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 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
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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 International Board 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
No. 4
Organizational Structure SERCOS International Board of Directors / Management
SERCOS Steering Committee (SSC)
Task Force(s)
Testing & Certification Laboratory
Technical Working Groups TWG Comm. / Hardware
TWG NRT
TWG Safety
TWG Encoder
TWG GDP
TWG Drive
TWG SCI + PG FDT
TWG IO
TWG Installation
TWG SNA
SERCOS Webdav / SERCOS Wiki (c) SERCOS International 2009
No. 5
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
CNC/Motion Control/PLC
Fiber-optic ring
Digital Intelligent Spindles
(c) SERCOS International 2009
Digital Intelligent Servo Drives or I/Os
No. 6
Drive buses vs. Field buses Performance Driven
Motion Networks (drive buses)
I/O Networks (field buses) Cost Driven PLC Driven (c) SERCOS International 2009
NC/MC Driven No. 7
Synchronization with SERCOS Machines with master drive and mechanical synchronization elements
Mechanical line shafts and gears
Machines with decentralized drives synchronized via motion networks
Sub-microsecond synchronization
Electronical line shafts and gears
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SERCOS interface Installed base 2500000
2000000
2 Million Real-Time nodes in November 2007
1500000
1000000
500000
More than 50 control suppliers, more than 30 drive suppliers, ~6 I/O device manufacturers
19 94 19 95 19 96 19 97 19 98 19 99 20 00 20 01 20 02 20 03 20 04 20 05 20 06 20 07
0
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Backup SERCOS I/II Device Manufacturers Controls
Drives
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 D.Electron Eckelmann
KAT KEBA KW-Software
Schneider Automation Sieb & Meyer SoftPLC
Fagor Automation Festo Föhrenbach
Sieb & Meyer Stögra Yaskawa
ECS
Lachmann & Rink
Triomotion
ACD Beckhoff Luetze
Phoenix Contact Sanyo Denki VIPA
I/O devices (c) SERCOS International 2009
No. 10
Existing SERCOS – Selected Applications
Gear Grinding
Wood working (c) SERCOS International 2009
Camshaft Grinding
Packaging Machines
High-speed Free-form Milling
Printing Machines No. 11
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)
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SERCOS III Conformizer Master Conformizer
Slave Conformizer Universität Stuttgart
Conformizer for SERCOS Master driver Windows
(c) SERCOS International 2009
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 Driver Windows
No. 13
Packaging Profile for SERCOS
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No. 14
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
No. 15
SERCOS goes Ethernet SERCOS II
SERCOS III
Master
Fiber Optic Ring (unidirectional) Baudrate up to 16 Mbit/s
Master
Full-Duplex Ethernet (bidirectional), Fiber optic or Copper Wire
Baudrate 100 Mbit/s
(c) SERCOS International 2009
No. 16
SERCOS III – New Features (1) Fast Ethernet (Full-Duplex) Standard Ethernet Frames Master
CAT5e
Line Topology
Baudrate : 100 Mbit/s Cycle time : 31,25 µs … 65 ms
Ring Topology
Cyclic Real-time Data Exchange
(c) SERCOS International 2009
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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
Hot plug device
No. 18
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
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SERCOS III – New Features (4) C2C
Master 1
Master 2
Slave
Master
Slave
Master
CC
Controller-to-Controller Communication (C2C) and Cross Communication (CC) (c) SERCOS International 2009
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