How Beckhoff EtherCAT Terminals Enhance Real-Time Communication in Automation

In automation, speed and precision are everything, and that’s where Beckhoff EtherCAT terminals excel. Offering low latency and high processing speed, these devices have come to be a key part of automation systems.

EtherCATs are popular in industrial automation for their real-time performance and high-speed data transfers. These cost-effective, low-latency hardware are essential for applications like robotics and motion control.

Let’s delve into how EtherCAT terminals enable real-time communication, scalability, and efficiency in modern industrial systems.

Understanding EtherCAT Technology

EtherCAT (Ethernet for Control Automation Technology) is a real-time fieldbus protocol based on Ethernet. These use a Master/Slave Architecture where a single master device sends out data frames that are passed through in a cycle from all the connected (slave) devices. 

Here, each slave device extracts the data it needs, processes it, and adds to the data frame, enabling “On-the-fly” processing. Further, distributed clocks enable precise synchronisation, which is key to ensuring real-time process control.

Their key features include: 

• High-speed and low-latency
• Real-time deterministic communication
• Ultra-fast cycle times
• Flexible network topologies
• Easy synchronization
• Ease of integration 
• High scalability

What Are Beckhoff EtherCAT Terminals?

The Beckhoff EtherCAT Terminals are a modular, industrial, high-performance I/O terminal system manufactured by Beckhoff. These offer ultra-high-speed communication and come with a plug-and-play design for flexible installation. 

Owing to their compact design, these devices have a small physical presence and enable a dense I/O configuration. Further, this robust system features a solid build, secure contacting, flexible wiring, and reliable performance. 

Additionally, these are compatible with a wide range of sensors, actuators, and controllers, including those from other prominent manufacturers like Schneider Electric PAC Controllers.

Real-Time Communication in Automation Systems

Unlike traditional fieldbuses that operate at lower speeds, the EtherCAT leverages high-speed Ethernet to complete thousands of I/O updates per millisecond. These sub-millisecond cycle times pave the way for process optimization, building extremely low-latency systems. 

Instead of simple data exchange, they employ a “processing on the fly” method, with each connected device processing its own data from the Ethernet frame. Further, it is non-CPU-intensive with the Direct Memory Access (DMA) function.

In addition, these devices allow easy integration with IT systems and facilitate interoperability. Thus, these are compatible with several industrial devices, such as the Schneider Electric PAC Controllers, thus enabling effective communication between devices.

Advantages for Industrial Applications

In Industrial Applications, the Beckhoff EtherCAT Terminals offer the following:

• Scalability for small to large automation networks.
• High-speed communication with very low latency.
• Modular expansion without re-engineering the entire system.
• Flexible installation for a wide range of network topologies.
• High-precision synchronization for complex industrial applications.
• Efficient precision control in robotics, packaging, CNC machines, and process automation.
• Simplified, error-proof, pre-assembled wiring and reduced cabling costs.
• Integrated power and signal transmission.
• Simplified installation and commissioning with automatic addressing.
• Energy efficiency, reduced CPU load, and lower overall system costs.
• Easy integration with third-party devices.

Reliability, Diagnostics, and Safety Features

The Beckhoff EtherCAT Terminals offer continuous monitoring and error detection of the connected industrial network. The hot-connect and distributed clock features help cut back on system downtime by allowing operators to add and remove modules while the system is active. 

The advanced diagnostic features allow fast and comprehensive error detection. Additionally, the cable redundancy can be set to create a fault-tolerant network. Thus, your industrial processes get to enjoy simultaneous actions, precise coordination between industrial components, a reduction in Master Load, and high jitter tolerance. 

Alongside the above, you also get integrated safety functions via Safety over EtherCAT (FSoE). FSoE itself works on the principle of “Black Channel”, i.e., the EtherCAT communication itself is not considered to be safety critical. 

To facilitate data safety over networks, the safety data is embedded and transported with the standard EtherCAT data frames. The device also enables integrity checks, which are taken up in each safety cycle. 

A Brief Comparison: Beckhoff EtherCAT Terminals vs. Traditional Fieldbus Systems

Here’s how well the Beckhoff EtherCAT Terminals perform and what they offer compared to traditional Fieldbus systems:

Feature / Protocol	EtherCAT (Beckhoff Terminals)	Profibus	Modbus	CANopen
Communication Speed	Ultra-fast (sub-millisecond cycle times)	Medium (up to 12 Mbit/s)	Slow to medium (up to 10 Mbit/s)	Medium (1 Mbit/s typical)
Latency	Very low (deterministic, real-time)	Moderate	Higher	Moderate
Scalability	Highly scalable; modular plug-and-play I/O	Limited expansion	Moderate	Good but less flexible
Wiring or Cabling	Simplified with standard Ethernet cables	Requires special Profibus cables	Serial/RS-485 wiring	Requires specific bus cabling
Diagnostics	Advanced error detection, live status monitoring	Limited diagnostics	Minimal	Basic
Synchronization	Distributed clocks for precise timing	Limited	None	Limited
Safety Integration	Built-in via Safety over EtherCAT (FSoE)	A separate safety system is required	Not supported	Limited
Future Readiness	Industry 4.0 and IIoT ready	Legacy technology	Legacy use	Moderate adoption

Table 1: Comparison between the different industrial communication systems.

Future-Proofing with Beckhoff EtherCAT Terminals

By opting for Beckhoff EtherCAT Terminals, you can future-proof your industry in the following ways:

• EtherCAT involves continuously evolving and upgrading the system instead of replacing it.
• The newer terminals are designed to optimize circuit architecture, ensuring future viability.
• The EtherCAT technology is scalable without replacing the established 100 Mbit/s technology.
• They can be integrated with PC-based control
• It supports Industry 4.0 and IIoT applications, alongside digitalization initiatives like process optimization and plant modularization.
• They offer seamless integration with modern controllers and cloud systems.
• The device is built for long-term availability by adapting to evolving industrial automation needs.

Wrapping Up

Beckhoff EtherCAT terminals provide ultra-fast, reliable, and scalable communication. This makes them the cornerstone for industries looking to optimize automation performance.  With Beckhoff’s commitment to long-term availability, the devices they offer stay reliable and efficient for years to come.

Effective Industrial Communication With Beckhoff EtherCAT Terminals

Are you, as an automation engineer or manufacturer, aiming for the next automation upgrade? Check out Beckhoff EtherCAT terminals and associated products or book a demo or consultation with an automation solutions provider.