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 * Doug Schuchart
 * 
 * * Mar 29, 2021
   * 
   * 6 min read




ETHERCAT: A FULFILLMENT AND PARCEL CENTER DIGITIZATION ENABLER


FROM ITS FUNCTIONAL PRINCIPLE TO GIGABIT EXTENSIONS, ETHERCAT OPTIMIZES
INTRALOGISTICS EQUIPMENT AND SUPPORTS MACHINE LEARNING, MECHATRONICS AND MORE








The nearly unlimited network size and performance of EtherCAT continues to solve
common technical challenges for material handling and intralogistics equipment
providers. It considerably reduces both engineering efforts and installation
time, equaling substantial cost savings. However, EtherCAT can also be an
important tool in the arsenal for solving an emerging opportunity: the complete
optimization of fulfillment and parcel operations.






More and more we hear about “lights out” operations, those that run completely
autonomously or with little intervention or interaction. Whether centers run
completely autonomously or with various levels of human and robotic
collaboration, one thing is certain: Digitization is the key to optimizing
fulfillment and parcel operations of the future, and digitization requires
highly-connected devices and the flow of large amounts of data. EtherCAT can
establish connectivity to all devices in the center, and its bandwidth for
communicating vast amounts of data is yet another benefit.



Let’s explore these EtherCAT advantages further, along with examples of how they
help companies achieve their digitization goals and enable smart fulfillment
operations with AI.







UNLIMITED ADVANTAGES WITH ETHERCAT






Before we dive into how EtherCAT’s bandwidth is an enabler of digitization, it’s
important to give an overview of other aspects of the protocol that make it
ideal for intralogistics, parcel and postal applications. The EtherCAT protocol
provides:



 * More than 65,000 devices on a single network segment. Examples of devices are
   single- or dual-axis drives; 4, 8, 16 or 32-point I/O blocks; network barcode
   scanners; or network safety scanners. Now increase the number of these
   devices to over 65,000 – that’s the “limit” for an EtherCAT segment, and
   multiple segments can be connected to a single Beckhoff controller.

 * Fastest fieldbus performance in the world, offering ultra-fast communication
   even to thousands of devices.

 * Flexible topology without impact on performance or synchronization. This
   includes true line topology, which is ideal for conveying and sortation
   equipment, without cascaded switch delays.

 * High security since EtherCAT is not based on the Internet Protocol (IP). IP
   is a pathway for malware and other security threats, as well as a source of
   significant configuration time which increases engineering cost.

 * Exceptional built-in diagnostics for quick identification of network issues
   and improved uptime.

 * Complete interoperability and openness supporting communication with all
   legacy fieldbus protocols and other Ethernet protocols.

It’s clear why so many global material handling equipment providers are adopting
EtherCAT into the control architecture of their equipment. Even with the
flexibility to control many devices on a single EtherCAT network with ultra-fast
performance, there remains considerable bandwidth for tunneling additional data.
This available bandwidth combines with EtherCAT’s openness and support of all
open fieldbus protocols to yield extraordinary advantages for users in the
intralogistics industry.






With the many communication gateways from Beckhoff to interface with the
EtherCAT network, virtually any open protocol can be tunneled through EtherCAT.
This capability eliminates the need for routing further cables back to PLC
cabinets, considerably reducing system complexity, cost and installation time.
Protocols such as IO-Link, ASi, EtherNet/IP, PROFINET and even fieldbuses more
common in brownfield sites, such as DeviceNet, PROFIBUS and CANopen, can all
communicate across the EtherCAT network without the need to run parallel
networks which add considerable cost and complexity. The benefits of EtherCAT
provide ultimate interoperability with any device as well as complete horizontal
communication across any facility, old or new. EtherCAT can serve as the perfect
communication highway for all important sensor data for control and operational
digitization.







BENEFITS OF ETHERCAT’S BANDWIDTH UTILIZATION FOR INTRALOGISTICS SYSTEMS






The exceptional bandwidth of EtherCAT is due to its unique functional principal
of “ethernet processing on the fly” and its unique bandwidth utilization.
EtherCAT G, the gigabit extension of the existing EtherCAT technology, sets even
new standards for data bandwidth while further improving the already unrivaled
network performance.






Consider, for instance, an extremely large conveyor application where the
conveyor belt is vulcanized with conductor loops for predictive analysis of
future belt breakage. In this real-world application example, an EtherCAT EL3702
2-channel analog input terminal with oversampling from Beckhoff enables system
updates for 200 channels of analog inputs at 100,000 samples per second per
channel across the network every 1ms. EtherCAT’s oversampling feature enables
sampling at a 10 µs sample distance. A total of 322 Mbit/s of user bandwidth is
required for the application. Yes, 322 Mbit/s of data! This successful EtherCAT
application is handled with just four network segments out of a single Beckhoff
machine controller with 12% remaining network bandwidth.






By simply replacing the standard EK1100 EtherCAT couplers with EK1400 EtherCAT G
couplers, the solution now has an update rate of 812 µs with 650 Mbit/s
bandwidth remaining – that is, 65% still available. The remaining bandwidth is
then available for other data communication and machine control. There is no
change required in I/Os, cabling or the machine controller and EtherCAT master,
just a simple replacement of the fieldbus couplers.






Put simply, EtherCAT is the one protocol that meets the requirements for
complete warehouse performance and digitization. This is just one example of how
digitization through EtherCAT, and the extended functionality of EtherCAT G, can
be used to optimize the operation of a fulfillment or parcel center. Efficient
communication of data is critical for the predictive maintenance of equipment to
improve uptime, but localized analytics software is also important for
actionable insights and performance gains.







MAKE THE MOST OF INCREASED DATA WITH MACHINE LEARNING (ML)






Machine learning, a subset of artificial intelligence, is another way in which
the operational data is used to optimize equipment in facilities. Since EtherCAT
enables the connection of all sensors across the center and can transmit vast
amounts of data directly to the machine controller, the Beckhoff controller is
the ideal location to collect and store the data as opposed to the use of
separate edge devices. Beckhoff controllers support multiple removable and
extendable storage media options for the collection of vast amounts of data, up
to several terabytes. Data can be stored locally in flat files or in SQL or
noSQL databases.






The data can then be used with Beckhoff’s TwinCAT real-time scope tools for
local analysis of events in real-time or those that occurred in the past.
TwinCAT Analytics can also be used to analyze data at the edge in the Beckhoff
machine controller. Results of local analyses can then be sent to the enterprise
system or the cloud via TwinCAT IoT, which includes vertical communication such
as OPC UA, MQTT and HTTPS/REST.






Here, further analysis can be applied with the use of open data science
platforms such as MATLAB and Python to create standard ONNX (Open Neutral
Network Exchange) machine learning inferences. The Machine Learning inferences
can be loaded back into the Beckhoff machine controller via TwinCAT Machine
Learning and run in real-time along with the TwinCAT PLC, making autonomous
decisions that direct the PLC logic in microseconds. Machine Learning inferences
running in the TwinCAT PLC open new possibilities for optimization including
more accurate predictive maintenance and operational equipment optimizations.







FASTER ROI FOR GAPPING, AS/RS, AGVS AND OTHER EQUIPMENT






An example of how Beckhoff is adapting ML inferences is with Beckhoff’s XTS
linear transport system, which is ideal for high-speed, dynamic gapping
applications. Beckhoff has used open-source data science platforms to develop an
ONNX machine learning inference that runs on the Beckhoff gapper machine
controller. The ML inference provides guidance to the XTS movers in real-time to
limit jerk and optimize acceleration for reaching its target destination. This
reduces the wear on the movers, extending the life of the bearings and providing
significant energy conservation. These technologies are ideal for reducing cost
and improving companies’ sustainability initiatives.






Similar ML inferences can be used in other common intralogistics equipment, one
example being the shuttles of an automated storage and retrieval system. AS/RS
systems can incorporate hundreds of shuttles; the lower cost of ownership via
reduced wear of mechanics as well as substantial energy savings can improve ROI
for the initial investment in automation. Similar approaches and optimization
can help to shorten the ROI of other automated equipment such as AGVs, smart
singulators, sorters and high-speed gappers, which may help companies realize
more automation in their operations to meet the changing demands of e-commerce.







WANT TO LEARN MORE ABOUT HOW ETHERCAT ENHANCES TODAY’S DISTRIBUTION AND
FULFILLMENT CENTERS? CONTACT YOUR LOCAL BECKHOFF SALES ENGINEER TODAY.








 







Doug Schuchart is the Material Handling & Intralogistics Industry Manager for
Beckhoff Automation LLC.






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 * EtherCAT

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