The Design and Real-Time Optimization of an EtherCAT Master for Multi-Axis Motion Control

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