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SERCOS – Motion, Safety and I/O
SERCOS Seminar Atlanta / September 16, 2009
Introduction to SERCOS
SERCOS Seminar AtlantaSeptember 16, 2009
Peter Lutz, Managing DirectorSERCOS International e.V.
No. 3(c) SERCOS International 2009
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
No. 4(c) SERCOS International 2009
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
No. 5(c) SERCOS International 2009
Organizational Structure SERCOS International
SERCOS Steering Committee (SSC)
Testing & CertificationLaboratory
TWG Drive
TWG Comm. /Hardware
TWG NRT
TWG SCI+ PG FDT
TWG Safety
TWG IO
TWG Encoder
Board of Directors / Management
Task Force(s)
Technical Working Groups
SERCOS Webdav / SERCOS Wiki
TWG Installation TWG SNA
TWG GDP
No. 6(c) SERCOS International 2009
SERCOS I/II – Highlights
CNC/Motion Control/PLC
Digital IntelligentSpindles
DigitalIntelligentServo Drivesor I/Os
Fiber-optic ring
Transmission Rate up to 16 Mbit/s Cycle time down to 62,5 µs Sub-microsecond synchronization Noise-free optical transmission
No. 7(c) SERCOS International 2009
Drive buses vs. Field buses
CostDriven
PerformanceDriven
NC/MCDriven
PLCDriven
Motion Networks(drive buses)
I/O Networks(field buses)
No. 8(c) SERCOS International 2009
Synchronization with SERCOS
Machines with master drive and mechanical synchronization elements
Machines with decentralized drives synchronized via motion networks
Mechanicalline shafts and gears
Electronicalline shafts and gears
Sub-microsecond synchronization
No. 9(c) SERCOS International 2009
SERCOS interfaceInstalled base
0
500000
1000000
1500000
2000000
2500000
2 Million Real-Time nodes in November 2007
More than 50 control suppliers, more than 30 drive suppliers, ~6 I/O device manufacturers
No. 10(c) SERCOS International 2009
SERCOS I/II Device Manufacturers
3S Elau Manz Automation ABB Hitachi
ABB Elexa MDSI ACD IIS
ACD ESA/GV MEI AMK KEB
AMK Fagor Automation Optronic Baumüller Kollmorgen Servotronics
andron Fidia OSAI Beckhoff Linmot
Automata Föhrenbach Pertex Berger Lahr LTi DRiVES
Automation Int. Giddings & Lewis Phoenix Contact Bosch Rexroth Metronix
Baumüller Hitachi Power Automation Danaher Motion Panasonic
Beckhoff Homag Procom DLR Parker Hannifin
Bosch Rexroth IBH Automation Rockwell Automation ECS Pertex
BWO Elektronik IIS RSI Elau Rockwell Automation
Cincinnati Machine ISG Sanyo Denki ESR Pollmeier Samsung
Cranfield Precision ISM Schleicher Etel Sanyo Denki
Danaher Motion KAT Schneider Automation Fagor Automation Sieb & Meyer
D.Electron KEBA Sieb & Meyer Festo Stögra
Eckelmann KW-Software SoftPLC Föhrenbach Yaskawa
ECS Lachmann & Rink Triomotion
Controls Drives
VIPALuetzeSanyo DenkiBeckhoffPhoenix ContactACD
VIPALuetzeSanyo DenkiBeckhoffPhoenix ContactACDI/O devices
Backup
No. 11(c) SERCOS International 2009
Existing SERCOS – Selected Applications
Printing MachinesPackaging MachinesWood working
High-speed Free-form MillingCamshaft GrindingGear Grinding
No. 12(c) SERCOS International 2009
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)
No. 13(c) SERCOS International 2009
SERCOS III 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
Windows
Master driver
Slave Conformizer
Windows
Slave Driver
Master Conformizer
Universität Stuttgart
No. 14(c) SERCOS International 2009
Packaging Profile for SERCOS
No. 15(c) SERCOS International 2009
SERCOS III : Next Evolution Step for SERCOS
Decision of SERCOS members in 2003:
SERCOS III = SERCOS + EthernetInnovation 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
No. 16(c) SERCOS International 2009
Master
SERCOS goes Ethernet
Master
Fiber Optic Ring (unidirectional)
Baudrate up to 16 Mbit/s
Full-Duplex Ethernet (bidirectional), Fiber optic or Copper Wire
Baudrate 100 Mbit/s
SERCOS II SERCOS III
No. 17(c) SERCOS International 2009
SERCOS III – New Features (1)
Master
Standard EthernetFrames
Fast Ethernet (Full-Duplex)
Line Topology
Ring Topology Baudrate : 100 Mbit/s
Cyclic Real-timeData Exchange
Cycle time : 31,25 µs … 65 ms
CAT5e
No. 18(c) SERCOS International 2009
SERCOS III – New Features (2)
Master
Redundancy, e.g. in case ofCable break
Hot pluggingof devices
Baudrate : 100 Mbit/s
Cycle time : 31,25 µs … 65 ms
Hot plug device
No. 19(c) SERCOS International 2009
SERCOS III – New Features (3)
Master
Direct Cross Comm. between Slaves
Integration ofStandard Ethernet
nodes
Baudrate : 100 Mbit/s
Cycle time : 31,25 µs … 65 ms
No. 20(c) SERCOS International 2009
SERCOS III – New Features (4)
C2C
CC
Master 1 Master 2 Slave Master Slave Master
Controller-to-Controller Communication (C2C) and Cross Communication (CC)
