exchange (c) SERCOS International 2009

  18. Hot plug device SERCOS III – New Features (2) Redundancy, e.g. in case of Cable break Hot plugging of devices Master Baudrate : 100 Mbit/s Cycle time : 31,25 µs … 65 ms (c) SERCOS International 2009

  19. SERCOS III – New Features (3) Direct Cross Comm. between Slaves Integration of Standard Ethernet nodes Master Baudrate : 100 Mbit/s Cycle time : 31,25 µs … 65 ms (c) SERCOS International 2009

  20. Master Master 2 Master Master 1 Slave Slave SERCOS III – New Features (4) C2C CC Controller-to-Controller Communication (C2C) and Cross Communication (CC) (c) SERCOS International 2009

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