PROFINET Technology For Factory & Process Automation: Hassan Kaghazchi, University of Limerick

PROFINET Technology for Factory & Process Automation
Hassan Kaghazchi, University of Limerick
Two Technologies One Organization
Introduction Motivation Requirements
PI (PROFIBUS & PROFINET International)

Regional PI Associations PI Competence Centers PI Test Laboratories PI Training Centers
Technology
Performance Diagnostics Safety Integration Profiles Wireless Conclusion
PROFIBUS International
Pharmatex 2008
PI: Worldwide Support

26 Regional PI Associations (RPA)
36 PI Competence Centers (PICC) in 21 countries 12 PI Training Centers (PITC) in 8 countries

W- EU
Technology
10 PI Test Laboratories (PITL) for certification tests

Finland RPA Norway RPA, PICC, PITC UK RPA, PICC, PITC Russia RPA Slovakia RPA China RPA PICC, PITL Japan RPA PICC, PITL Korea RPA, PICC
Belgium RPA, PICC
France RPA, PICC
Italy RPA, PICC
Sweden RPA, PICC
America
Brazil RPA, PICC USA RPA, PICC, PITC, PITL PROFIBUS International Southern Africa RPA, PICC, PITC Australia/ New Zealand RPA Pharmatex 2008
Middle-East RPA South-East-Asia RPA, PICC Thailand PICC 3
Asia
E- EU
Denmark RPA
Germany + Austria RPA, PICC PITC, PITL Ireland RPA, PICC, PITC
Netherlands RPA, PICC, PITC, PITL
Switzerland RPA, PICC, PITC
Czech Rep. RPA PICC, PITL Poland RPA, PICC
PI Membership Growth
Vendors Distributors Consultancies Integrators End users Institutes Training institutes
> 1.400 members worldwide
Technology
total
Europe
Asia America
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
4
PROFIBUS Status: Oktober 2007 International
Pharmatex 2008
PROFIBUS DP nodes
PROFIBUS Nodes
25 m
25 m
20 m
In 2007: 4.5 m nodes!

18.8 m
Technology
Performance
15 m
At the beginning of 2004, we said: Over the next 4 years, we will double the number of installed PROFIBUS nodes to 20 million.
Diagnostics Safety
10 m
Integration Profiles Wireless Conclusion

1994 1999 2008
5m
Time
1990
2000
2004
2007
Pharmatex 2008
PROFINET: What is counted?

HMI
Technology
Proxies Motion Control & drives Robots
Controllers
Decentralized peripherals
Sensors Proxies
Decentralized peripherals
Pharmatex 2008
Installed PROFINET nodes end 2007

PROFINET nodes

4m
Technology
3m
3m
1m
1.14 m
Time 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Pharmatex 2008
Growth: New ARC reference

PROFINET nodes

4m
Technology
According to a study done by the ARC Advisory Group, there will be a 27.5% annual 3 m increase on the market for Ethernet-capable devices and I/Os over the next 5 years.
2m
1m
1.14 m
Time 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Pharmatex 2008
PROFINET nodes: Outlook to 2010

PROFINET nodes

4m
Technology
3m
3m
2m
Average annual increase of 37%
1m
1.14 m
Time 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Pharmatex 2008
PROFIBUS and PROFINET: A comparison

PROFINET/PROFIBUS nodes
4m
Technology
Performance Diagnostics
3m
2m
Safety Integration Profiles Wireless Conclusion

Time
Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9
1m
Pharmatex 2008
10
PROFINET For all corporate functions
ERP
Technology
MES
Control Level Field Level
Seamless from the management to the field level from planning to production
PROFIBUS International Pharmatex 2008
11
PROFINET The solution for all industries

For all industries and applications
Technology
For the overall workflow
Pharmatex 2008
12
PROFINET for Scalable Real-time Solutions

PROFINET with RT (Real Time) PROFINET with IRT (Isochronous Real Time) Synchronously clocked application Planning
Technology
PROFINET is the only Ethernet solution that uniformly covers all the requirements of real-time communication without restricting openness.
Performance / Cost
13
PROFINET - The scalable communication

The seamless solutions for all applications
From IT, standard TCP/IP, real-time communication, to Motion Control Simultaneously on one line
Technology
Internet
Automation
Motion Control
<100ms
<10ms
<1ms
IT services
RT
TCP/IP IRT
Is real-time Ethernet
14
PROFINET Example application

Line
System
Technology
Cell
Field
INTERBUS
PROFIBUS
PROFINET
Wireless
Pharmatex 2008
15
PROFINET as Modular Technology

Application Profiles Introduction Motivation Requirements Fieldbus integration II
IO-Link CANopen FF
Encoder LVSG Ident Systems
Process Automation
MES
Technology
Motion Control
Safety
Fieldbus integration I
PROFIBUS INTERBUS DeviceNet HART AS-I
Decentral Peripherals
Real-time Communication
WEB Integration
Train Application
Distributed Automation
Network Installation & Network Management
Test + Certification
Data Security
WLAN
Pharmatex 2008
16
PROFINET Technology
= 100 MBit/s Switched Fast Ethernet
= Unrestricted TCP/IP Communication
Technology
= Real-Time Communication
= WLAN Technology
= Failsafe Communication
Pharmatex 2008
17
PROFINET IO system elements
Engineering system
IO supervisor

Software
(STEP7, PC WORX, etc.)

Network configuration I/O address assignment Parameter values Configuration download
(Monitor, diagnostics, OPC)

Read input/output data Write parameter data Accepted by IO controller Evaluate diagnostics
Ethernet
Technology
Devices
IO controller (PLC, PC, etc.)

Network management Consumer for input data Provider for output data Transmit start parameter Receive alarms Evaluate diagnostics
IO device (field device)

Provider for input data Consumer for output data Device parameter Send alarms Provide diagnostics
Pharmatex 2008
18
Real Time (RT)

Uses standard components (e.g. switches) or hardware support Performance class as good as modern fieldbus systems (e.g. PROFIBUS) Typical field of application is factory automation High performance by minimizing the protocol overhead in the devices IT Appli-
Technology
Real-time telegrams get priority

Facilitates refresh times of 1 or 2 ms for current data volume
cations
PROFINET Applications
e.g. HTTP SNMP DHCP...
Configuration Diagnostics
User Data
TCP/UDP IP Ethernet
Real Time
Real Time (RT)
Pharmatex 2008
19
Isochronous Real Time (IRT) with PROFINET

If the performance of Real Time (RT) is not sufficient:
Reserves bandwidth for PROFINET IO Uses synchronously clocked data transfers Decouples real-time communication from standard communication (TCP/IP)
Technology
Performance Diagnostics Safety Integration
IRT
RT RT RT
TCP/IP TCP/IP
Reserved for IRT

RT RT RT
TCP/IP TCP/IP
IRT RT RT
TCP/IP
Profiles Wireless Conclusion
Pharmatex 2008
20
Mode of Operation of PROFINET with IRT

Reserving bandwidth allocates separate time slots for real-time communication
Real-time properties not influenced by TCP/IP or by broadcast or multicast communications High performance even with highly cascaded switches Precisely timed data transfer
Technology
Performance Diagnostics Safety Integration Profiles
Basic technology for synchronously clocked applications

IRT Interval TCP/IP IRT Interval TCP/IP Cycle 2 = time window IRT Interval TCP/IP Cycle n
Cycle 1
e.g. 1 ms position control clocking Wireless Conclusion

Isochronous Communication TCP/IP Communication
IO Data
TCP/IP Data
Pharmatex 2008
21
Motion Control and TCP/IP PROFINET
Technology
Maximum performance and flexibility Motion control with simultaneous image data transfer Non-reactive coexistence
IRT and TCP/IP on a single cable

22
PROFINET for Clock-Synchronised Applications (1)

RT applications are not generally synchronous:
Different asynchronous cycles Applications, data transfers and field devices each operate on their own processing cycles Cycle times are very imprecise Jitter is of the order of the cycle times
Communication cycle Application cycle Device cycle
Technology
Controller
Field device
Field device
Drive
Pharmatex 2008
23
PROFINET for Clock-Synchronised Applications (2)

Based on clock-synchronized data transfer
Application, data transfers and device cycles

are synchronous Cycle times < 1ms with jitter precision < 1s Typical field of application is motion control
Technology
Performance Diagnostics Safety
Communication cycle Application cycle
Device cycle
Integration Profiles Wireless Conclusion Controller Field device Field device Drive
Pharmatex 2008
24
PROFINET for Clock-Synchronized Applications (3)

Couples the various cycles from terminal to terminal
Synchronized clocking improves performance and control and regulation behavior even for standard PLC applications
Technology
Performance Diagnostics Safety Integration Profiles Wireless Conclusion T1 T2 T3 T6 T7 T5
PLC CPU
Decentral peripherals
Optimal regulation with short program cycles

25
Conventional Engineering
Fixed bandwidth reserved for user data IO communication of conventional engineering Devices and switches with standard switching functionality learn the communication routes automatically Highly flexible when setting up and subsequently modifying the network Short response times even for large data volumes
Technology
Pharmatex 2008
26
Performance Figures (1)

Performance figures for applications using PROFINET and IRT Introduction Motivation Requirements
Cycle time Number of participants*) Jitter
1 msec 272 <1ms
500 msec 128 <1ms
250 msec 56 <1ms
Technology
Reserved for open communication with IT standard protocols
50%
50%
50%
*) Number of devices each with 40 bytes of input data and 40 bytes of output data on a controller with four ports, taking into account the limitations of the specific controller as regards IO area, cycle time and number of participants.
PROFINET offers adequate performance reserves for e.g. dynamic transmission of cam plate data parallel and unrestricted IT communication ...
PROFINETs performance reserves are more than adequate for the foreseeable future
27
Performance Figures (2)

Achievable positioning precision
Introduction
Movement during a cycle, jitter
Sample application
100 nsec
Motivation
Cycle time, jitter 250 sec 125 sec 10 sec 1 sec
Requirements
speed
Technology
500 mm/sec (30 m / min)
125 m
62.5 m
5 m
0.5 m
50 nm
Machine Tool
Potential for simultaneously transferred TCP/IP packets

Cycle time Jitter No. of participants
Simultaneously transferable TCP/IP data *)
1 msec 1 msec 250 sec
< 1 sec 70 9 MB / sec
< 1 sec 150 6 MB / sec
< 1 sec 35 6 MB / sec

*) Standard length of TCP/IP packets from 64 to 1536 bytes Max. possible data transfer rate for fast Ethernet: 12 MB/sec
Pharmatex 2008
28
Isochronous Real Time (IRT) with Route Planning

If the performance is to be optimized even further:
Objective:
x trains should travel from A to B in the shortest possible time

A
Ancillary
Technology
constraints: Prescribed railroad network, Time spent standing in stations, Journey time between stations. achieved by planning: i.e. by optimizing both the route and the departure times
Objective
Scheduling the communications Specifying transfer times and transfer routes
Optimizing the available bandwidth

29
Hardware Support for IRT

1 TCP/IP
Introduction Motivation Requirements IT Applications

e.g.. HTTP SNMP DHCP...
Device parameterization and configuration Reading diagnostic data Negotiating a channel for user data
PROFINET Applications 1 Configuration

Diagnostics User Data
Technology
Real Time RT 2
Real time
TCP/UDP IP Ethernet
2 RT
High-performance cyclic user data transfer Event driven notifications and alarms
Isochronous Real Time IRT
3 IRT
Synchronously clocked user data transfers Hardware support from ERTEC and NetX Jitter <1sec
Real time
ERTEC
Pharmatex 2008
30
IRT in Standard PLC Why?

Uses the same network for process data and standard Ethernet data (e.g. VoIP) without this affecting the process data Under IRT process data is transferred with its own interval Machine and plant structure with numerous line-switched subscribers and short refresh times IRT devices guarantee shorter throughput times (30%) PLC synchronous initiates drive functions (e.g. positioning) for a number of motion controllers PLC as sync master provides deterministic cyclical communication for PROFINET with IRT
Technology
Pharmatex 2008
31
The PROFINET IO device model

A PROFINET device has a modular structure with slots that contain subslots.
A slot/subslot can contain a module/submodule

The subslot is the addressable element. Slot 0 is representative of the device,
Technology
Subslot 0 is representative for the module.

PROFINET IO device
Slot 0
Slot 1
Virtuelles IO-Device
Slot 2 Subslot 0 Subslot 2 Subslot n
Virtual IO device
Slot n Subslot 0 Subslot 2 Subslot n
PN
Subslot 0 Subslot 1 Subslot n
Subslot 0 Subslot 2 Subslot n
Pharmatex 2008
32
Comfortable diagnosis with topology upload
Technology
Components identify their neighbors

33
Diagnosis with graphic view
Technology
Maintenance information in system transferred through standard interfaces to asset management systems
35
Integrated diagnostics archive

PROFINET messages are stored on the control system.
Date/time System Device name (BMK, ...)
Diag+ 2.0 View: Diag Archive Info
Technology
Offline ?
Priority
Plain text description Message types Diagnostics alarm appears / disappears
Connection interruption appears / disappears

Difference of the target / actual set-up Error when establishing the connection
Pharmatex 2008
36
Comfortable diagnostics with topology upload
Introduction
Device status
Motivation Requirements
Available / not available Error message is available Diagnostics alarm Maintenance alarm Automatic device exchange is possible Priority
Technology
Plain text description
Detailed information
Text output of the error cause
Pharmatex 2008
37
PROFIsafe on PROFINET IO
PROFIsafe on PROFIBUS and PROFINET
PROFINET IO
Technology
PROFIBUS DP PROFIsafe: V2 mode
Increased performance demands No separate safety bus needed
PROFIsafe on PROFIBUS and PROFINET

38
IRT Real-time Communication and PROFIsafe
Technology
Synchronization Domain
PROFIsafe can also be used with IRT without any restrictions

39
Pharmatex 2008
Status and prospects Fieldbus integration

PROFINET Specifications FieldbusIntegration Basics FieldbusIntegration Specific INTERBUS FieldbusIntegration Devices
Technology
Performance Diagnostics Safety Integration Profiles Wireless
PROFIBUS
Existing AS-interface
IO LINK
HART Fieldbus Foundation (FF)
Draft
Conclusion
DeviceNet
Pharmatex 2008
40
Objective target of the fieldbus integration Develop migration concepts to ....

... ensure investment and know-how protection,
seamless engineering,
... integrate devices without PROFINET connection, ... add currently missing functions,
Technology
... reduce connection costs to fieldbus level.

... open up special application areas.
Pharmatex 2008
41
Requirements to the fieldbus integration The fieldbus and device configuration is effected in the engineering system of the control system.
Technology
In the control system, fieldbus devices can be individually addressed.

Diagnostics messages from fieldbus and device errors can be precisely resolved. PROFINET offers worldwide remote access with web services for diagnostics and maintenance. Everything on one cable allows for horizontal and vertical integration.
42
PROFINET has the largest installed base

Integration of fieldbus systems into PROFINET via proxies without changing the existing field devices transparently, without the need for programming Protection of investment
for device manufacturers and system operators
Technology
Pharmatex 2008
43
The proxy concept Key to integration
Engineering system PROFINET
Technology
Proxy 1
SPS
IO
Fieldbus 1
Proxy 2
Fieldbus 2
The proxy is a representative for fieldbus systems to Ethernet.
It is an IO device in PROFINET and master for the fieldbus.

44
Fieldbus integration in PROFINET Scenarios

PROFINET Introduction Motivation Requirements Fieldbus
P Proxy Modular illustration

Physical device
Technology
Logic device 1
Logic device 2 Logic device 3
D Device
P D D
Logic device 3
Compact illustration
Physical device
Transparent illustration
Physical device
Logic device 1
Logic device 2
Every fieldbus device is a module in the proxy Every fieldbus module is a submodule in the proxy
Logic device 1
Logic device 2
Logic device 3
All fieldbus devices are one module in the proxy

Every fieldbus device is a virtual PROFINET device

Pharmatex 2008
45
Fulfillment degree of the requirements
Transparent Integration in the engineering system Fieldbus devices can be individually addressed Precise diagnostics Low updating times
Modular
Compact
Technology
O O O
Selection of the modular integration concept for fieldbuses

46
Operation
Introduction Motivation Requirements IO controller IO controller configuration tool PROFINET PROFINET device description (GSDML) PROXY module
Technology
Performance Diagnostics Safety Integration Profiles
Conclusion
Fieldbus
Wireless
Pharmatex 2008
47
Profiles and their effective application

The PROFIBUS profiles will be completed by a mapping for PROFINET.
User benefits Application of international and worldwide common standards Accepted by user associations, e.g. NAMUR and OMAC Interoperability between devices from different manufacturers Manufacturer benefits Only one test tool for device development and certification preparation needed Support by PI Competence Centers
Technology
Certification test by accredited PI Test Labs
Examples for this are PROFIdrive or PROFIsafe for PROFIBUS and PROFINET
48
PROFINET - wireless
Technology
IEEE 802.11 (WLAN) Cyclic data traffic Monitoring of the wireless connection Redundant wireless operation on two separate frequency bands for increased availability IEEE 802.15.2 (Bluetooth)
49
PROFINET WLAN Technology
Technology
Industrial WLAN IEEE 802.11 Cyclical data traffic
Monitoring of the radio link

Redundant radio operation on two separate frequency bands for increased availability PROFIsafe via WLAN
50
PROFINET The comprehensive solution
Technology
Integration
Safety
Diagnostics
Performance
Pharmatex 2008
51
Ethernet for automation = PROFINET
Technology
Pharmatex 2008
52

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PROFINET Technology For Factory & Process Automation: Hassan Kaghazchi, University of Limerick

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PROFINET Technology for Factory & Process Automation

Hassan Kaghazchi, University of Limerick

Two Technologies One Organization

Introduction Motivation Requirements

PI (PROFIBUS & PROFINET International)

PI: Worldwide Support

36 PI Competence Centers (PICC) in 21 countries 12 PI Training Centers (PITC) in 8 countries

10 PI Test Laboratories (PITL) for certification tests

Belgium RPA, PICC

France RPA, PICC

Italy RPA, PICC

Sweden RPA, PICC

Middle-East RPA South-East-Asia RPA, PICC Thailand PICC 3

Netherlands RPA, PICC, PITC, PITL

Switzerland RPA, PICC, PITC

Czech Rep. RPA PICC, PITL Poland RPA, PICC

Introduction Motivation Requirements

> 1.400 members worldwide

PROFIBUS Status: Oktober 2007 International

Introduction Motivation Requirements

In 2007: 4.5 m nodes!

Integration Profiles Wireless Conclusion

PROFINET: What is counted?

Introduction Motivation Requirements

Installed PROFINET nodes end 2007

Introduction Motivation Requirements

Growth: New ARC reference

Introduction Motivation Requirements

PROFINET nodes: Outlook to 2010

Introduction Motivation Requirements

Average annual increase of 37%

PROFIBUS and PROFINET: A comparison

Introduction Motivation Requirements

Safety Integration Profiles Wireless Conclusion

PROFINET For all corporate functions

Introduction Motivation Requirements

Control Level Field Level

PROFINET The solution for all industries

For the overall workflow

PROFINET for Scalable Real-time Solutions

Introduction Motivation Requirements

PROFINET - The scalable communication

PROFINET Example application

PROFINET as Modular Technology

Network Installation & Network Management

Introduction Motivation Requirements

= 100 MBit/s Switched Fast Ethernet

= Unrestricted TCP/IP Communication

PROFINET IO system elements

Introduction Motivation Requirements

(STEP7, PC WORX, etc.)

(Monitor, diagnostics, OPC)

IO controller (PLC, PC, etc.)

IO device (field device)

Real Time (RT)

Introduction Motivation Requirements

Real-time telegrams get priority

e.g. HTTP SNMP DHCP...

Real Time (RT)

Isochronous Real Time (IRT) with PROFINET

Reserved for IRT

Profiles Wireless Conclusion