Real-Time EtherCAT Solutions for Warehouse & Distribution Logistics

Achieving Deterministic, High-Performance Control

Modern warehouse environments rely on complex, distributed systems of coordinated machines and software. Conveyor systems, robotic picking units, sortation machines, and mobile transport robots must process vast amounts of data in real time. Efficient and safe operation depends on deterministic communication between all devices and centralized control systems. Non-deterministic communication can lead to bottlenecks, collisions, and inefficient workflows.

For example, Autonomous Mobile Robots must execute coordinated tasks using real-time data from drives, sensors, and I/O. Applications such as dynamic obstacle avoidance, navigation, path planning, and synchronous motion require deterministic data exchange at high speed to ensure safe, precise, and efficient operation.

acontis’ EC-Master EtherCAT MainDevice stack delivers ultra-low-latency, hard real-time communication optimized for embedded controllers. Features like Distributed Clocks (DC), Split Frame Processing, and flexible network topology support make it ideal for demanding applications. EC-Master can ensure that all components—from drives to sensors—are available, synchronized, and responsive, providing the real-time performance required for AMR, AGV, and other warehouse systems.

Additionally, while many logistics systems still rely on CAN-based communication, the increasing complexity and performance demands of modern warehouse automation are accelerating the shift toward EtherCAT. acontis technologies’ proven EtherCAT MainDevice stack simplifies this transition, providing a scalable, high-performance solution that supports future growth and advanced control architectures.

Ensuring Functional Safety

For automated Warehouse and Distribution systems operating in environments with humans or sensitive equipment, functional safety is paramount. The communication system must reliably transmit safety-critical data and ensure safe reactions in case of errors.
The EtherCAT protocol supports Safety over EtherCAT (FSoE), which uses the “black channel” principle to embed safety data within the standard EtherCAT frame. FSoE requires minimal resources while delivering high performance and short reaction times, making it ideal for safe motion control applications in robotics.
acontis' EC-Master EtherCAT MainDevice stack provides the robust and reliable communication backbone for implementing FSoE. It supports ENI file import, offers configuration interfaces to Safety Configuration Tools, and enables strategies for rapid and secure device replacement. EC-Master also supports advanced EtherCAT feature packs like Hot Connect, Master Redundancy, and Cable Redundancy for added flexibility and safety. These features empower developers in this industry to create safe, standards-compliant systems without compromising performance.

System Security and Integrity

Cybersecurity and operational integrity are critical in modern warehouse and distribution logistics systems. EtherCAT offers inherent protection as it does not use Internet Protocol (IP) routing, preventing most common cyberattacks. EtherCAT’s hardware enforces strict frame filtering, permits physical port deactivation, and prevents devices from interpreting or transmitting unauthorized data, even if firmware integrity is compromised.

EtherCAT requires no additional cybersecurity measures beyond standard controller hardening, eliminating the need for complex certificate management. acontis’ EC-Master integrates with secure operating systems like QNX, while EC-Monitor provides passive network monitoring and traceability to support compliance and incident response.

Managing System Complexity, Configuration, and Maintenance

Warehouses often deploy diverse and complex hardware and software environments—including vision systems, PLCs, robotic arms, conveyors, and cloud-connected analytics—often running together on the same platform. For example, an AMR may consist of multiple systems, such as an autonomous mobile base that transports a tool or robotic arm mounted on top. Additionally, the AMR base is typically required to support interchangeability of the tool or robot it carries. Coordinating these systems on limited hardware while maintaining real-time performance presents a significant challenge.

acontis Real-time Hypervisors enable multiple operating system environments to run on a single industrial PC, allowing workload and hardware consolidation without sacrificing determinism or safety.

EtherCAT has become the industrial communication protocol of choice for complex logistics and warehouse systems, thanks to its unmatched interoperability and extensive ecosystem of EtherCAT-enabled devices. Thousands of manufacturers supply EtherCAT SubDevices, providing engineers with a wide selection of compatible components for virtually any application. Additionally, EtherCAT networks can support up to 65,535 devices, offering exceptional scalability for both simple setups and highly complex automation systems.

EC-Master also supports advanced features such as Hot Connect and Superset ENI, enabling greater system flexibility and simplified device configuration.

For efficient configuration and maintenance, acontis provides a comprehensive suite of software tools for intuitive EtherCAT network setup and diagnostics. Tools like EC-Engineer, EC-Inspector, and EC-Monitor offer advanced real-time analysis, error detection, and performance optimization, helping warehouse operators minimize downtime and maintain optimal system health.

Testing and Simulation

Testing systems before physical deployment helps ensure safety and performance in the field. Simulating EtherCAT networks accelerates development and reduces the need for expensive hardware prototypes.

acontis' EC-Simulator enables full network simulation and virtual commissioning. Developers can test EtherCAT topologies, simulate faults and errors, and validate behavior under real-world conditions. This shortens development cycles, reduces hardware costs, and improves system robustness.