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Hakan Bastedt
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README.md
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# Making my own EtherCAT device
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# MetalMusings EtherCAT device
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This repository contains software, pcb shematics and layouts, reference documentation etc
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that I used during the creation of my own EtherCAT device.
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This repository contains the EtherCAT devices I have designed, built and put in use in linuxcnc.
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Everything should be here - Schematics, PCB layouts, and what is needed to build the boards.
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Software tools to create an ESI-file and program the ESC eeprom.
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Software tools to create the application running on a STM32F407VG.
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I have (so far) used two different ESC ICs: LAN9252 and Ax58100.
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Both work, I can't really see a difference.
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The Ax58100 has a leg spacing of 0.4 mm, 0.5 mm for the LAN9252.
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On paper the Ax58100 has more builtin functionality like stepper motor drivers,
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but the documentation is lacking. Or my understanding of the documentation is lacking.
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The LAN9252 is the true and tested IC of the two. If you don't know, go for the LAN9252.
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I learned most of what I know about EtherCAT through a number of Youtube Videos I made.
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There are accompanying git branches. For example, for video 8 you can check out the
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Video8 branch to get the software tree in the state at the video.
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More info on the videos, which now more are of historical intereste, but also a bit of learning
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by following [this link](Videos.md)
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This job is documented in a series of Youtube videos, from my first attempts to understand
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how EtherCAT works, to making my own pcb, program it and testing it in LinuxCNC.
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=======
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## Make my own EtherCAT device 9. About time. Step generator
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## EaserCAT 2000 - a testbench for ESC+MCU, SOES, stepper generator, linuxcnc
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This was something, I almost gave up. But here it is. A working step generator.
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Actually, not one but two step generators for the EaserCAT 2000 board.
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For a step generator it is all about timing, timing and timing.
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I'll walk you through what I had to do to get it to work.
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It can give some general insight into how EtherCAT for linuxcnc works.
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Biggest changes this time are in the [Firmware folder](Firmware).
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The [Documentation folder](Documentation) has design details on the second step generator.
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A small but fatal indexing bug was fixed in the EEPROM_generator.
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For all details, read the git log. Too much to mention all.
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[](https://youtu.be/lBDBcseFki8)
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## Make my own EtherCAT device 8. EaserCAT 3000
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Introducing the new **EaserCAT 3000** board. It's an evolution of the EaserCAT 2000
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and intended to be used in my plasma cutter. It features four stepper driver outputs,
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input for a THCAD arc voltage card, an encoder, an analog output (for spindle +- 10V),
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eigth digital inputs, four digital outputs, plus some 12 I/O for any possible extension.
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The KiCAD files are in the [KiCAD folder](Kicad/Ax58100-stm32-ethercat)
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[](https://youtu.be/boanv6ihYtI)
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## Make my own EtherCAT device 7. Turning in the lathe
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I have now put things together so the EaserCAT 2000 card controls
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my small CNC lathe. Two stepper generators, one each for the X and Z axes,
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and an encoder counter for the spindle encoder are on this small card.
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While it works there are still issues caused by the variation in cycle time. Thankfully
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I was able to reduce the variation from 80-100 microseconds down to 2-3 microseconds,
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[](https://youtu.be/Bqi1KXEVI1Q)
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## Make my own EtherCAT device 6. Stepper motor driver
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The stepper driver generator shows up and makes some stepper motor sounds. The two big things
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this time have been setup of the timer for the stepper pulses and synchronizing the EtherCAT
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cycle with the linuxcnc servo-thread cycle. Thankfully I don't show much of that.
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[](https://youtu.be/QNNEA0wO4Mw)
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## Make my own EtherCAT device 5. The lathe is alive
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I hook up the EaserCAT 2000 board to my mini-lathe and make it work.
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Documentation is available here, please select the *Video5* branch.
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[](https://youtu.be/wOtMrlHCCic)
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## Make my own EtherCAT device 4. The PCB is here
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In this video it starts to be interesting. I have got the pcb and I try to make it work.
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Now I finally make documentation available, see [this folder](Pcb-1-lan9252).
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[](https://youtu.be/An0VrKYAv88)
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## Make my own EtherCAT device 3. Encoder
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I made a rudimentary EtherCAT encoder module. To test it I need something better than my test setup so I start to design my own PCB to be used for testing with LinuxCNC.
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[](https://youtu.be/oNIBOpeTpQ4)
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## Make my own EtherCAT device. 2. MCU and SPI
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Testing the SPI connection between the MCU and the LAN9252 chip. Get into state diagrams for EtherCAT and for CIA402.
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[](https://youtu.be/F9HdCEG6kow)
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## Make my own EtherCAT device. 1 Digital IO
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My first tries with the LAN9252 chip. Getting accustomed to some tools.
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[](https://youtu.be/IGmXsXSSA4s)
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# EtherCAT PCB based on LAN9252 and STM34F407
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##### The firmware is in the **Firmware** folder.
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Open this in PlatformIO. PlatformIO might be able to install all necessary software. If not, you need at least Arduino for STM32 (STM32duino) and SPI. PlatformIO might be able to figure that out, I hope so.
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SPI settings are in lib/soes/hal/spi.cpp if you are interested.
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SOES is the Arduino port of SOES from <https://github.com/kubabuda/ecat_servo/tree/main/examples/SOES_arduino>
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My own code is in main.cpp. The encoder counter code is in STM34_Encoder.cpp
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###### The PCB design is in **Kicad**.
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Open this with Kicad. I have put the symbols and footprints in there, just set the right paths.
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The design is in the state I ordered the pcb from Aisler, Germany.
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###### The **Schematics** folder
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contains reference documentation, schematics of several LAN9252 evaluation boards and other boards. This is from where I got inspiration and ideas to the design. No I didn't read all the reference documentation - I copied most from these designs and that's why it also worked the first time. [Freerouting](https://github.com/freerouting/freerouting) was used to route the pcb. Normally I route the nets by hand but this time it was a bit much and it came out quite nice and, most importantly, it worked.
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##### ESI xml file generator is in **EEPROM_generator**.
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Access the folder with a file browser and click on index.html to make or update your own xml file (and other necessary files, incl eeprom bin). Copy the contents to Firmware/lib/soes
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and to Twincat esi xml file directory `c:\twincat\3.1\io\modules\ethercat`
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The original EEPROM_generator is found here <https://github.com/kubabuda/EEPROM_generator>
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##### **CubeMX-files** are for reference only.
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The .ioc file can be opened in CubeMX. The STM32F407 processor has functions tied to specific pins, the .ioc file has this info. This is just for reference.
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##### ESI (EtherCAT Slave Information) files
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I have put [Dig_8IN_8OUT.xml](Dig_8IN_8OUT.xml) here, this is an example ESI file for the LAN9252 IC standalone, no MCU needed. It's sometimes handy to have the simplest possible ESI file at ahnd, here it is. You find the ESI file for the Encoder application [here](Firmware/lib/soes/MetalMusings_EaserCAT_2000_encoder.xml)
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##### **linuxcnc** contains modifications to make EaserCAT 2000 work
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The configuration files and the hal component I used are placed here.
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##### LAN9252_eeprom_store_valid
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Arduino sketch to program the AT24C32 eeprom with a valid eeprom content. Hook up the eeprom using I2C and run the program. The verification in the of theprogram must be passed for valid programming.
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This was the first card that got used in Linuxcnc. Follow [link here](Cards/EaserCAT-2000/)
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I think I got it working pretty well in the end. There was, and still is, an issue with
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synchronization between the linuxcnc servo-loop and the ESC DC loop.
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I don't remember the status of it anymore, it was some time ago I worked with it.
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The main thing was that it lacked optocouplers and isolation for the external signals.
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## EaserCAT 3000 - All in one board with Ax58100
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This card is an evolution of the EaserCAT 2000 and was intended to be used in my plasma cutter.
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It features four stepper driver outputs, input for a THCAD arc voltage card, an encoder,
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an analog output (for spindle +- 10V), eigth digital inputs, four digital outputs,
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plus some 12 I/O for any possible extension. The IOs are isolated from the MCU.
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However, I couldn't get this card to work, almost at all. The Ax58100 didn't even load the eeprom.
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Struggling with the documentation for the Ax58100, which formed my negative opinion about that,
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I gave up and let it sit for over half a year. It was first when a user came and asked questions
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around it had another look. I built a new board, and it all started to work.
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At time of writing it all seems to work.
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[Link here](Cards/EaserCAT-3000-Digital-Stepper-Analog-Encoder-Frequency/)
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## EaserCAT 4000 - THCAD reader
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Faced with the problems with the EaserCAT 3000 board, and still wanting to use EtherCAT in
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my upcoming plasma cutter, I made this board whos single purpose is to read the PWM frequency
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from Mesa's THCAD board. The THCAD board reads the voltage between the nozzle and the workpiece
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which is 100V something. Highly isolated, and with a voltage to frequency converter it
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delivers a differential pwm signal. The frequency of this signal can be related to the voltage.
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That's what is needed for linuxcnc torch height control.
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In the tests on the bench this can read up to 200 kHz, but its's better to be below 100 kHz.
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It seems to work fine. Implementation is with interrupts. The best option would be to use
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TIM2's PWM_INPUT function. I tried a lot but couldn't get it to work. It still works for
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its intended use. If time and interests are in phase with the moon, I might look at that again.
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[Link here](Cards/EaserCAT-4000-THCAD-Reader/)
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## EaserCAT 5000 - Digital IO without MCU
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A card, just doing Digital Input and Digital Output. The intentions is to read limit switches
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and some other switches around the plasma torch. And to switch on the plasma torch.
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It's a single LAN9252, configured for local IO. To IO pins are optocouplers attached for isolation.
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At point of writing it has not been run yet. Still waiting for parts.
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[Link here](Cards/EaserCAT-5000-Digital-8In-8Out-LAN9252-only/)
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###License
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