By enabling real-time communication and efficient data transfer, SANYO DENKI’s integrated solutions reduce process delays, improve automation reliability, and drive higher productivity across manufacturing operations. This blog explores the role of EtherCAT, EtherNet/IP, and OPC UA within the framework of ISA-95 standards, detailing how these technologies work together to provide robust and seamless control in automation systems.
Key Components of the Motion Control System Configuration
- EtherCAT-Enabled SANMOTION G-Series Servo Amplifier:
Designed for high-speed, deterministic motion control.
Communicates with the servo motion controller via EtherCAT for real-time operation at ISA-95 Levels 0 and 1. - Ethernet/IP Enabled SANMOTION C-Series Servo Motion Controller:
Acts as the central controller, managing motion control, device communication, and data sharing.
Supports EtherCAT, EtherNet/IP, and OPC-UA, enabling integration across ISA-95 Levels. - Communication Protocols (click for a full tutorial about ISA-95 communication layers.)
EtherCAT: Real-time motion control at ISA-95 Levels 0 and 1, ensuring synchronization and precision.
EtherNet/IP: Broader device communication at ISA-95 Levels 1 and 2 for integration with sensors, actuators, and safety systems.
OPC-UA: System-level data sharing at ISA-95 Levels 3 and 4, bridging operational and enterprise systems. A tutorial about ISA-95 communication layers is available in our blog post “Improve Production Insights with Embedded Protocols for ISA-95 Integrated Automation
SANMOTION Servo Amp and Motion Controller Communication (EtherCAT Integration for Real-Time Control)
- Operates at ISA-95 Levels 0 and 1, focusing on real-time, deterministic communication between the servo drive and the motion controller using EtherCAT.
- Core Roles:
- Motion Execution (Level 0): The C-Series motion controller directly communicates with the G-Series servo drive to control the servo motor’s position, velocity, and torque. EtherCAT ensures precise, time-critical feedback loops between the motion controller and the servo drive.
- Control Coordination (Level 1): The C-Series motion controller synchronizes multi-axis motion across multiple G-Series servo drives, leveraging EtherCAT’s distributed clock capabilities for accurate timing and real-time updates. Position setpoints and other motion parameters are transmitted at millisecond intervals to the servo drives.
SANMOTION Controller Integration with Peripheral Systems (EtherNet/IP for Broader Communication)
- Operates at ISA-95 Levels 1 and 2, enabling the C-Series motion controller to communicate with additional devices, such as sensors, actuators, or safety PLCs, alongside the G-Series servo drive.
- Core Roles:
- Device Integration (Level 1): The C-Series motion controller facilitates communication between the G-Series servo drive and peripheral devices, such as obtaining feedback from sensors or sending commands to actuators. EtherNet/IP handles these broader communications, including the exchange of auxiliary sensor data and safety signals.
- Supervisory Functions (Level 2): The C-Series motion controller provides non-real-time diagnostics, configuration, and system status updates to supervisory systems (e.g., HMIs or SCADA). It integrates data from the G-Series servo drive and peripheral devices, ensuring seamless interaction and overall system monitoring.
Data Sharing with Higher-Level Systems (OPC-UA for Enterprise Connectivity)
- Operates at ISA-95 Levels 3 and 4, enabling a SANMOTION controller to share information from the servo drive and connected devices with enterprise-level systems.
- Core Roles:
- Operational Monitoring (Level 3): The SANMOTION controller aggregates data from EtherCAT and EtherNet/IP networks, including performance metrics, fault logs, and system status from the SANMOTION servo drive. This data is processed and shared with monitoring systems using OPC-UA for production optimization.
- Enterprise Integration (Level 4): A SANMOTION controller communicates with MES or ERP systems to share aggregated data from SANMOTION servo drives and peripheral devices. This enables enterprise systems to make data-driven decisions for production planning, maintenance scheduling, and business analytics, aligning operational and business goals.
Practical Motion Control Protocol Use Cases
- Motion Control with EtherCAT (ISA-95 Levels 0 and 1):
- A robotic arm with EtherCAT-enabled servo drives executes precise, synchronized movements.
- Real-time commands from the motion controller synchronize all axes via EtherCAT distributed clocks.
- Device Integration with EtherNet/IP (ISA-95 Levels 1 and 2):
- Sensors detect object positions and relay data to the motion controller via EtherNet/IP.
- A safety PLC sends emergency stop signals to the motion controller, which relays them to the EtherCAT network for immediate action.
- Data Sharing with OPC-UA (ISA-95 Levels 3 and 4):
- The motion controller aggregates operational data (e.g., servo drive health and KPIs) and publishes it to an MES or SCADA system for monitoring and optimization.
- An ERP system retrieves aggregated data for production scheduling and predictive maintenance.
Conclusion
By leveraging EtherCAT, EtherNet/IP, and OPC-UA, this integrated servo system delivers real-time control, seamless device integration, and comprehensive data sharing across the entire production environment. EtherCAT ensures precise motion control at the foundation of machine automation, while EtherNet/IP connects critical auxiliary and safety systems for operational reliability. OPC-UA then bridges the gap between operational data and enterprise-level management, providing crucial visibility across all levels of the ISA-95 framework. This end-to-end integration not only enhances productivity through faster decision-making and synchronized operations but also supports scalable, flexible automation.