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Copyright of Machine Tool & Hydraulics is the property of Guangzhou Mechanical Engineering Research Institute (GMERI) and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

To address the issues of low bandwidth, weak real-time performance, and poor synchronization in traditional fieldbuses for multi-axis motion control, a solution for the implementation of an EtherCAT master based on the IgH EtherCAT Master open-source software framework and an embedded hardware platform is proposed. On a hardware platform centered around the AM64x Sitara processor, a Linux real-time operating system based on the Xenomai real-time kernel is constructed, and the IgH master framework is ported to realize a high-performance EtherCAT master. The configuration process of the EtherCAT bus is detailed, a master application program is developed, and methods for the real-time performance optimization of the master—such as exclusive CPU usage by the master process and the optimization of the network card driver—are proposed. Finally, experiments are conducted on a six-axis servo control platform, with the packet analysis of the periodic EtherCAT data frames sent by the master. The experimental results show that the optimized master, under a high-speed communication cycle of 500 microseconds, maintains maximum jitter within 20 microseconds and average jitter within 1 microsecond, meeting the requirements for high-precision multi-axis motion control. [ABSTRACT FROM AUTHOR]

This paper presents a modular hardware control system tailored for industrial applications. The system presented is designed with electrical protection, guaranteeing the reliable operation of its modules in the presence of various field noises and external disturbances. The modular architecture comprises a principal module (mP) and dedicated expansion modules (mEXs). The principal module serves as the network administrator and facilitates interaction with production and control processes. The mEXs are equipped with sensors, conditioning circuits, analog-to-digital converters, and digital signal processing capabilities. The mEX's primary function is to acquire local processing field signals and ensure their reliable transmission to the mP. Two specific mEXs were developed for industrial environments: an electrical signal expansion module (mSE) and the vibration signals expansion module (mSV). The EtherCAT protocol serves as a means of communication between the modules, fostering deterministic and real-time interactions while also simplifying the integration and replacement of modules within the modular architecture. The proposed system incorporates local and distributed processing in which data acquisition, processing, and data analysis are carried out closer to where data are generated. Locally processing the acquired data close to the production in the mEX increases the mP availability and network reliability. For the local processing, feature extraction algorithms were developed on the mEX based on a Fast Fourier Transform (FFT) algorithm and a curve-fitting algorithm that accurately represents a given FFT curve by significantly reducing the amount of data that needs to be transmitted over the mP. The proposed system offers a promising solution to use computational intelligence methodologies and meet the growing need for a modular industrial control system with reliable local data processing to reach a smart industry. The case study of acquiring and processing vibration signals from a real cement ball mill showed a good capacity for processing data and reducing the amount of data. [ABSTRACT FROM AUTHOR]

Copyright of Cyber Security & Data Governance is the property of Editorial Office of Information Technology & Network Security and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

Recent advances in industrial, railway, and in-vehicle communications demand network architectures that ensure low latency, high synchronization, and efficient bandwidth utilization. While Ethernet for Control Automation Technology (EtherCAT) effectively handles real-time cyclic traffic, managing non-real-time acyclic traffic, such as Ethernet/IP frames, remains challenging. Existing Ethernet-over-EtherCAT (EoE) schemes struggle to balance these traffic types, resulting in inefficient bandwidth use and increased latency under high network loads. To overcome these challenges, we propose an adaptive grouping mechanism for acyclic secondary devices, coupled with a dynamic telegram assignment method, to optimize bandwidth utilization and reduce delay for acyclic traffic without compromising the performance of the cyclic secondary devices traffic. Extensive simulations demonstrate that our approach reduces packet delay and increases bandwidth utilization, even in networks with a large number of acyclic secondary devices. Specifically, the simulation results reveal that our approach achieves up to a 99% reduction in the mean packet delay and significantly enhances bandwidth utilization, making it suitable for complex industrial applications where high performance and scalability are essential. This work offers a practical solution for advancing EtherCAT’s capability to support diverse traffic types in demanding communication environments.

RISC-V offers a modular technical approach combined with an open, royalty-free instruction set architecture (ISA). However, despite its advantages as a fundamental building block for many embedded systems, the escalating complexity and functional demands of real-time applications have made adhering to response time deadlines challenging. For real-time applications of RISC-V, real-time performance analysis is required for various ISAs. In this paper, we analyze the real-time performance of RISC-V through two real-time approaches based on processor architectures. For real-time operating system (RTOS) applications, we adopted FreeRTOS and evaluated its performance on HiFive1 Rev B (RISC-V) and STM3240G-EVAL (ARM M). For real-time Linux, we utilized Linux with the Preempt-RT patch and tested its performance on VisionFive 2 (RISC-V), MIO5272 (x86-64), and Raspberry Pi 4 B (ARM A). Through these experiments, we examined the response times on the real-time mechanisms of each operating system. Additionally, in the Preempt-RT experiments, scheduling latencies were evaluated by means of the cyclictest. These are very important parameters for implementing real-time applications comprised of multi-tasking. Finally, in order to show the real-time capabilities of RISC-V practically, we implemented motion control of a six-axis collaborative robot, which was performed on the VisionFive 2. This implementation provided a comparative result of RISC-V's performance against the x86-64 architecture. Ultimately, the results indicated that the real-time performance of RISC-V for real-time applications was feasible. A noticeable achievement of this research is its first implementation of an EtherCAT master on RISC-V designed for real-time applications. The successful implementation of the EtherCAT master on RISC-V shows real-time capabilities for a wide range of real-time applications. [ABSTRACT FROM AUTHOR]

The increasing demand for rapid application development tools, especially those employing high-level languages such as Python, has underscored the importance of utilizing a wide array of popular libraries while addressing real-time constraints in distributed hardware systems. This paper introduces PyIgH, a unified architecture of an IgH EtherCAT master based on Python, specifically designed to satisfy hard real-time requirements in an EtherCAT network. Implemented as a Python module, PyIgH exposes the functionalities and capabilities of an open-source EtherCAT master, facilitating seamless configuration and control of EtherCAT slave devices within the Python runtime environment. Real-time adaptation of the POSIX library, encapsulated within Python, is also utilized to satisfy the timing requirements of EtherCAT. The feasibility of the proposed approach is verified by analyzing the real-time performance in terms of periodicity and in-controller delay of the EtherCAT control task with a 1 kHz cycle. Experimental results demonstrate that PyIgH is suitable for hard real-time applications and serves as a valid alternative to conventional low-level EtherCAT masters. Additionally, a practical application involving motion control of a six-axis collaborative robot showcases consistent performance of PyIgH within a real-time multi-tasking environment. • A Python-based EtherCAT master for distributed hard real-time control systems. • Configuration and control of EtherCAT devices within the Python runtime environment. • Comprehensive performance analysis compared with conventional and existing solutions. • Practical experiments on a 6-axis collaborative robot motion control for validation. • Potential to integrate AI models with real-time tasks and control EtherCAT devices. [ABSTRACT FROM AUTHOR]