EtherCAT Master Dummy ESC for Synchronization Jitter Reduction
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Solution Overview
Problem
Existing EtherCAT control devices face timing synchronization challenges between a master and slaves, particularly in high-speed and precise control scenarios, leading to synchronization jitter that can cause errors in motor operations of robots.
Innovation Solution
The implementation of a dummy EtherCAT Slave Controller (ESC) in the master device, using the Precision Time Protocol (PTP) method, allows for synchronization between the master and slaves, enabling the master to operate as a time slave and slaves to synchronize with each other, thereby reducing jitter and ensuring precise timing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional EtherCAT timing synchronization is used between master and slave, then data communication control is achieved, but synchronization jitter occurs leading to timing errors in high-speed operations
Solution Approach 1:
The patent introduces a dummy ESC as an intermediary component within the master device. This dummy ESC acts as a mediator that generates reference timing signals independent of the actual slave controllers, allowing the master to synchronize with slaves using a stable reference clock rather than relying on potentially jittery slave timing feedback. The dummy ESC's timing signals serve as a buffer between the master's operational commands and the slaves' execution, eliminating the synchronization jitter that occurs in traditional master-slave timing protocols.
2Productivity
If the master operates as a time master in traditional EtherCAT, then control commands are issued to slaves, but timing synchronization jitter causes errors in motor operations
Solution Approach 1:
The dummy ESC performs preliminary timing preparation by pre-calculating and buffering timing reference signals before actual motor operations occur. The master device uses these pre-prepared timing references from the dummy ESC to issue control commands at high speed without waiting for slave feedback timing adjustments. This preliminary timing preparation ensures that even high-speed control commands maintain precise synchronization with slave execution, preventing the timing jitter that would otherwise cause motor operation errors.
3Reliability
If synchronization is performed using slave ESCs according to PTP method, then timing coordination between slaves is achieved, but the master-slave synchronization jitter persists
Solution Approach 1:
The patent creates a timing equipotential state by having the master device synchronize with slaves using reference clocks from the dummy ESC rather than allowing slaves to negotiate timing among themselves. All slaves receive timing references from the same master-generated source (dummy ESC), placing them all at the same timing potential level. This eliminates the cumulative timing drift and synchronization loss that occurs when slaves attempt to coordinate timing independently through PTP methods, ensuring consistent timing coordination without time loss.
Data Source
AI summary
An EtherCAT control device and a factory automation system having the same are provided. The EtherCAT control device includes a master including a dummy EtherCAT slave controller (ESC) and a first slave configured to communicate data with the master according to an EtherCAT protocol, such that the master synchronizes a timing with the first slave according to a precision time protocol (PTP) method using the dummy ESC.


