Issue 01/2015
the automation bus magazine
In the context of Industry 4.0
Tradition & innovation
25 years of Sercos International –
10 years of Sercos® III technology:
a review
How Sercos contributes to the
implementation of Industry 4.0
Perfect synchronization with
Phoenix Contact's Axioline
I/O-system and Sercos
Cover Story
Dear readers,
Sercos International: 25 years of
commitment to tradition and innovation
At the beginning there was a clearly defined objective: the Sercos® founders – made up of drive and
control system suppliers – wanted to define an open
standard for the upcoming digital drive technology
together with the machine manufacturers, with hard
real-time capability as the ultimate benchmark.
Over the course of time, Sercos has developed from
a specific drive interface into a universal automation
bus. It is characterized by its open technology and
vendor independence and thus guarantees users and
manufacturers high investment security.
Today, modern data bus systems not only allow machines and facilities to carry out production with safety and precision, but also support consistency across
the various hierarchical levels of a factory, in the mold
of Industry 4.0.
As a universal automation bus, Sercos meets these
demands: Excellent performance and real-time capability, a multi protocol-enabled network infrastructure,
and a universal manufacturing data model to unify
the exchange of information within machines and facilities with superior IT systems. With this approach,
Sercos became the first choice for countless market
leaders in machinery and plant manufacturing.
New Products
New Sercos brochure
This was Sercos 2014!
Free Sercos webinars
Events 2015
Cover Story
Implementing the vision of
Industry 4.0 with Sercos technology
Communicate flexibly and
continuously with Sercos
Market shares of fieldbuses
and Industrial Ethernet
Exact positioning based on Sercos III
and the Axioline I/O system
Cover Story
Slip rings for Sercos networks
OPC UA Companion Specification announced
for Sercos
AS-i Safety and Sercos –
two complementary angles
We hope you enjoy reading…
New Products
Altera Corporation
BWO Elektronik GmbH
Morgan Rekofa GmbH
Sercos International e.V.
Review & Outlook
SPS IPC Drives 2014
SPS IPC Drives 2015 in Parma, Italy
New Products
Review & Outlook
New Sercos
This was Sercos
Worldwide – independent – open –
cross-linked: That’s Sercos!
You know the user organization and the technology but may not really know what we do
year after year? Then have a look at our 2014
annual review (data is compared to 2013):
Into the future with
tradition and innovation
In this current edition of Sercos News you will find
reports about the latest developments and trends related to the Sercos automation bus.
Peter Lutz
Managing Director
Sercos International e.V.
Review & Outlook
This brochure gives you an insight into the user organization: who we are, what we do, how we use our know-how
for your success, and how members contribute to build the
network of the future.
You will also learn more about the benefits of becoming a
member and the advantages your company can gain from
a Sercos membership.
This brochure can be downloaded online or requested via
E-mail at
In 2014, Sercos International recorded a growth in membership of approximately 30%. In addition to new members in
Europe, the user organization saw a strong growth in China
and Japan.
Become part of the Sercos community!
You will find more information on this subject on > Organization.
Membership growth of approximately 30%.
Continuously increasing presence in print and
online media: in 2014, we increased our presence
by more than 20%.
Growing interest in Sercos®: the number of readers
of Sercos articles rose by 2/3.
1,500 contacts gathered during 11 events, among
them leading exhibitions such as Hanover Fair and
SPS IPC Drives in Nuremberg, both in Germany;
but also many smaller, more regional events such
as MC4 in Bologna, Italy.
More than 30,000 direct mailings sent alone in Europe.
19 webinars in German and English related to
technology and industry topics.
An increase in visitors to our new website greater
than 20%.
Plus, a number of new brochures such as the “Quick route to
Sercos”, the updated Sercos III brochure and Product Guide
were produced. The latter now features around 300 products
from approximately 130 vendors from different industries.
Cover Story
New Products
Review & Outlook
Hanover Fair 2
O4/13 – O4/1
Hanover - Germ
“Topology – Part I”
“Sercos certification”
“Topology – Part II”
“Configuration of real-time data”
Webinar: Topo
logy – Part I
online event
“Service channel handling”
Free Sercos webinars
For three years Sercos International has offered interested parties the opportunity for free
personal development with its webinars – and participation is continuously on the rise!
These online events feature technical and industry-specific
topics and offer the opportunity for questions and dialogue.
Recorded webinars can also be downloaded after a short
registration so that interested parties can listen/watch
whenever it suits best.
Topology is one of the technical topics in the second quarter this year and, due to the extensive content, you will find
two webinars on this item.
Rigobert Kynast, Bosch Rexroth AG, Technical Leader
Sercos® III communication at Sercos International e.V., explains in the first part Sercos devices with two ports and
two connectors as well as the difference between physical and logical topologies. He will also give an example of
simple physical topologies. The webinar also covers how a
device detects the existing topology and how a topology
extension with integrated power connection works.
The webinar on June 17 will cover the internal topology
of a Sercos slave, the signaling of the internal topology in
the device status, and topology properties of multi-slave
devices. Kynast will also talk about topology changes by
the master via device control and topology switching by the
In addition to these technical webinars, Peter Lutz,
Managing Director at Sercos International, will cover the
benefits of gaining a Sercos certification in a webinar on
May 6. He will also speak about the guidelines by which
devices are tested and introduce tools, that can be used
by companies to carry out a pre-test check. Lutz will complete the webinar by introducing authorized laboratories for
Sercos certification.
Webinars in the second half of 2015 will cover the configuration of real-time data, service channel handling, diagnosis
and more.
All webinars are scheduled for 30 minutes plus additional
time for a general exchange and questions. The webinars
will all begin at 16:00 CET (Central European Time). You can
register via > News & Events.
Neue Produkte
Webinar: Serco
s certification
, online event
ves Italia 2O1
O5/12 – O5/
Parma – Italy
Rückblick & Vorschau
Industrial Ope
n Network
(ION) Roadsho
O7/O7 & O7
Osaka & Tok
yo – Japan
O8/24 – O8/2
Mumbai – India
16. PlugFest
Date & locat
ion to be dete
Industrial Autom
ation Show
11/1O – 11/
Shanghai – Chin
15. PlugFest
O5/2O – O5/
Stuttgart - G
ves 2O15
11/24 – 11/2
Nuremberg - Ge
Webinar: Topo
logy – Part II
, online event
Industrial Tech
nology Eff icien
, Segrate - It
System Contro
l Fair
12/O2 – 12/O
Tokyo – Japan
Machine Automa
, Segrate - It
Cover Story
New Products
Review & Outlook
Cover Story
Friedrich Scheurer: Sercos applies a summation frame to
provide maximum payload content in an Ethernet telegram
and provides a non-gradable ratio of user data compared
to telegram overhead. To illustrate this, please imagine
how busses and cars utilize the space on the road. The car
stands for individual telegrams between devices and the
bus represents the summation frame. You can decide by
yourself which is consuming fewer resources. The Sercos
approach is the best prerequisite for your applications in the
Smart Factory of today and tomorrow.
Friedrich Scheurer
Sales Product Management Sercos Technology
Bosch Rexroth AG
Implementing the vision of
Industry 4.0 with Sercos technology
An interview with Friedrich Scheurer, Sales Product Management Sercos Technology at
Bosch Rexroth AG
Sercos International: Mr. Scheurer, Industry 4.0 is the hot
topic in industry. What is the relationship of Industry 4.0
and Sercos® and what does Sercos contribute to it?
Friedrich Scheurer: Industry 4.0 summarizes trends in
industrial communication to increase the efficiency of industrial processes by independent interaction of machines,
storage systems and other equipment. This is called the 4th
industrial revolution, coming after mechanization, electrification or mass production and digitization.
Transparent and integrated networking is the foundation
for effective interaction. Standard Ethernet connects every
component along all automation levels.
However, it is important to define standardized protocols
and their semantics. In addition to OPC-UA for vertical integration, Sercos combined with non-real-time applications
is ideal for networking of future production processes.
Because Sercos is directly based on Standard Ethernet
with all networking opportunities available at any time.
Sercos International: That is still very general, Mr. Scheurer.
How can you make this more visible and intelligible?
Friedrich Scheurer: Let’s have a look at the example of
energy efficiency. One important claim of the smart or intelligent factory is the increase in energy efficiency. This saves
costs and reduces CO2 emissions significantly. The Sercos
Energy profile provides mechanisms to monitor energy
consumption as well as tailored plant control (various energy modes for different loads; short, long and unplanned
breaks; manufacturer-independent profile).
An example of an application was shown at last year’s SPS
IPC Drives in Nuremberg with the “Transparent Machine
Tool Demo”. Applying Sercos energy makes you save twice.
In a standardized manner the existing functions of Sercos
are used to satisfy tasks of energy data acquisition and energy consumption control. Energy saving means cost saving.
Sercos International: Sercos is not the only Industrial
Ethernet variant that is based on Standard Ethernet. What
distinguishes Sercos?
Beyond that, Sercos is one of the few protocols in the automation world that combines this property with absolute
manufacturer independence and openness. Every company can collaborate, and all users benefit from the results.
All decisions made are based on democratic principles and
An initiative for a common network infrastructure for
Sercos and EtherNet/IP took effect in spring 2012. So
Sercos International and the ODVA are the only fieldbus
organizations known to me that get actively involved with
the reduction of the Babylonian confusion at the field level.
New Products
Review & Outlook
This is the fundamental idea of Sercos since the very beginning in the 1980s.
Sercos International: How does the integration of Sercosbased automation into vertical business processes inside
the Smart Factory work?
Friedrich Scheurer: For a few years now Sercos
International together with ODVA has been developing
how machines and monitoring systems can be integrated
into business processes. This is part of the “Optimization
of Machine Integration“ (OMI) Initiative. This extends far
beyond the particular Sercos activities. Publications can be
read at in the Pressroom.
Sercos International: Which concrete solutions are available and when will they arrive at customers?
Sercos International: In the discussion of Industry 4.0 we
often talk about cyber-physical systems (CPS). What is the
contribution of Sercos to CPS?
Friedrich Scheurer: Today, we at Bosch Rexroth can offer
you a solution to integrate Sercos netwoks into a superordinate infrastructure. An OPC-UA server in Bosch Rexroth
automation systems (e.g., IndraMotion MLC and MTX)
provides the available data and services within Sercos
networks as a standardized namespace to all OPC-UA
clients. There remote monitoring and control of any Sercos
element (node) is possible. Only the user or operator determines the purpose, let it be managerial or procedural.
Friedrich Scheurer: Cyber-physical systems are the smallest intelligent units to establish future cooperating control
networks. By the way, their implementation into production
is called cyber-physical production systems. Standardized
protocols are needed in order that these systems are able
to interact. This includes the semantics to equip these systems with a uniform “language”.
An example of an OPC-UA application could be seen at
last year’s SPS IPC Drives in Germany. Our exhibit, the
“Transparent Machine Tool”, visualized the workspace and
the state of chip removal by a tablet app. The update is carried out at an amazing cycle time of 1 ms. In an app – called
MTX monitor that uses OPC-UA as well – condition monitoring, diagnostics and tool data can be gathered.
Sercos offers exactly these language descriptions for the
total area of automation. Namely it is a very simple language of parameters for I/Os, drives and/or direct cross
communication between controls (C2C) and subsystems
(DCC), and all that in real-time. Indeed real-time is a requirement of the interaction between subsystems of networks
for value creation inside a Smart Factory.
This evolution towards networking between all kinds of devices increases transparency and maximizes controllability
of plants consisting of different subsystems.
Sercos International: The profile formation can be found in
other fieldbuses and Industrial Ethernet variants. How does
the user benefit from Sercos?
Friedrich Scheurer: First of all, Sercos provides – as mentioned before – the basic connectivity based on Standard
Ethernet. This way the integration into the IT world of a
company or your personal environment is already done for
the most part. Standard IP routing through devices of the
Sercos network or the simple connection to any free port
of the Sercos network allow access using any Standard
Ethernet device. Therefore engineering can be done from
everywhere and at any time.
Friedrich Scheurer: Sercos is not limited to just compatibility but offers interoperability between systems of various
manufacturers. Compatibility sounds good, but it means
only that systems fit together, they can be plugged together. Interoperability has much more added value. Systems
cooperate correctly and completely and are exchangeable.
Sercos International: Often Industry 4.0 is linked together
with integrated engineering. How does Sercos technology
facilitate that?
Cover Story
Sercos International: How shall I imagine this in detail?
Which particular measures have been taken?
Friedrich Scheurer: The entire capabilities of Sercos (except real-time) are mapped into an IP-based protocol. It is
called Sercos Internet Protocol Services (SIPS). One of the
purposes it was created for is the cooperation of engineering tools and devices in Sercos networks. Via SIPS, services
for configuration, parameterization, software update, diagnostics, commissioning and even non-real-time automation
can be realized. In short, the protocol is called “Sercos over
IP”. One of the main focuses is the acceleration of parameter. As opposed to the service channel, a single Ethernet
telegram is able to transfer a multitude of settings.
Sercos International: This means commissioning operations is simplified and accelerated. How do you react if an
unexpected error occurs?
New Products
Review & Outlook
Protocol Services (SIPS) are used in this case, since all
data, diagnostic information, parameters and status information is accessible over standard IP communication. If a
software update is necessary, the SIP services provide the
capability to do that.
Ingenious solution,
freedom in engineering
Sercos International: In a plant according to the concept
of Industry 4.0 we need many components. Can I get these
products from Sercos and who will help me?
Friedrich Scheurer: More than 200 Sercos III products
are included within the current product guide from Sercos
International. This is more than a 50% increase compared
to spring 2012. If we include Sercos I + II products there
are 135 manufacturers and more than 300 products. This
is a broad repertoire to realize almost every application
completely. Indeed, we from Bosch Rexroth are interested
that all users have enough choice in every device category.
Bosch Rexroth is actively
networking with most of
the Sercos device manufacturers. That is very successful and helps to optimize the interoperability of
the devices.
Sercos International: Are
you able to show us examples of the variety?
Friedrich Scheurer: Yes, you got that right. Not only in mass
(series) commissioning, where automated sequences load
configuration data, parameters or firmware into the automation devices, but also during prototype commissioning,
Sercos is very well prepared. If something goes wrong, we
connect the Sercos Monitor. This software tool collects all
important data within seconds and presents this information in a comprehensive view using a Windows GUI. The
Sercos Monitor can be downloaded as freeware from the
homepage of Sercos International (
downloads/tools/). In the simplest case it can be used with
just the Ethernet port or your computer.
The Standard Ethernet characteristics are very helpful even
in the unpleasant case of machine downtime. Due to the
transparency of the networks, every Sercos node is subject
to analysis. The Sercos standard defines diagnostic codes
and trace functions and uses the bandwidth of the Ethernet
technology. Among other techniques, the Sercos Internet
Friedrich Scheurer: This
is very simple. Just look
at the portfolio of Bosch
Rexroth. We offer all important device categories
including all relevant technologies from servo-controlled
pumps and electric and hydraulic drives, to general I/O,
both modular and block in IP20 or IP67. Also machine control panels, tightening systems, welding systems, motion
simulation systems and last but not least, automation
suites such as IndraMotion MLC, MLD, MTX; Sercos master solutions Sercans S and M including the Softmaster
Sercans XS with Sercos III. In particular, the Softmaster
Sercans XS is a very smart solution, where automation and
standard IT hardware come together. This solution enjoys
all its advantages with the next generation of Standard
Ethernet controllers, such as the Intel i210.
Freedom and efficiency redefined
Open Core Engineering increases software engineering efficiency and offers an unprecedented level of freedom through extended access to the control core: Independent creation of
customized functions with high-level languages, simultaneously running on your firmware as
well as on smart devices. Differentiate yourself from your competition and protect your
expert knowledge.
You can see: Sercos is one of the most mature fieldbuses,
if not the most mature one, but it did not collect dust. On
the contrary, it is fully future-oriented.
Sercos International: Thank you, Mr. Scheurer!
Bosch Rexroth AG
Cover Story
New Products
Review & Outlook
Communicate flexibly and
continuously with Sercos
In addition to real-time and safety-critical data, the Sercos transmission principle makes it possible
to transmit any other Ethernet protocol, such as EtherNet/IP and TCP/IP, via a common network
infrastructure. Additional cable or additional network components, such as gateways or switches,
are not required for this. To keep the cyclic and clocked communication of Sercos III intact, the
non-Sercos protocols are sent on the Unified Communication Channel (UCC), which is an integral
part of the Sercos transmission. This standard and multi-protocol-capable network infrastructure
enables engineers and users to reduce the costs and complexity of machine integration. At the
same time, they can retain their preferred product suppliers and automation devices without
additional hardware expense.
An increasing number of manufacturers are using Industrial
Ethernet solutions to implement new machine concepts
and to connect systems. The advantages over traditional
fieldbus systems are obvious. There is sufficient bandwidth
available to transmit safety-critical data as well as IT protocols via a common medium in addition to fast real-time data
interoperable. Moreover, most devices that support various real-time Ethernet protocols cannot coexist in a network. Most real-time Ethernet solutions use the network
on an exclusive basis, meaning that only devices of one’s
“own” protocol can be operated on the network. Devices
that support other real-time Ethernet protocols, as well as
standard Ethernet participants, can be connected only via
gateways or special switches (figure 1).
In addition, users and manufacturers benefit from the
use of standardized Ethernet hardware, such as passive
and active infrastructure components. However, a uniform standard remains a dream: There is a large number
of competing communication solutions, and although
they all use the Ethernet technology, they specify different protocols and profiles in the superimposed ISO/OSI
layers. Thus, devices that support different Industrial Ethernet standards are not compatible with each other or
Gateways make it possible to combine heterogeneous bus
systems – bus systems that differ in terms of their characteristics and protocol – with each other. However, such
protocol converters are highly complex, since the gateway
integrates into two bus systems and the mapping of the
protocols and data must be configured. Equipment costs
are also correspondingly high. A more economical and simple solution for coupling networks or network segments are
switches. However, this requires that the coupled bus systems be of the same type (e.g., coupling of Fast Ethernet
with Gigabit Ethernet) and that the “foreign” protocols do
not hamper the correct behavior of the real-time Ethernet
ISO/OSI model
ISO/OSI model
Bus system A (physics A + protocol A)
Bus system B (physics B + protocol B)
Figure 1: Use of network components to couple bus systems
Sercos® is pursuing a different path, as the Sercos transmission process allows Sercos devices and other Ethernet devices to be combined without additional hardware.
A logic system integrated into each Sercos device allows
the direct connection of Ethernet devices (see figure 2a).
The integrated switch monitors compliance with a defined period of time so that the real-time behavior of the
Sercos network is not negatively hindered. This process
also allows an external switch (see figure 2b) to be connected to any Sercos device.
Cover Story
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Review & Outlook
a) Connection of Ethernet devices with integrated switch
device 1
Dipl.-Ing. Peter Lutz
Managing Director
Sercos International e. V.
b) Connection of Ethernet devices with external switch
device 1
device 2
Figure 2: Use of switches to couple Sercos devices with any Ethernet
The Sercos transmission process
The Sercos transmission process is based on cyclical communication in which a Sercos III communication cycle is
subdivided into two time slots (channels) using time control
(figure 3). The collective telegrams specified by Sercos III
are transmitted as a broadcast in the real-time channel, and
are processed by the Sercos III devices during the cycle.
In contrast, any other Ethernet telegrams can be transmitted in the UCC. Communication cycles and the division of
the 100 Mbit/s bandwidth into the real-time and UCC can
be adjusted for each application. The highly efficient Sercos
telegrams ensure that only a part of the bandwidth is used
for the real data exchange.
D 3
For example, Sercos needs only about 400 microseconds
of a 2-millisecond cycle for an application with 64 drives.
Thus, there are 1.6 milliseconds available for the transmission of other protocols. Since the UC Channel sits directly
on the Ethernet layer, any Ethernet user can be connected
to the network without any additional hardware. Tunneling
of the protocols is not required. Even before a Sercos III
communication is initiated by the master, the network
users can exchange data, for example via TCP/IP or the S/IP
protocol specified by Sercos.
Since the common use of the cable has no negative impact
on the real-time behavior of the various protocols, they remain fully functional even in a common network infrastructure. Since the corresponding communication mechanisms
are already an integrated component of the Sercos transmission process, existing specifications do not need to be
altered with respect to this. Only a few simple installation
rules are to be followed when setting up the network infrastructure.
EtherNet/IP, TCP/IP, …
Sercos III
Sercos real-time channel
Ethertype = 0x88CD
HDR: Header
S3H: Sercos III header
Unified Communication Channel
Ethertype ≠ 0x88CD
MDT: Master Data Telegram (MDT):
AT: Reply telegram
MST: Master Sync Telegram
tcyc: Cycle time (31.25 µs … 65 ms)
t6: Start of the UC channel
t7: End of the UC channel
Figure 3: Transmission of Sercos, EtherNet/IP and TCP/IP protocols via a
cable using a time-multiplex procedure
Cover Story
Application example: Multi-protocol-capable
infrastructure for Sercos and EtherNet/IP
To clarify the possible application, the combination of
Sercos and EtherNet/IP devices is considered in the following: To control a mixed Sercos and EtherNet/IP network
infrastructure, a Sercos master and an EtherNet/IP scanner are required. These functionalities can be combined in
one single device (a dual stack master, see figure 4). If no
redundancy is required, the devices are connected in a line
topology. When the last Sercos device identifies a Sercosunknown device on its second Ethernet port, it transmits
only non-Sercos telegrams which are destined for other
devices. In the reverse direction, the device transmits
incoming telegrams via the first Ethernet port to the dual
stack master and uses the UCC to this end. Standard
Ethernet telegrams which come in during the time reserved
for the real-time channel will be retained and subsequently
When the application requires a Sercos ring for redundant
data transmission of real-time data and therefore no free
Sercos port is available, an IP switch must be integrated
into the ring. Its function is to connect and disconnect the
EtherNet/IP packets into the Sercos ring. The EtherNet/IP
devices can be arranged in different topology types: star
and line topologies as well as Device Level Ring (DLR). The
common infrastructure complements the Sercos solution
portfolio, as in addition to the extensive Sercos III product
New Products
With Sercos III, one solution covers the entire range of
communication needs in production: vertical integration
with office systems, synchronous control of multi-axis systems, data transfer between decentralized controls, and
the guaranteed transmission of safety-relevant information.
The multi-protocol capability of Sercos makes it possible
to transmit various communication protocols simultaneously via a common and uniform network infrastructure.
For example, EtherNet/IP and TCP/IP devices can coexist
with Sercos devices without the real-time characteristics or
the functionality of the individual protocols being hindered.
Thus gateways are not required, since the various protocols
can coexist and do not need to be mapped onto each other.
This promotes the necessary efficiency required for economical development of modern machines and facilities.
Thanks to Sercos, anyone who wants to develop their machines and facilities economically and easily can limit themselves to one solution and one cable for all applications, without having to accept losses in terms of flexibility and safety.
Cover Story
New Products
Review & Outlook
Source HMS:
Market shares of fieldbuses
and Industrial Ethernet
This estimate is based on the approximately 3 million fieldbus and Ethernet connections sold by HMS
worldwide to date in the field of production automation as well as an evaluation of current market
studies by well-known market research institutes.
There is no prospect of market saturation neither for fieldbuses nor for Industrial Ethernet. There are even additional
networks coming, such as Mechatrolink and CAN FD.
Standard I/O
Servo drives
Sercos III devices
(with integrated switches)
HMS anticipates stable growth for fieldbuses and Industrial
Ethernet. In 2015, fieldbuses continue to dominate with a
66% market share. The company sees the market share
for Ethernet-based systems at 34%. HMS expects growth
rates for fieldbuses in the single-digit percentage range,
while it anticipates growth rates for Industrial Ethernet in
the double-digit percentage range.
Dual Stack Master
range, EtherNet/IP devices of any manufacturer can now
also be used. With this concept, the number of communication interfaces and therefore the hardware complexity in
machines and facilities are significantly reduced. The continuous networking increases the operating efficiency in
engineering and in the operation of the facilities.
Motion Logic
Control / PLC
Standard I/O
Review & Outlook
These figures show that the transition from fieldbuses to
Industrial Ethernet is taking place much more slowly than
originally expected. Even though the growth rate percentages are considerably higher for Industrial Ethernet than for
fieldbuses, the number of installed fieldbus nodes is many
times higher than that of Ethernet nodes if one considers
the absolute figures.
Fieldbus versus Industrial Ethernet
Simplicity, low costs and reliability are reasons why fieldbuses are still being used.
High speed, larger data quantities, better real-time characteristics, the integration of safety protocols, energysaving and their pervasiveness into office networks make
Ethernet systems an interesting option for users.
EtherNet/IP devices
Figure 4: Combination of Sercos III and EtherNet/IP devices using the
example of a line topology
Cover Story
New Products
Review & Outlook
Cover Story
same chronological order creates opportunities to detect
precisely time-coordinated events and to execute movements correspondingly.
Carsten Henning and Stefan Pollert
Product Management I/O Systems
Phoenix Contact Electronics GmbH
Exact positioning based
on Sercos III and the
Axioline I/O system
The controls built into complex drive systems must fulfill the highest synchronization requirements.
Thanks to the combination of Sercos III and the Axioline I/O system from Phoenix Contact, events
can be detected precisely coordinated with respect to time, and movements can be executed in a
correspondingly synchronous fashion.
The term “synchronicity” can be described as the time simplification of two or several of the same processes. Many
people feel that simultaneousness is particularly aesthetic.
Synchronized divers or swimmers have been named as examples. Considered on their own, such flows of movement
may be precise and harmonious. However, if one attempts
to detect both actions at the same time, they show themselves as taking place at slightly different times and the
movements, which are actually synchronous, then seem
completely uncoordinated. So humans have only a limited
ability to take in and make sense of several identical flows
of movement that take place at slightly different times.
Therefore, the synchronization of two processes seems like
a simplification of complexity. Movements are brought into
chronological order based on the same computation of time.
Transferred to the solution of a technical task involving automation, synchronicity is about placing mechanical movements and electrical events into a logical chronology. Here,
signal transmission and processing plays a crucial role.
However, the different run times of signals in individual
components prove to be a problem. Mechanical devices
impact run times differently than electronic products. A
comparison of electronic systems reveals that there is a
different time impact on the signal run times in this case
as well. Here, lag times are referred to that make the
coordination of processes complex to varying degrees. If
the same tasks, such as the transmission of signals via
communication channels, can now be arranged in a uniform fashion, i.e. synchronized, this simplifies the entire
automation solution. In turn, such an arrangement with the
Only a few communication systems
offer synchronous signal transmission
The highest requirements are in a set of controls used in
complex drive systems, as found in packaging and woodprocessing machines or pick-and-place machines, for example. Precise synchronization is always required when
spatially distributed processes require identical actions, for
example if several servo axes are to implement simultaneously coordinated movements. In today’s automation technology environment, only a few communication systems
exist that can ensure synchronicity of signal transmission.
With Profinet IRT (Isochronous Real Time), applications
with cycle times of less than 31.25 microseconds and a
jitter of less than a microsecond can be implemented. This
is achieved via a process in which the signal run times
are clearly predetermined (deterministic). The Sercos® III
protocol works even more precisely. Here, the user can
implement cycle times of a minimum of 31.25 microseconds with a synchronization accuracy (jitter) of fewer than
20 nanoseconds. The high accuracy is achieved thanks to a
special time slot process. At present, the Ethercat system,
which is characterized by cycle times of less than 100 microseconds and a jitter smaller than a microsecond, holds
the largest market share among real-time communication
systems. The solution is based on the approach of precisely
harmonized, distributed clocks implemented into the slaves
designed for the synchronization tasks.
Analog input information available deterministically
and synchronously in the control
The application of a painting robot clarifies the advantages
offered by the synchronization of automation technology.
Source: Dürr AG
Figure 1: Exact spray head positioning and pressure
control by means of synchronous communication
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The complexity of a painting robot consists of driving a
spray head along a defined trajectory while applying the
paint to a car body with determined pressure (figure 1).
Such a robot typically consists of four to six individual axes.
In order to reach the target position of the spray head as
accurately and quickly as possible, the target positions
must be sent to all drives simultaneously. For this purpose,
Sercos III, which transfers the data to the drives serially, is
often used as a drive bus. However, the target positions of
the individual drives can be transmitted in synchronization
to each other, i.e. on a logically parallel basis.
The second challenge results from the pressure control
of the paint liquid. In the example described, an I/O station can be integrated into the Sercos network in which
the drives are installed. For the purposes of ascertaining
the paint quantity, both the pressure and the through-flow
velocity are of interest. Both pieces of information are captured by sensors with analog outputs and transferred to the
analog outputs of a Phoenix Contact Axioline I/O station.
Since a high control accuracy is achieved only if the analog input information is available deterministically and synchronously in the control, Axioline is particularly suitable for
implementing the task.
Fast I/O system renders expensive
control units superfluous
In the application example, the bus coupler synchronizes with the local bus on the Sercos cycle (figure 2). In
addition, the bus coupler knows the information relating
to the update time of the analog input. This is 250 microseconds with the standard analog inputs. In the painting
robot application, the Axioline local bus cycle amounts to
only 3 microseconds. This data proves to be important
for the synchronization of the Sercos devices so that a
universal synchronization time can be determined in the
Source: Phoenix Contact GmbH
Figure 2: The Axioline local bus synchronizes to the superimposed
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Schneider Electric’s
PacDrive 3 technology
Source: IMA Klessmann GmbH
Figure 3: Synchronous position detection for moving machine elements
Consequently, the analog input starts the measurement
253 microseconds before synchronization time so that
the analog data can be transferred to the Sercos cycle as
accurately as possible. This process allows absolutely deterministic and synchronous communication, even if the analog modules are found in two different I/O stations, since
the delays of various length cables are also compensated
for. Thus, the use of the synchronous Axioline I/O system
eradicates the need for expensive control units.
Wherever drives have to perform a positioning task, there
is a use for synchronous I/O systems. Another example is
the electric vertical drive shaft for moving movable machine
parts (figure 3). Here, several spatially separated SSI absolute encoders can detect the position of the element to be
moved, although in most cases each encoder is assigned
to a drive. Thanks to simultaneous reading of the SSI encoders, individual target/actual deviations compared to
other drives are determined in real-time, in addition to the
current position. This is especially important in cases where
mechanical elements are not to tilt. Therefore, several small
drives can move machine elements simultaneously easily
and cost-effectively using the synchronous position detection.
Schneider Electric’s PacDrive 3 technology incorporates the advantages of the latest
technologies into a proven concept for controlling modern production, assembly,
and packaging machines with a motion/robotic component. PacDrive 3 unifies PLC,
IT, and motion functionalities on a single hardware platform and is one of four hardware
platforms of MachineStruxure, Schneider Electric’s solution package for general
machinery applications. PacDrive 3’s scalable controller performance allows economical
automation of applications ranging from small systems with only a few servo axes to
high-performance solutions with up to 99 servo axes including multi robot applications.
With Sercos®, Schneider Electric has created a fully Ethernet-based communication
solution for PacDrive applications. Enabling communication with both drives and field
devices, Sercos also smoothes the way for the integration of safety automation:
In PacDrive 3, standard communication and safe communication merge into one Sercos is the basis. The Safe Logic Controller Modicon SLC permits programming
of the safety functions, the Modicon TM5/TM7 safe I/O system is connecting safety
signals to the SLC.
Whether the Sercos system or other transmission protocols are used with the synchronization function, the
Axiobus implements the synchronicity precisely right into
the application via the network. In the process, not the
Axiobus but the superimposed network alone determines
the performance of the synchronization. Moreover, the user
does not have to install any special modules, since the function is integrated into the Axiobus as standard. Thus, the
Axioline I/O system from Phoenix Contact contributes to
the simplification of solutions for increasingly complex
automation tasks. In this way, the user saves time planning
and implementing the application.
Reliable data transmission and processing even with short Sercos cycle time
Source: Phoenix Contact GmbH
The Sercos III Bus Coupler for Axioline constitutes the link be-
protocol, this means that
tween the real-time I/O system and a third-generation Sercos
the current data is transmit-
network. Up to 63 Axioline modules can be connected to the bus
ted and processed even in
coupler, with the cycle time of the local buses increasing by only
the event of a Sercos cycle
a microsecond per module (figure 4). In the event of an additional
of 31.25 microseconds. The
local bus offset of 2 microseconds, the local bus cycle time of a
synchronous output of sev-
typical Axioline station amounts to only 10 microseconds. Due
eral digital standard outputs
to the special design of the Axioline bus coupler with develop-
takes place with an accuracy
ment technology, no delay results in the transfer of the local
to each other of less than a
bus data to the superimposed Axioline system. For the Sercos
Figure 4: Axioline with Sercos III Bus
Coupler simplifies complex tasks
Schneider Electric SAS Head Office
35, Rue Joseph Monier • F-92500 Rueil-Malmaison • France
Phone: +33 (0) 1 41 29 70 00 • Fax: +33 (0) 1 41 29 71 00
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Today, this syndicate collaborates on an international
basis under the umbrella of Sercos International e.V.
As an association of users, manufacturers and research institutes, the user organization is responsible
for the technical development, standardization, certification and marketing of the Sercos technology.
Conformance tests in the user organization’s test
laboratories guarantee that Sercos implementations are standard-compliant, ensuring that devices
from different manufacturers can be combined.
Based in Germany, the organization presently has
more than 90 member companies located around
the world and has national liaison offices in North
America and Asia.
Into the future with
tradition and innovation
25 years of Sercos International – 10 years of Sercos III technology: a review
Digital intelligent drives offer the highest precision and
speeds for numerically controlled machines, at the same
time minimizing equipment costs. In order to benefit from
these advantages, an efficient digital interface is required
for control. Although Sercos® was originally designed as
such an interface, over the course of the last two decades
Sercos has developed into a universally deployable realtime interface for all automation applications.
Sercos history
The Sercos story goes back to the mid-1980s. In the fall
of 1985, the ad-hoc machine tool interface working party
of the VDW (German Machine Tool Builders’ Association)
and the ZVEI (German electronics industry association) approved a revised version of the “machine tool drive signal
interface”, better known by the name +/–10 V interface.
At the time, this was the only standardized interface for
combining numerical controls with speed-controlled drive
units. Using an A/D converter, the digital target speed
on the NC side was converted into an analog signal and
then was processed further on the drive side, either on an
analog basis or digitally again by means of reconversion.
In order to overcome the numerous weaknesses of ana18
log technology (including high fluctuation voltages, limited
resolution, offset and a lack of communication between
NC and drive), some machine tool manufacturers were already working with the first digital solutions based on the
RS-232 interface. However, it was clear to the initiators of
the “Digital Drive Interface” working group that the correct
and future-oriented solution had to be a digital bus system.
For this solution, a requirements document first had to be
written that summarized the current problems and visions.
An expert team of machine tool manufacturers, drive manufacturers and control manufacturers set to work and the
Sercos interface concept came into being as the first digital
bus system between the control and the drives.
The Sercos user organization
In 1988, the concept was established, along with the clocksynchronous transfer concept, the most important profiles
and the desire to offer an ASIC as basis for the master
and slave interfaces. So in 1990 Fördergemeinschaft
SERCOS interface (FGS) was founded. Its members undertook both financing the Sercos concept and also supporting
it for the future.
The three Sercos generations
The first generation, which was presented to the
public for the first time at the EMO show in Hanover
in 1989, supported 2 and 4 Mbit/s transmission rates,
and initially was used mainly in demanding tool machine applications.
In the following years, Sercos was successfully deployed in a wide variety of applications around the
globe and in a wide variety of industries. In 1995,
Sercos was recognized as IEC standard 61491.
In 1999, the second generation of the standard followed. The transmission rate was increased to 8
and 16 Mbit/s, a new ASIC was developed, and the
service was expanded to include asynchronous data
Since 2001, this technology has been available based
on the SERCON816 ASIC, with backward compatibility with the first generation ensured.
The recipe for success of Sercos III, the third generation of Sercos, which was launched into the market
with initial prototypes in 2005, is: “use of the transmission medium and the protocol of Ethernet while
preserving the tried-and-tested Sercos mechanisms.”
The combination of these two technologies creates
new, innovative opportunities for the automation
technology of the future.
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1985: “Machine tool interface” ad-hoc working group
1989: Presentation of the Sercos interface at the EMO
(European Machine Tool Show) in Hanover
Foundation of Fördergemeinschaft SERCOS interface
(FGS), now: Sercos International. Founding
members: ABB, AEG, AMK, Bosch, Indramat
and Siemens
1990: First Sercos test laboratory at
Technical University Darmstadt, Germany
1994: Foundation of Sercos North America
1995: Recognition as international standard
IEC 61491 (Sercos I)
1998: Foundation of Sercos Japan
2001: New test laboratory at ISW, University of Stuttgart, Germany
2002: Adoption of edition 2 of the international standard
IEC 61491 (Sercos II)
2003: Start of development of Sercos III
2005: Launch of Sercos III technology
20 year celebration at the EMO in Hanover, Germany
2006: Cooperation between Sercos International and
the ODVA to develop CIP Safety on Sercos
2007: Recognition of Sercos III as an international
standard (IEC 61784/61158 and IEC 61800-7)
2007: 2 million Sercos real-time nodes installed worldwide
2007: Opening of a branch in China
2008: Cooperation between Sercos International and the
FDT Group for FDT/DTM annex for Sercos III
2010: 25 years of Sercos
2011: Machinery initiative:
Cooperation with OPC Foundation and ODVA
2012: Foundation of Sercos Asia
2015: 25 years of Sercos International –
10 years of Sercos III technology
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Slip rings for Sercos networks
Conventional slip rings are electromechanical components and together with a brush form a sliding
contact. Thus, currents or signals can be transmitted between stationary and rotating parts where
the use of cables would not be possible.
The slip rings used for Sercos® III are fully compatible with
Ethernet 100BASE-T and have an RJ45 or M12 input and
output. Thus the CAT5 and/or CAT5e specifications are fully
complied with. Because of the cushioning effect caused
by the use of a slip ring, Ethernet´s 100 meters maximum
cable length decreases only marginally. No additional signal
delays are produced. However, hardware-based slip rings
have the problem of making permanently reliable electrical
contact, since all sliding contacts produce friction – adherent to their functional principle – which causes abrasion.
Thus, contact-free slip rings are used as an alternative in
applications in which the slip rings are exposed to heavy
mechanical demands and rough environmental conditions.
In the process, a radio circuit ensures that the data transfer works reliably in each situation. In order to be used in
Sercos networks, contact-free slip rings must be able to
perform data transfer of 100 Mbit/s full duplex and possess
an RJ45 or M12 input and output. As with the conventional
version, two drilled copper cores enable 100BASE-T compatibility. In the process, secure signal transmission takes
place via an integrated PHY transceiver. Since all incoming data are forwarded to the output, no MAC address is
required. Even the signal quality is not hindered by the use
of contact-free slip rings. As with other Sercos devices, the
amplitude and the phase are fully restored at the output.
Since all relevant information can be transmitted securely
via Sercos, slip rings do not require any more analog or
digital outputs. The wireless version requires only a 24 V
DC power supply.
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OPC UA Companion Specification
announced for Sercos
Sercos International announced to develop an OPC Unified Architecture (UA)
Companion Specification for Sercos®.
This specification describes the mapping of the Sercos
information model to OPC UA so that functions and data of
Sercos devices are made available and accessible via OPC
UA. This initiative aims at simplifying the communication
between machine periphery and supervisory IT systems,
supporting the requirements of Industry 4.0 regarding
semantic interoperability.
In September, Sercos International launched a “call for
experts”, in order to invite members and specialists to
contribute to this OPC UA initiative. A draft of the Sercos
OPC UA Companion Specification is already available and is
currently being reviewed by a technical working group consisting of device manufacturers, technology providers and
research institutes. The final specification for publication
shall be available in the first half of 2015.
In today’s automation systems Sercos devices from many
different manufacturers have to be integrated and maintained, resulting in significant total cost of ownership (TCO)
Examples of Sercos capable slip rings
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during the entire product life cycle. At the same time product planning and control require process and machine related information to facilitate the efficient use of the manufacturing resources. This challenge can be faced best with
a standardized OPC UA Sercos information model that
brings together the well-defined device profiles of Sercos
with the data exchange standard of OPC UA. Use cases
cover a broad range from device parametrization and network configuration up to energy management and preventive maintenance.
The mapping rules specified by Sercos can be used for
different implementation approaches. On the one hand,
the OPC UA server functionality can be implemented in a
Sercos master device (e.g. CNC or PLC). On the other hand
it is possible to implement this functionality in a Sercos
slave device. In the latter case, the OPC UA accesses are
executed in parallel to the Sercos real-time communication
or even without any Sercos real-time communication.
Slip rings for realtime communication
from Servotecnica
Contactless Ethernet
rotary coupler
Slip ring SRK
Endless rotating
transfer systems from
Inclusion of OPC UA in the Sercos system architecture
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AS-i Safety and Sercos –
two complementary angles
Integration of AS-i Safety in Sercos really works? It shouldn’t be a surprise any longer. Three years
ago Bihl+Wiedemann introduced the AS-i 3.0 Sercos Gateway with integrated Safety Monitor and
Safe Link (BWU2588). This development showed even then that a lot is still possible in the area
of safety gateways. And rightly so, as it turns out. Now the “Sercos idea” has been logically extended with the CIP Safety Gateway on Sercos (BWU2758). The user gains the following benefits:
For one thing, CIP Safety on Sercos enables standard and safety signals to be exchanged over one
and the same cable; and in addition, two modes are available – the gateway can operate like a
CIP Safety target or a CIP Safety originator. The integrated safety technology makes it possible.
The development of new technologies and the consistent
further development of existing components is part of the
reason for success. The realization of the first AS-i master to
specification 3.0 and the first AS-i master in a stainless steel
housing with expanded diagnostics functions are just two
examples from the internationally active AS-i experts and
solution providers for safety-relevant applications.
A convincing connection
How did the fieldbus systems AS-i Safety and Sercos find
each other? Sercos is known as an automation bus for networking the controller peripherals, for example drives or
modular I/Os. AS-Interface has made its name especially as
an IP67 installation system for simple sensors and actuators. AS-i is thought of as “simple and rugged” in the positive sense, as well as “cost-effective and easy to install.”
The following three gateway versions are currently available
for connecting Sercos and AS-i:
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evaluated together. In addition, two relay outputs and two
fast electronic safe outputs are integrated into the gateway
– whereby the safety outputs, independent per SIL3, can
be expanded to maximum 32, or even 992 as part of safety
coupling via Ethernet. Along with these comprehensive features, the gateway is also economically attractive thanks to
the modest installation effort required, the small footprint in
the control cabinet, and the fast startup and ease of replacing a device made possible by the integrated chip card.
■ The AS-i 3.0 Sercos Gateway for standard signals: exchange of standard I/O signals with the controller via Sercos
but no safety coupling between AS-i components and
The AS-i 3.0 Sercos Gateway with integrated Safety
Monitor and Safe Link: safe minicontroller in the gateway
and transmission of the signals to the higher level controller
for diagnostics, but no safety information exchange with the
drives via Sercos or the safety program in the gateway
■ The AS-i 3.0 Sercos Gateway, CIP Safety on Sercos:
exchange of standard signals and safety signals over Sercos
and two operating modes – as CIP Safety target (safety program in the higher level controller) and CIP Safety originator
(safety program in the gateway)
Its strength lies in the electromechanics: The “yellow cable”
is a kind of symbol for the uniqueness of AS-Interface. The
transmission of power and data on the same cable makes
it both reliable and unmistakable. Another advantage in this
connection is the free choice of network topology. And last
but not least: the AS-i products themselves are fully compatible with each other regardless of manufacturer.
Sercos can do
The AS-i 3.0 Sercos Gateway with integrated Safety Monitor
and Safe Link showed in 2012 that coupling of Sercos and
AS-i is quite simple. In practical terms this means the device
functions both as a Sercos slave and AS-i master with up
to 248 AS-i input- and output signals in one unit, with AS-i
parameters set at just the push of a button.
CIP Safety Gateway from Bihl+Wiedemann as CIP Safety originator in the
Sercos network. The Gateway communicates directly with the safe participants (CIP Safety targets) without an additional safety controller
AS-i 3.0 Sercos Gateway with integrated Safety Monitor,
CIP Safety on Sercos (BWU2758)
In 2014, the company from Mannheim, Germany, expanded
its range with the addition of the CIP Safety Gateway
on Sercos. “We are now able to offer our customers an
all-round successfully realized product,” noted Product Manager Johanna Schüßler with satisfaction. Two AS-i masters
for two AS-i networks are available – including an integrated
switch. The safe inputs are expandable to maximum 62 x 2
channels, with three 2-channel safe inputs already integrated directly in the device. Just as impressive are the safe outputs: six fast electronic safe outputs directly in the unit add
speed to the mix and ensure that the CIP Safety Gateway
is a perfect match for high-performance drive technology.
AS-i Sercos Gateways from Bihl+Wiedemann (from left to right:
AS-i 3.0 Sercos Gateway for standard signals, AS-i 3.0 Sercos Gateway
with integrated Safety Monitor and Safe Link, AS-i 3.0 Sercos Gateway,
CIP Safety on Sercos)
AS-i 3.0 Sercos Gateway with integrated Safety Monitor
and Safe Link (BWU2588)
Efficiency and cost optimization is a convincing pair. The
Sercos Gateway with integrated Safety Monitor provides
the user with an AS-i master. This allows up to 31 2-channel safety inputs expandable to 1922 safety inputs to be
Review & Outlook
But even the equipment features don’t tell the whole story.
With CIP Safety on Sercos the wiring effort is also reduced:
There is just one cable, the Sercos cable, which carries both
standard data and safety data. And drives with integrated
safety technology are connected only through this Sercos
cable. This means elimination of additional cables, such as
for safely stopping the drive.
Need short response times? Communication via Sercos is
fast, since the safety program runs directly in the gateway
and communicates with the safe drives with no detours.
And the programming? Simple and clear! The safety program runs directly in the gateway, with no additional higher
level controller needed, which has the positive side-effect of
also significantly reducing the financial outlay.
Used as a CIP Safety target the CIP Safety Gateway operates like a pure gateway. Safe inputs are reported to the
higher level safety controller and safe outputs are switched.
Safety preprocessing of the signals in the gateway is also
possible. Used as a CIP Safety originator the new gateway
is able to safely monitor drives with a CIP Safety connection
reliably without the need for a higher level safety controller.
Here the drives are controlled as usual by the standard controller, with the CIP Safety Gateway monitoring the drives
and safely switching them off in case of doubt.
Sercos users benefit doubly with the Sercos Gateways from
Bihl+Wiedemann. Safety drives are monitored in the simplest and most cost-effective way possible, while the advantages of AS-i are enjoyed when it comes to wiring simple
sensors and actuators on the lowest field level.
All-round powerful
“Our engineers have allowed new ideas and intelligent improvements to flow into the new AS-i Safety Gateways for
Sercos,” emphasizes Johanna Schüßler. Efficiency, functionality and ease of use are the bullet points on every user’s
wish list – along with fully featured hardware. It will be interesting to see what enters the market in the next few years
in terms of innovations and improvements. We’re counting
on greatness.
Key features of the new CIP Safety Gateway on Sercos:
■ Simple integration of AS-i Safety into Sercos
■ Monitoring of safety drives via CIP Safety
with no additional safety controller
■ Applications up to SIL3/Cat.4/PLe
■ Chip card for ease of replacement
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Integrated switch
2 AS-i masters in one gateway
3 two-channel safe inputs built-in, expandable up to 62 two-channel safe inputs
■ 6 independent safe outputs built-in, expandable
up to maximum 64 independent safe outputs
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Altera Corporation
101 Innovation Drive | San Jose, CA 95134 | USA
: +1 408 544-7000 |
Sercos IP core available for Altera Cyclone V FPGAs and SoCs
Sercos International announced the availability of the
Sercos® III IP Core for Altera’s low-cost, low-power
Cyclone® V devices.
The IP core is available for Sercos III master and slave controllers (SERCON100M/S). It includes all hardware functions, such as timing, synchronization and processing of
cyclic and non-cyclic data on the basis of two integrated
Ethernet MACs. Sercos III master and slave devices can be
implemented as a single chip solution using either Cyclone
V FPGAs or Cyclone V SoCs, which integrate an ARM® dualcore Cortex™-A9 processor.
The on-going use of the flexible and continually developing
FPGA technology brings significant cost and performance
benefits to the Sercos community. In addition, using Altera’s Cyclone V FPGA and SoC devices to implement a
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BWO Elektronik GmbH
Teckstrasse 11 | 78727 Oberndorf a.N. | Germany
: +49 (0)7423 925-0 |
+49 (0)7423 925-110 |
BWO/Vektor C/CT
single-chip embedded Sercos III Industrial Ethernet Protocol with integrated PLC and motion control functionality
enables faster time-to-market and significant performance
advantages at a low cost for factory automation customers.
Detailed documentation on the IP core, reference designs
and example Ethernet interface diagrams are available
from Sercos International. Technical support and customerspecific design services are provided by Cannon-Automata,
Ried/Germany, and Caronno, Pertusella/Italy
Cyclone V FPGAs and SoCs facilitate a broad range of new
application areas. The Cyclone V SoC with its integrated
ARM processor delivers significant performance improvements for computing-intensive applications. For example,
complete Sercos master devices can be implemented in
the form of a single-chip solution.
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The BWO/Vektor C/CT is a software-based CNC control consisting of self-developed hardware and software.The new
compact class by BWO: all-in-one, as stand-alone-device
or implemented into the machine. Maximum performance
and maximum functionality with minimum space requirements.The complete control system is integrated in a housing with 15-inch large, capacitive touch screen. Expandable
up to 32 axes and 8 channels in a compact version or with
external CPU to 128 axes and 32 channels. The modern interface makes the operation of the machine very easy – it is
simple and intuitive.With BWO XPROMA tool it is very sim-
ple to create individual user interfaces. It allows to integrate
own corporate design and operator guidance for best possible operation of the machine. BWO/Vektor C/CT is ideally
suited to compact machines – but also suitable for demanding control tasks: from microprecision milling machines to
gear cutting machines. BWO high-end CNC-control stands
for extremely high processing speed and thus increases the
productivity of your product. Ideal for all-in-one solutions
for CNC machines and robotics. Because only one control
system is needed for both systems. The robot can be programmed according to DIN 66025 or in high-level language.
TCP/IP etc.
 Sercos® - and EtherCAT-Slave
with IO-Profile (FSP-IO and
 adjustable size of synchronous real-time data
(32 - 2048 byte)
 asynchronous data channel
(SVC and CoE)
 standard Ethernet channel
over additional RJ45
connector (UCC and EoE)
 IEEE1588 support
Automata GmbH & Co. KG
Tel. + 49 (0) 8233-7916 0
FAX + 49 (0) 8233-7916 99
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Morgan Rekofa GmbH
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SPS IPC Drives
SPS IPC Drives
2014 showed that the Sercos automation bus
is continuing its successful course
2015 in Parma, Italy
Sercos International successfully completed its 13th participation in the SPS IPC Drives Show and recorded a lead increase of approximately 40% compared to the previous year.
In addition to their quantity, the quality of the leads also rose,
with the user organization attracting – together with members and co-exhibiting providers of automation technology
– an interested expert audience to its new stand in hall 2.
Sercos International will share a
joint booth (booth C058, hall 2) with
member companies at this year’s
SPS IPC Drives in Parma, Italy.
Co-exhibiting companies include
Bosch Rexroth, Cannon-Automata
and Schneider Electric Automation
showing their latest technology and
innovations in automation.
Bergstrasse 41 | 53533 Antweiler | Germany
: +49 (0)2693 9333-120 | : +49 (0)2693 9333-5120 |
Endless rotating transfer systems
Morgan Advanced Materials, founded in 1856 and today
with 9,000 employees, is one of the world´s leading manufacturer of endless rotating transfer systems with its brand
Rekofa. The so-called slip rings or swivels are developed
and manufactured in Germany. In a capsuled housing, they
transmit high current with more than 1,000 A, data signals
(up to 1 Gbit in optical version) and different media (e.g. air,
water, oil, glue) as a hybrid slip ring system.
Sercos International e.V.
Kueblerstrasse 1 | 73079 Suessen | Germany
: +49 (0)7162 946865 | :+ 49 (0)7162 946866 |
Sercos IPS Conformizer available as free testing tool
Sercos International offers a free testing tool to verify the
correct implementation of the Sercos® Internet Protocol
Services (S-IPS).
S-IPS defines various services to access devices in Sercos
networks by using common Internet protocols. Some of
these services are also called S/IP and are based on the
Transmission Control Protocol (TCP), as well as the User
Datagram Protocol (UDP).
These services include functions for device identification,
network configuration, and access to Sercos parameters
and diagnostics. In addition, the IPS defines a firmware
update via the Trivial File Transfer Protocol (TFTP).
The speciality of IPS is that these services do not require a
Sercos master or a running Sercos real-time communication.
Even in cyclic real-time operation the specified services can
be used. In this case the IPS telegrams are transferred via
the UC channel (Unified Communication Channel) of Sercos,
without having a negative influence on the real-time behavior of the network.
The IPS Conformizer is a very powerful and user-friendly tool
which helps vendors and users to easily verify the correct
and complete implementation of IPS. The provision of the
testing tool reflects the increasing importance of Internet
protocols that support innovative solutions in the context of
Industry 4.0. This involves for example, the commissioning,
but also the remote maintenance and diagnosis of Sercos
devices that can be easily accomplished through Intranet or
The Sercos IPS Conformizer is available for Windows XP/7
and provides various test functions based on the NUnit test
framework ( for Microsoft.NET environments. These test functions allow a targeted test of
individual IPS services and are thus suitable for the development-accompanying test of IPS devices. In addition, the
test functions of the IPS Conformizer can be expanded specifically to a manufacturer via an open interface. Members
of the Sercos user groups have also access to the source
code of the software so that they can adjust the code to their
requirements and are able to integrate the test software in
their own quality control tools.
Interested parties had the opportunity to acquire a variety
of information under the keywords “innovative – interactive – technically adept.” A live demo from Bosch Rexroth
showed the company’s expertise in cross-technology solutions for metal-cutting machine tools, engraving personalized business card holders for visitors. The IndraMotion
MTX open CNC platform is the basis for the machine’s high
performance and great flexibility. With Sercos®, all real-time
communication requirements are handled in the machine.
The Sercos real-time Ethernet bus is used with the
IndraDrive drives, I/O modules and with the reliable communication with the SafeLogic compact. In addition to the
large number of physically exhibited products, interested
parties could learn about more Sercos-capable solutions on
multitouch monitors. Interested parties could select products according to manufacturer, category, master, slave, etc.
simply by touching the monitor. At present there are more
than 300 Sercos-capable products from approximately
135 providers.
Some of the new products were reflected in the expert presentations, which took place on a half-hourly basis between
10 am and 4 pm. In addition to product presentations, such
as the Axioline product family from Phoenix Contact and
the Sercos/ Ethercat-Bridge from Cannon-Automata, there
were also subject-specific presentations on topics such as
Industry 4.0, energy efficiency and much more. Around 80
exhibits of more than 20 providers – including a large number of new products and safety solutions – completed the
presence of the user organization.
You 5/P DR
an hanc RMA ES
iPa e t
dm ow
ini! in
Sercos International e. V.
Kueblerstrasse 1
73079 Suessen
: +49 (0)7162 9468-65
: +49 (0)7162 9468-66
Editing and design
MILANO medien GmbH
Hanauer Landstrasse 196A
60314 Frankfurt am Main
: +49 (0)69 4800054-0
: +49 (0)69 4800054-9
No longer miss a
bus with our Safety
Safety Basic Monitor with switchable
AS-i Master – the new cost brake for
3 safe signals or more
hall 9, booth H01
13. April 2015 – 17. April 2015
Safety Technology by
Safe Link over Ethernet: The simplest way of coupling
many safe signals
Optimal PLC connection via fieldbus, all diagnostic data
in the controller, safety and standard signals mixed
Universally expandable with Safety I/O Modules + Standard
I/O Modules in IP20 or IP67, Speed Monitors for up to
40 axis, Safety Relay Output Modules
More information on your application safety at:
Safe Link over Ethernet
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