Internship/Graduation: Flexible EtherCAT device

EtherCAT is a high-performance industrial Ethernet technology widely used in automation systems. Creating a flexible EtherCAT slave device can enable the development of various embedded modules such as digital I/O interfaces, motor controllers, and sensor nodes. This assignment offers a unique opportunity to explore both the theoretical and practical aspects of embedded system design, industrial communication protocols, and FPGA-based development.

About Demcon

Each one of our companies differentiates itself in its own domain with unique expertise and skills. This way they help customers improve their performance and achieve more. On the basis of their passion for technology our companies are able to combine forces. By sharing knowledge and working together we increase our social impact. Demcon high-tech systems is a multidisciplinary development and engineering partner for mechatronic challenges, from concept to realization, in the field of high-tech systems.

Your assignment

Design and implement a flexible EtherCAT slave device that can serve as a foundation for multiple embedded applications. The device should be configurable to support different functionalities (e.g., digital I/O, motor control) and be based on a flexible architecture, preferably using an FPGA.

Assignment

Research Component

• Investigate existing EtherCAT slave solutions available on the market (e.g., Beckhoff ET1100, Microchip LAN9252, TI TMS320F28388D).
• Compare chip-level solutions vs. FPGA-based implementations in terms of cost, performance, flexibility, and ease of integration.
• Explore existing tools and platforms used within the company for EtherCAT development (e.g., TwinCAT, SOEM, custom IP cores).
• Interview engineers or review internal documentation to gather insights on past experiences and lessons learned.

Implementation Component

• Define the architecture of a modular EtherCAT slave device.
• Select appropriate hardware components (FPGA, PHY, connectors, power supply).
• Develop firmware/software to handle EtherCAT communication and basic device functionality.
• Implement at least two example applications:
• A digital I/O module (e.g., toggling LEDs, reading switches).
• A basic motor controller (e.g., PWM generation, encoder feedback).
• Validate the device using an EtherCAT master (e.g., TwinCAT or SOEM-based test setup).

Deliverables

• Research report comparing EtherCAT slave solutions and summarizing internal tool evaluations.
• Selected hardware and bill of materials (BoM)
• Firmware/software source code with documentation.
• Functional prototype of the EtherCAT slave device.
• Final presentation and demo of the working system.

Learning Outcomes

Deep understanding of EtherCAT protocol and industrial communication. Hands-on experience with embedded system design and FPGA development. Exposure to real-world engineering workflows and toolchains. Ability to conduct technical research and translate findings into practical design decisions.

Your growth, our pride!

Demcon offers a dynamic, growing and innovative organization. With our complex projects and multidisciplinary teams we offer you a lot of challenge and variety in this position. Thanks to enthusiastic and dedicated colleagues, our working atmosphere is good, open and informal, with a flat organizational structure.

You will have a regular supervisor who will coach you and all mutual wishes and expectations will be clearly agreed upon before the start of the assignment. Furthermore, the standard working method gives you the opportunity to act, in a motivating working atmosphere, within the team. So you get a good impression of what it is like to be part of the world of Demcon. And that can be a very good start of your career.