A Platform for Constructing Precision Electric Drive Control Systems Based on the EtherCAT Industrial Fieldbus
DOI:
https://doi.org/10.24160/1993-6982-2025-4-31-36Keywords:
mechatronic systems, EtherCAT, real time control systems, Linux, open-source softwareAbstract
EtherCAT fieldbus technology is intended to construct systems for real-time control of precise mechatronic systems. In many cases it can be convenient to deploy the EtherCAT master device on a PC along with other drivers, software components, and user interfaces. In that case, the use of the Beckhoff TwinCAT software would be a commonly adopted solution. Unfortunately, in view of the currently existing political environment, this software is not accessible. The aim of the article is to find a solution that would make it possible to set up a platform for designing an electric drive control system using the EtherCAT industrial fieldbus entirely on the basis of open-source software components. Such solution would make it possible to ensure production security of domestic equipment manufacturers. The proposed solution is based on an open-source Ubuntu operating system with a patched core, tuned to ensure high-performance real-time synchronization of the algorithms computed in the master and slave devices. For implementing the EtherCAT master’s stack, the open-source IgH EtherCAT master software was chosen. For developing the web-application for the human machine interface, the CppCMS open-source software development tool was used. Experiments were carried out, the results of which have shown that the proposed platform can technically replace TwinCAT in the field of precision mechatronics with an acceptable cycle time jitter of a few microseconds at the considered EtherCAT bus cycle frequencies of 1 kHz and 4 kHz. However, the newly proposed platform has a significant drawback in comparison with TwinCAT, which has been under development for several years to fit the specifics of EtherCAT fieldbus. The proposed tool is currently far from being quite convenient for a developer and requires far more competences in information technologies, networking, and low-level code development skills. The future efforts will be taken to improve the platform and supplement it with tools to expedite commercialization of domestically produced systems based on the EtherCAT industrial fieldbus.
References
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27. Bejlis (Tonkih) A. Case Study: CppCMS Benchmarks vs Java, C#, PHP [Электрон. ресурс] http://cppcms.com/wikipp/en/page/benchmarks_all (дата обращения 02.12.2024).
28. JSON-RPC 2.0 Specification [Электрон. ресурс] https://www.jsonrpc.org/specification (дата обращения 02.12.2024).
29. Atodiresei A., Băutu A., Simona D. Optimization of Sensor Data Gathering Interface for Platmarisc Project // Sci. Bulletin of Naval Academy. 2023. V. 26(2). Pp. 136—143.
---
Для цитирования: Осипов Д.А., Рассудов Л.Н. Платформа для построения систем управления прецизионными электроприводами по промышленной шине EtherCAT // Вестник МЭИ. 2025. № 4. С. 31—36. DOI: 10.24160/1993-6982-2025-4-31-36
#
1. Nguyen H., Nguyen T. P., Ngo H.Q.T. Using EtherCAT Technology to Launch Online Automated Guided Vehicle Manipulation with Unity-based Platform for Smart Warehouse Management. IET Control Theory and Appl. 2023;1:229—243.
2. Ghonge N. P. Computed Tomography in the 21st Century: Current Status and Future Prospects. J. Intern. Medical Sci. Academy. 2013;26:35—42.
3. Rosenblatt E., Zubizarreta E. Radiotherapy in Cancer Care: Facing the Global Challenge. N.-Y: Intern. Atomic Energy Agency, 2017.
4. Beckhoff Information System [Elektron. Resurs] https://infosys.beckhoff.com (Data Obrashcheniya 01.11.2024).
5. Calvo F. e. a. Intraoperative Radiotherapy with Electrons: Fundamentals, Results, and Innovation. Ecancermedicalscience. 2013;7:339.
6. Ivan M., Ernek M., Miklovicova E. TwinCAT Control of CNC Machine over CoE. Proc. XXII Intern. Conf. Process Control. Štrbské Pleso, 2019:91—96.
7. BECKHOFF Automation and IntraOp Medical of U.S.A. Innovative Radiation Therapy Uses Flexible PC-based Control Platform. PC Control Magazine. 2013;2.
8. Nwador A.F., Sanubi F.A., Clark E.V. Sanctions as Tool for Strategic Deterrence: an Assessment of Targeted Sanctions in Russia. J. Public Administration, Finance and Law. 2023;27:544—565.
9. EtherCAT Product Guide [Elektron. Resurs] https://www.ethercat.org/en/products.html (Data Obrashcheniya 01.12.2024).
10. Kollmorgen Automation Suite IDE User Manual EN [Elektron. Resurs]: https://www.kollmorgen.com/sites/default/files/2024-06/KAS_IDE_User_Manual.pdf (Data Obrashcheniya 02.12.2024).
11. CODESYS for Users [Elektron. Resurs] https://www.codesys.com/index.php?eID=tx_securedownloas&p=151&u=0&g=0&t=1727454954&hash=99216d01707bd2386e33d37e8a99afdb44f&file=/fileadmin/Download/EN/Brochures/CODESYS-Anwender-en.pdf (Data Obrashcheniya 02.12.2024).
12. Kithara RealTime EtherCAT [Elektron. Resurs] https://kithara.com/en/products/real-time-ethercat (Data Obrashcheniya 02.12.2024).
13. EtherCAT Realtime Master Library Documentation [Elektron. Resurs] https://www.sybera.de/download/manual_ect_clu_e.pdf (Data Obrashcheniya 02.12.2024).
14. KINGSTAR Fieldbus Powered by EtherCAT [Elektron. Resurs] https://kingstar.com/products/ethercat/ (Data Obrashcheniya 02.12.2024).
15. Koenig-pa GmbH. Files for Download [Elektron. Resurs] https://koenig-pa.de/files-download (Data Obrashcheniya 02.12.2024).
16. Programmnye Resheniya dlya Promyshlennoy Avtomatizatsii [Elektron. Resurs] https://visutechsystem.by/pdf/VS_Product_catalogue_RU.pdf (Data Obrashcheniya 11.11.2024). (in Russian).
17. EtherCAT SDK [Elektron. Resurs] https://docs.rt-labs.com/ethercat-sdk (Data Obrashcheniya 02.12.2024).
18. IgH EtherCAT Master 1.5.2 Documentation [Elektron. Resurs] https://docs.etherlab.org/ethercat/1.5/pdf/ethercat_doc.pdf (Data Obrashcheniya 02.12.2024).
19. Acontis EC-Master vs Open Source (IgH EtherCAT-Master (EtherLab) and Simple Open EtherCAT Master (SOEM)) [Elektron. Resurs] https://www.acontis.com/en/ethercat-master-options-ec-master-vs-open-source-etherlab-SOEM.html (Data Obrashcheniya 02.12.2024).
20. Delgado R., Choi B.W. Real-time Servo Control using EtherCAT Master on Real-time Embedded Linux Extensions. Intern. J. Appl. Eng. Research. 2017;12(21):11179—11185.
21. Oliveira D.B., Oliveira R.S. Timing Analysis of the PREEMPT RT Linux Kernel. Software Practice and Experience. 2015;46(6):789—819.
22. Choi B.W., Shin D.G., Park J.H., Yi S.Y., Gerald S. Real-time Control Architecture using Xenomai for Intelligent Service Robot in USN Environment. Intelligent Service Robotics. 2009;2(2):139—151.
23. Altenberg J. Introduction to Realtime Linux [Elektron. Resurs] https://www.youtube.com/watch?v=BKkX9WASfpI&t=2864s (Data Obrashcheniya 02.12.2024).
24. Rassudov L.N. i dr. Razrabotki Opytnykh Obraztsov Avtomaticheskikh Transportnykh Liniy s Pryamym Elektroprivodom. Elektrichestvo. 2023;4:44—54. (in Russian).
25. Rassudov L. e. a. Digital Twin Implementation for Accelerating the Development of Flexible Transportation System Control Software. Proc. IEEE 62nd Intern. Sci. Conf. Power and Electrical Engineering of Riga Technical University. Riga, 2021:1—4.
26. Bejlis (Tonkih) A. CppCMS — C++ Web Framework [Elektron. Resurs] http://cppcms.com/wikipp/ru/page/main (Data Obrashcheniya 02.12.2024).
27. Bejlis (Tonkih) A. Case Study: CppCMS Benchmarks vs Java, C#, PHP [Электрон. ресурс] http://cppcms.com/wikipp/en/page/benchmarks_all (Data Obrashcheniya 02.12.2024).
28. JSON-RPC 2.0 Specification [Elektron. Resurs] https://www.jsonrpc.org/specification (Data Obrashcheniya 02.12.2024).
29. Atodiresei A., Băutu A., Simona D. Optimization of Sensor Data Gathering Interface for Platmarisc Project. Sci. Bulletin of Naval Academy. 2023;26(2):136—143
---
For citation: Osipov D.A., Rassudov L.N. A Platform for Constructing Precision Electric Drive Control Systems Based on the EtherCAT Industrial Fieldbus. Bulletin of MPEI. 2025;4:31—36. (in Russian). DOI: 10.24160/1993-6982-2025-4-31-36
2. Ghonge N. P. Computed Tomography in the 21st Century: Current Status and Future Prospects // J. Intern. Medical Sci. Academy. 2013. V. 26. Pp. 35—42.
3. Rosenblatt E., Zubizarreta E. Radiotherapy in Cancer Care: Facing the Global Challenge. N.-Y: Intern. Atomic Energy Agency, 2017.
4. Beckhoff Information System [Электрон. ресурс] https://infosys.beckhoff.com (дата обращения 01.11.2024).
5. Calvo F. e. a. Intraoperative Radiotherapy with Electrons: Fundamentals, Results, and Innovation // Ecancermedicalscience. 2013. V. 7. P. 339.
6. Ivan M., Ernek M., Miklovicova E. TwinCAT Control of CNC Machine over CoE // Proc. XXII Intern. Conf. Process Control. Štrbské Pleso, 2019. Pp. 91—96.
7. BECKHOFF Automation and IntraOp Medical of U.S.A. Innovative Radiation Therapy Uses Flexible PC-based Control Platform // PC Control Magazine. 2013. Iss. 2.
8. Nwador A.F., Sanubi F.A., Clark E.V. Sanctions as Tool for Strategic Deterrence: an Assessment of Targeted Sanctions in Russia // J. Public Administration, Finance and Law. 2023. Iss. 27. Pp. 544—565.
9. EtherCAT Product Guide [Электрон. ресурс] https://www.ethercat.org/en/products.html (дата обращения 01.12.2024).
10. Kollmorgen Automation Suite IDE User Manual EN [Электрон. ресурс]: https://www.kollmorgen.com/sites/default/files/2024-06/KAS_IDE_User_Manual.pdf (дата обращения 02.12.2024).
11. CODESYS for Users [Электрон. ресурс] https://www.codesys.com/index.php?eID=tx_securedownloas&p=151&u=0&g=0&t=1727454954&hash=99216d01707bd2386e33d37e8a99afdb44f&file=/fileadmin/Download/EN/Brochures/CODESYS-Anwender-en.pdf (дата обращения 02.12.2024).
12. Kithara RealTime EtherCAT [Электрон. ресурс] https://kithara.com/en/products/real-time-ethercat (дата обращения 02.12.2024).
13. EtherCAT Realtime Master Library Documentation [Электрон. ресурс] https://www.sybera.de/download/manual_ect_clu_e.pdf (дата обращения 02.12.2024).
14. KINGSTAR Fieldbus Powered by EtherCAT [Электрон. ресурс] https://kingstar.com/products/ethercat/ (дата обращения 02.12.2024).
15. Koenig-pa GmbH. Files for Download [Электрон. ресурс] https://koenig-pa.de/files-download (дата обращения 02.12.2024).
16. Программные решения для промышленной автоматизации [Электрон. ресурс] https://visutechsystem.by/pdf/VS_Product_catalogue_RU.pdf (дата обращения 11.11.2024).
17. EtherCAT SDK [Электрон. ресурс] https://docs.rt-labs.com/ethercat-sdk (дата обращения 02.12.2024).
18. IgH EtherCAT Master 1.5.2 Documentation [Электрон. ресурс] https://docs.etherlab.org/ethercat/1.5/pdf/ethercat_doc.pdf (дата обращения 02.12.2024).
19. Acontis EC-Master vs Open Source (IgH EtherCAT-Master (EtherLab) and Simple Open EtherCAT Master (SOEM)) [Электрон. ресурс] https://www.acontis.com/en/ethercat-master-options-ec-master-vs-open-source-etherlab-SOEM.html (дата обращения 02.12.2024).
20. Delgado R., Choi B.W. Real-time Servo Control using EtherCAT Master on Real-time Embedded Linux Extensions // Intern. J. Appl. Eng. Research. 2017. V. 12(21). Pp. 11179—11185.
21. Oliveira D.B., Oliveira R.S. Timing Analysis of the PREEMPT RT Linux Kernel // Software Practice and Experience. 2015. V. 46(6). Pp. 789—819.
22. Choi B.W., Shin D.G., Park J.H., Yi S.Y., Gerald S. Real-time Control Architecture using Xenomai for Intelligent Service Robot in USN Environment // Intelligent Service Robotics. 2009. V. 2(2). Pp. 139—151.
23. Altenberg J. Introduction to Realtime Linux [Электрон. ресурс] https://www.youtube.com/watch?v=BKkX9WASfpI&t=2864s (дата обращения 02.12.2024).
24. Рассудов Л.Н. и др. Разработки опытных образцов автоматических транспортных линий с прямым электроприводом // Электричество. 2023. № 4. С. 44—54.
25. Rassudov L. e. a. Digital Twin Implementation for Accelerating the Development of Flexible Transportation System Control Software // Proc. IEEE 62nd Intern. Sci. Conf. Power and Electrical Engineering of Riga Technical University. Riga, 2021. Pp. 1—4.
26. Bejlis (Tonkih) A. CppCMS — C++ Web Framework [Электрон. ресурс] http://cppcms.com/wikipp/ru/page/main (дата обращения 02.12.2024).
27. Bejlis (Tonkih) A. Case Study: CppCMS Benchmarks vs Java, C#, PHP [Электрон. ресурс] http://cppcms.com/wikipp/en/page/benchmarks_all (дата обращения 02.12.2024).
28. JSON-RPC 2.0 Specification [Электрон. ресурс] https://www.jsonrpc.org/specification (дата обращения 02.12.2024).
29. Atodiresei A., Băutu A., Simona D. Optimization of Sensor Data Gathering Interface for Platmarisc Project // Sci. Bulletin of Naval Academy. 2023. V. 26(2). Pp. 136—143.
---
Для цитирования: Осипов Д.А., Рассудов Л.Н. Платформа для построения систем управления прецизионными электроприводами по промышленной шине EtherCAT // Вестник МЭИ. 2025. № 4. С. 31—36. DOI: 10.24160/1993-6982-2025-4-31-36
#
1. Nguyen H., Nguyen T. P., Ngo H.Q.T. Using EtherCAT Technology to Launch Online Automated Guided Vehicle Manipulation with Unity-based Platform for Smart Warehouse Management. IET Control Theory and Appl. 2023;1:229—243.
2. Ghonge N. P. Computed Tomography in the 21st Century: Current Status and Future Prospects. J. Intern. Medical Sci. Academy. 2013;26:35—42.
3. Rosenblatt E., Zubizarreta E. Radiotherapy in Cancer Care: Facing the Global Challenge. N.-Y: Intern. Atomic Energy Agency, 2017.
4. Beckhoff Information System [Elektron. Resurs] https://infosys.beckhoff.com (Data Obrashcheniya 01.11.2024).
5. Calvo F. e. a. Intraoperative Radiotherapy with Electrons: Fundamentals, Results, and Innovation. Ecancermedicalscience. 2013;7:339.
6. Ivan M., Ernek M., Miklovicova E. TwinCAT Control of CNC Machine over CoE. Proc. XXII Intern. Conf. Process Control. Štrbské Pleso, 2019:91—96.
7. BECKHOFF Automation and IntraOp Medical of U.S.A. Innovative Radiation Therapy Uses Flexible PC-based Control Platform. PC Control Magazine. 2013;2.
8. Nwador A.F., Sanubi F.A., Clark E.V. Sanctions as Tool for Strategic Deterrence: an Assessment of Targeted Sanctions in Russia. J. Public Administration, Finance and Law. 2023;27:544—565.
9. EtherCAT Product Guide [Elektron. Resurs] https://www.ethercat.org/en/products.html (Data Obrashcheniya 01.12.2024).
10. Kollmorgen Automation Suite IDE User Manual EN [Elektron. Resurs]: https://www.kollmorgen.com/sites/default/files/2024-06/KAS_IDE_User_Manual.pdf (Data Obrashcheniya 02.12.2024).
11. CODESYS for Users [Elektron. Resurs] https://www.codesys.com/index.php?eID=tx_securedownloas&p=151&u=0&g=0&t=1727454954&hash=99216d01707bd2386e33d37e8a99afdb44f&file=/fileadmin/Download/EN/Brochures/CODESYS-Anwender-en.pdf (Data Obrashcheniya 02.12.2024).
12. Kithara RealTime EtherCAT [Elektron. Resurs] https://kithara.com/en/products/real-time-ethercat (Data Obrashcheniya 02.12.2024).
13. EtherCAT Realtime Master Library Documentation [Elektron. Resurs] https://www.sybera.de/download/manual_ect_clu_e.pdf (Data Obrashcheniya 02.12.2024).
14. KINGSTAR Fieldbus Powered by EtherCAT [Elektron. Resurs] https://kingstar.com/products/ethercat/ (Data Obrashcheniya 02.12.2024).
15. Koenig-pa GmbH. Files for Download [Elektron. Resurs] https://koenig-pa.de/files-download (Data Obrashcheniya 02.12.2024).
16. Programmnye Resheniya dlya Promyshlennoy Avtomatizatsii [Elektron. Resurs] https://visutechsystem.by/pdf/VS_Product_catalogue_RU.pdf (Data Obrashcheniya 11.11.2024). (in Russian).
17. EtherCAT SDK [Elektron. Resurs] https://docs.rt-labs.com/ethercat-sdk (Data Obrashcheniya 02.12.2024).
18. IgH EtherCAT Master 1.5.2 Documentation [Elektron. Resurs] https://docs.etherlab.org/ethercat/1.5/pdf/ethercat_doc.pdf (Data Obrashcheniya 02.12.2024).
19. Acontis EC-Master vs Open Source (IgH EtherCAT-Master (EtherLab) and Simple Open EtherCAT Master (SOEM)) [Elektron. Resurs] https://www.acontis.com/en/ethercat-master-options-ec-master-vs-open-source-etherlab-SOEM.html (Data Obrashcheniya 02.12.2024).
20. Delgado R., Choi B.W. Real-time Servo Control using EtherCAT Master on Real-time Embedded Linux Extensions. Intern. J. Appl. Eng. Research. 2017;12(21):11179—11185.
21. Oliveira D.B., Oliveira R.S. Timing Analysis of the PREEMPT RT Linux Kernel. Software Practice and Experience. 2015;46(6):789—819.
22. Choi B.W., Shin D.G., Park J.H., Yi S.Y., Gerald S. Real-time Control Architecture using Xenomai for Intelligent Service Robot in USN Environment. Intelligent Service Robotics. 2009;2(2):139—151.
23. Altenberg J. Introduction to Realtime Linux [Elektron. Resurs] https://www.youtube.com/watch?v=BKkX9WASfpI&t=2864s (Data Obrashcheniya 02.12.2024).
24. Rassudov L.N. i dr. Razrabotki Opytnykh Obraztsov Avtomaticheskikh Transportnykh Liniy s Pryamym Elektroprivodom. Elektrichestvo. 2023;4:44—54. (in Russian).
25. Rassudov L. e. a. Digital Twin Implementation for Accelerating the Development of Flexible Transportation System Control Software. Proc. IEEE 62nd Intern. Sci. Conf. Power and Electrical Engineering of Riga Technical University. Riga, 2021:1—4.
26. Bejlis (Tonkih) A. CppCMS — C++ Web Framework [Elektron. Resurs] http://cppcms.com/wikipp/ru/page/main (Data Obrashcheniya 02.12.2024).
27. Bejlis (Tonkih) A. Case Study: CppCMS Benchmarks vs Java, C#, PHP [Электрон. ресурс] http://cppcms.com/wikipp/en/page/benchmarks_all (Data Obrashcheniya 02.12.2024).
28. JSON-RPC 2.0 Specification [Elektron. Resurs] https://www.jsonrpc.org/specification (Data Obrashcheniya 02.12.2024).
29. Atodiresei A., Băutu A., Simona D. Optimization of Sensor Data Gathering Interface for Platmarisc Project. Sci. Bulletin of Naval Academy. 2023;26(2):136—143
---
For citation: Osipov D.A., Rassudov L.N. A Platform for Constructing Precision Electric Drive Control Systems Based on the EtherCAT Industrial Fieldbus. Bulletin of MPEI. 2025;4:31—36. (in Russian). DOI: 10.24160/1993-6982-2025-4-31-36
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Published
2025-06-24
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Electrical Complexes and Systems (2.4.2)
