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EtherCAT is Ethernet for Control Automation Technology.

It is a technology based on Ethernet and was developed specifically with industrial automation in mind.

EtherCAT uses standard frames as well as the physical layer as characterized in IEEE 802.3 Ethernet Standard however it addresses some specific concerns for industrial automation such as Rapid response times, minimal data requirements for each device, and costs for implementation.

Ethernet is not a practical solution for many industrial applications as it routes frames of data to and from a vast number of separate addresses, individually, where the data may be something as simple as a single register to obtain a real-time analog reading.

This node-specific routing requires massive bandwidth as the data packets are only moved when the Master or Client requests the data.

EtherCAT, in contrast, uses the same physical and data link layers as Ethernet but the protocols deviate from there.

Ethernet, as stated previously, is able to route data through many different nodes, in a master/slave configuration, sending and receiving based on requests.

With EtherCAT, the master sends data, possibly only a single frame for the entire node network that will pass through each node.

The master is the boss and is the only node allowed to send a frame. The frame is then forwarded, downstream, by each node in the network. This approach helps to assure real-time operation and avoids delays.

Each EtherCAT device processes the data frame that is relevant to it in its hardware/software, on the fly, and adds its data to the data frame as it is passing through the network.

EtherCAT networks do not require external switches in the network. Each EtherCAT device typically has two Ethernet ports, the first port being the receiving port or previous node’s cable and the second port connected to the next node in the network.

The processing of the data, on the fly in the hardware of the device, is a major advantage of EtherCAT.

Although there is still a small delay in the data frame as the device adds its data to it, it is greatly reduced by the often single data stream of EtherCAT versus the multiple Ethernet frames used in an Ethernet network.

This advantage can also be a disadvantage. Many devices may not be able to handle these highly decreased cycle times and EtherCAT network may need to be slowed to accommodate these devices. Since the EtherCAT network can be slowed, mark the disadvantage as an advantage once again.

In conclusion, EtherCAT is Ethernet with some really nice bells and whistles.

Designed with the industrial arena in mind, EtherCAT has great advantages over the standard Ethernet network.

Those include drastically increased speed, reduced data traffic, decreased hardware cost for implementation, and more and more accurate data due to the distributed clock mechanism.

It’s increasing in popularity among controls engineers desiring a real-time and robust high-speed network for industrial controls.

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