Research and development of an EtherCAT slave for custom & modular I/O & edge processing

Thesis description

CTRL Engineering develops advanced automation and control solutions for industrial applications, including custom testbenches, motion control systems, and in-house electronics hardware. In industrial automation environments, real-time communication between controllers and field devices is critical — and EtherCAT has established itself as one of the leading protocols for this purpose due to its deterministic, high-performance characteristics.

Currently, off-the-shelf EtherCAT slave devices offer limited flexibility when it comes to custom I/O configurations and local data processing. CTRL sees an opportunity to develop a tailored EtherCAT slave solution that combines modular I/O hardware with integrated edge processing capabilities, enabling smarter, more adaptable automation systems.

Thesis objective

The goal of this thesis is to research and develop a custom EtherCAT slave device featuring modular I/O and integrated edge processing. The student will design a custom PCB or further develop an existing hardware platform, combined with firmware for real-time EtherCAT communication. The result should be a scalable, modular device that integrates seamlessly into industrial EtherCAT systems — reducing system complexity and improving performance in demanding automation environments.

Research Deliverables

• A technical research report evaluating EtherCAT slave architectures, available chipsets, and real-time firmware approaches.
• A custom PCB design (or extension of an existing platform) supporting modular I/O configurations.
• A firmware implementation enabling reliable real-time EtherCAT communication and edge data processing.
• A proof-of-concept integration demonstrating the device operating within an EtherCAT network.
• A documented evaluation of the design’s scalability, flexibility, and performance under industrial conditions.

Research question examples

• “What hardware and firmware architectures are best suited for implementing a custom EtherCAT slave with modular I/O?”

“How can edge processing be effectively integrated into an EtherCAT slave device to reduce upstream data load and system complexity?”
“What design strategies ensure reliable real-time performance and flexible I/O configuration in a modular EtherCAT slave platform?”

Student profile

We are looking for a motivated student with a genuine interest in electronics, embedded systems, and industrial communication protocols. Relevant skills and interests include:

• Experience or strong interest in PCB design and electronics hardware development
• Knowledge of embedded firmware development (C, C++, or similar)
• Affinity with industrial communication protocols, particularly EtherCAT or similar fieldbus technologies
• Interest in real-time systems, edge computing, and hardware/software co-design
• Ability to work independently and communicate technical findings clearly

Speciality: Electronics, Hardware — 1 student position available.

Interested?

We would love to hear from you! Please contact the dedicated CTRL contact person for this case. We can set up a meeting to get to know each other and discuss whether your wants and needs match ours.