Application NotesTechnical Documentation & Guides
EtherCAT Motion Control with Trio Controllers
How to set up and tune EtherCAT networks for multi-axis motion on Trio Motion controllers.
Overview
EtherCAT is what most high-performance motion networks run on now. It's deterministic, and cycle times drop under 1ms. Trio Motion controllers act as the EtherCAT master directly, so they talk to EtherCAT servo drives, I/O modules, and other slaves without a separate master card. This note covers network layout, configuration, and tuning for multi-axis systems.
Trio EtherCAT Master Architecture
Trio controllers (MC4N, MC664, Flex-6 Nano) have EtherCAT master ports built in. At startup they scan the network and configure each slave on their own. The controller handles network management, Distributed Clocks sync, and error recovery, and there's no extra hardware or software license to buy.
- Automatic network scanning and slave configuration
- Distributed Clocks synchronization with sub-microsecond accuracy
- Hot-connect support for dynamic slave addition/removal
- Built-in network diagnostics and error counters
Network Design Best Practices
EtherCAT runs a line (daisy-chain) topology, up to 100m of Cat5e between nodes. Wire the drives in the order they sit on the machine and the cabling stays simple. When a straight line doesn't fit the layout, EtherCAT junction modules let you branch into a star or tree.
Cycle Time Optimization
Cycle time sets the motion update rate. Trio controllers run cycle times from 250µs to 4ms. Shorter cycles give you tighter dynamic response but eat more processing bandwidth. For most servo work, 1ms is the sweet spot between response and stability.
Minimum cycle time ≈ (N × 2.5µs) + 100µs overhead, where N is the number of slaves. A 16-axis system requires approximately 140µs of network time per cycle.Typical Applications
- Multi-axis coordinated motion
- High-speed pick-and-place
- CNC and laser processing
- Packaging machinery
Related Products
MC4N • MC664 • Flex-6 Nano
TrioBASIC Programming for Motion Applications
A start on TrioBASIC, the language you write motion programs in on Trio controllers, covering program structure, motion commands, and debugging.
Overview
TrioBASIC is Trio's own language for motion control. The syntax is BASIC with motion commands added on top, so you can get a complex motion program running fast without learning a new paradigm. Programs run on the controller itself, which makes execution deterministic and means you don't need a PC connected once it's deployed.
Program Structure
TrioBASIC programs are split into processes that run concurrently on the controller. Each one can drive one or more axes on its own:
- Up to 14 concurrent processes (model dependent)
- Each process runs in its own time slice within the servo cycle
- Processes can communicate via global variables and TABLE data
- Priority-based scheduling with deterministic execution
- AUTORUN capability for automatic program startup
Motion Commands
The motion commands hide the servo drive communication underneath. MOVE, MOVEABS, and MOVECIRC handle basic moves; CAM, CONNECT, and MOVELINK handle synchronized motion. Every command is axis-aware, and you set which axes it acts on with the BASE and AXIS directives.
Debugging with Motion Perfect
Motion Perfect is Trio's IDE for TrioBASIC. You get live variable watching, breakpoint debugging, oscilloscope plotting, and program upload and download. The scope is the part you'll lean on when tuning motion profiles. It captures position, velocity, following error, and current, all synchronized to the servo cycle.
Typical Applications
- Custom machine motion sequences
- Multi-axis coordinated motion
- Electronic line shafting
- Registration and print mark correction
Related Products
All Trio Motion controllers
Multi-Axis Coordination and Path Planning
Coordinating multiple axes on Trio controllers: interpolated moves, path blending, and electronic cam and gear relationships.
Overview
A lot of machines need several axes working in tight coordination for contouring, synchronized dispensing, or robotic manipulation. Trio controllers do this coordination in firmware: linear and circular interpolation, electronic camming and gearing, and path blending for smooth continuous motion.
Linear and Circular Interpolation
Trio controllers run 2D and 3D interpolated motion, with several axes following one calculated path. Linear interpolation moves in straight lines; circular interpolation (MOVECIRC) traces arcs in any plane. The path planner works out each axis trajectory so the tool holds the programmed feedrate along the path.
- MOVE and MOVEABS for linear interpolation (up to 32 axes)
- MOVECIRC for circular arcs in 2D
- MHELICAL for helical interpolation (arc + linear)
- Programmable feedrate override (0-300%)
- Automatic acceleration/deceleration at path start/end
Electronic Camming
The CAM command ties a follower axis to a master position through a cam table you define in the controller's TABLE memory. Tables hold up to 65,536 points and use cubic spline interpolation, so motion stays smooth at any speed. You can link, reverse, and phase-shift cams while they're running.
CAM table resolution: position accuracy = travel / (N-1) where N is the number of cam points. For ±1µm accuracy over 100mm travel, use at least 100,001 points.Path Blending and Look-Ahead
Path blending removes the stops between segments when you're running a string of moves back to back. Trio controllers look ahead at the moves coming up and set the velocity at each blend point accordingly. That matters on CNC, laser cutting, and dispensing, where a stop between moves leaves a mark.
Typical Applications
- CNC machining and routing
- Laser cutting and welding
- Dispensing and coating
- Robotic path planning
Related Products
MC4N • MC664 • Flex-6 Nano