Design, Implementation and Testing of an EtherCAT-based Network for Multi-modal Distributed Sensing Architectures

This paper introduces an EtherCAT-based communication infrastructure designed for large-area multi-modal sensor networks in robotic applications. The system addresses critical application-oriented challenges, such as bandwidth optimization, cable routing efficiency, network scalability and fault tolerance. The proposed architecture is experimentally validated with ProxySKIN, a distributed sensing technology integrating arrays of tactile and proximity sensors, designed to cover large areas of robotic manipulators. The implemented solution leverages a redundant EtherCAT network driven by custom-made miniaturized slave devices to collect comprehensive data regarding the robot’s surrounding space. Bench-test experiments conducted on over 6400 pressure sensors and 20 multi-zone proximity sensors show reliable data collection with minimal communication latency through a unique EtherCAT backbone.