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PROFINET Technology for Factory & Process Automation

PROFINET Technology for Factory & Process Automation. Hassan Kaghazchi, University of Limerick. Two Technologies – One Organization. France RPA, PICC. Belgium RPA, PICC. Ireland RPA, PICC, PITC. Norway RPA, PICC, PITC. Czech Rep. RPA PICC, PITL. W- EU. Sweden RPA, PICC. E- EU.

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PROFINET Technology for Factory & Process Automation

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  1. PROFINET Technology for Factory & Process Automation Hassan Kaghazchi, University of Limerick

  2. Two Technologies – One Organization Pharmatex 2008

  3. France RPA, PICC Belgium RPA, PICC Ireland RPA, PICC, PITC Norway RPA, PICC,PITC Czech Rep. RPA PICC, PITL W- EU Sweden RPA, PICC E- EU Italy RPA, PICC Denmark RPA Poland RPA, PICC Netherlands RPA, PICC, PITC, PITL Germany + Austria RPA, PICC PITC, PITL Russia RPA Switzerland RPA, PICC, PITC Finland RPA UK RPA, PICC, PITC Slovakia RPA China RPA PICC, PITL Japan RPA PICC, PITL Asia Korea RPA, PICC Brazil RPA, PICC Middle-East RPA America Australia/ New Zealand RPA Thailand PICC USA RPA, PICC, PITC, PITL Southern Africa RPA, PICC, PITC South-East-Asia RPA, PICC PI: Worldwide Support • 26 Regional PI Associations (RPA) • 36 PI Competence Centers (PICC) in 21 countries • 12 PI Training Centers (PITC) in 8 countries • 10 PI Test Laboratories (PITL) for certification tests Pharmatex 2008

  4. PI Membership Growth • Vendors • Distributors • Consultancies • Integrators • End users • Institutes • Training institutes > 1.400 membersworldwide total Europe Asia America Status: Oktober 2007 Pharmatex 2008

  5. 25 m PROFIBUS DP nodes PROFIBUS Nodes 25 m In 2007: 4.5 m nodes! 20 m 18.8 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. 15 m 10 m 5 m Time 2008 1994 1999 2004 2007 2000 1990 Pharmatex 2008

  6. HMI Controllers Decentralized peripherals Sensors Proxies Proxies Robots Motion Control& drives Decentralizedperipherals PROFINET: What is counted? Pharmatex 2008

  7. 1.14 m 1.14 m Installed PROFINET nodes end 2007 PROFINET nodes 4 m 3 m 3 m 1 m Time 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Pharmatex 2008

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

  9. 4 m 3 m 3 m Average annual increase of 37% 2 m 1 m PROFINET nodes: Outlook to 2010 PROFINET nodes 1.14 m Time 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Pharmatex 2008

  10. PROFIBUS and PROFINET: A comparison PROFINET/PROFIBUS nodes 4 m 3 m 2 m 1 m Time Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Pharmatex 2008

  11. PROFINET – For all corporate functions ERP MES ControlLevel Field Level Seamless from the management to the field level from planning to production Pharmatex 2008

  12. PROFINET – The solution for all industries • For all industries and applications • For the overall workflow Pharmatex 2008

  13. PROFINET for Scalable Real-time Solutions PROFINET with RT (Real Time) PROFINET with IRT (IsochronousReal Time) Synchronously clocked application Planning Performance / Cost PROFINET is the only Ethernet solution that uniformly covers all the requirements of real-time communication without restricting openness. Pharmatex 2008

  14. Internet • Automation • Motion Control <100ms <10ms <1ms IT services TCP/IP IRT RT Is real-time Ethernet 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 Pharmatex 2008

  15. PROFINET – Example application Line System Cell Field INTERBUS PROFIBUS Wireless PROFINET Pharmatex 2008

  16. PROFINET as Modular Technology • Application Profiles • Encoder • LVSG • Ident Systems MES Process Automation • Fieldbus integration II • IO-Link • CANopen • FF Motion Control Safety Train Application WEB Integration DecentralPeripherals Real-time Communi-cation • Fieldbus integration I • PROFIBUS • INTERBUS • DeviceNet • HARTAS-I Distributed Automation Network Installation & Network Management Test +Certification Data Security WLAN Pharmatex 2008

  17. PROFINET Technology • = 100 MBit/s Switched Fast Ethernet • = Unrestricted TCP/IP Communication • = Real-Time Communication • = WLAN Technology • = Failsafe Communication Pharmatex 2008

  18. Software PROFINET IO system elements Devices • Engineering system • (STEP7, PC WORX, etc.) • Network configuration • I/O address assignment • Parameter values • Configuration download • IO supervisor • (Monitor, diagnostics, OPC) • Read input/output data • Write parameter data • Accepted by IO controller • Evaluate diagnostics Ethernet • 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

  19. 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 PROFINET Applications • IT Appli-cations • e.g. • HTTP • SNMP • DHCP... • Real-time telegrams get priority • Facilitates refresh times of 1 or 2 ms for current data volume Configuration Diagnostics User Data TCP/UDP Real Time IP Real Time (RT) Ethernet Pharmatex 2008

  20. RT RT RT RT RT RT RT RT RT TCP/IP TCP/IP TCP/IP TCP/IP TCP/IP TCP/IP TCP/IP IRT IRT IRT IRT IRT IRT IRT IRT TCP/IP IRT 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) Reserved for IRT Pharmatex 2008

  21. 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 • Basic technology for synchronously clocked applications IRT Interval IRT Interval IRT Interval TCP/IP TCP/IP TCP/IP Cycle 2 = time window Cycle 1 Cycle n e.g. 1 ms position control clocking Isochronous Communication TCP/IP Communication IO Data TCP/IP Data Pharmatex 2008

  22. Motion Control and TCP/IP PROFINET • Maximum performance and flexibility • Motion control with simultaneous image data transfer • Non-reactive coexistence  IRT and TCP/IP on a single cable Pharmatex 2008

  23. 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 Field device Field device Drive Controller Pharmatex 2008

  24. PROFINET for Clock-Synchronised Applications (2) • Based on clock-synchronized data transfer • Application, data transfers and device cyclesare synchronous • Cycle times < 1ms with jitter precision < 1µs • Typical field of application is motion control Communication cycle Application cycle Device cycle Field device Field device Drive Controller Pharmatex 2008

  25. T4 PLC CPU T5 T3 T2 T6 T7 T1 Decentral peripherals 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 Optimal regulation with short program cycles Pharmatex 2008

  26. 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 modifyingthe network • Short response times even for large data volumes Pharmatex 2008

  27. Performance Figures (1) • PROFINET offers adequate performance reserves for e.g. • dynamic transmission of cam plate data • parallel and unrestricted IT communication • ... Performance figures for applications using PROFINET and IRT *) 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’s performance reserves are more than adequate for the foreseeable future Pharmatex 2008

  28. Performance Figures (2) • Achievable positioning precision • Potential for simultaneously transferred TCP/IP packets • Cycle time • 1 msec • 1 msec • 250 µsec • Jitter < 1 µsec < 1 µsec < 1 µsec • No. of participants 70 150 35 *)Standard length of TCP/IP packets from 64 to 1536 bytes Max. possible data transfer rate for fast Ethernet: 12 MB/sec • Simultaneouslytransferable TCP/IP data *) 9 MB / sec 6 MB / sec 6 MB / sec Pharmatex 2008

  29. A B 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 • Ancillary constraints:Prescribed railroad network,Time spent standing in stations, Journey time between stations. • Objective achieved by planning:i.e. by optimizing both the route and the departure times • Scheduling the communications • Specifying transfer times and transfer routes Optimizing the available bandwidth Pharmatex 2008

  30. Hardware Support for IRT TCP/IP • Device parameterization and configuration • Reading diagnostic data • Negotiating a channel for user data Real Time RT • High-performance cyclic user data transfer • Event driven notifications and alarms Isochronous Real Time IRT • Synchronously clocked user data transfers • Hardware support from ERTEC and NetX • Jitter <1μsec 1 PROFINET Applications • IT Appli- cations • e.g.. • HTTP • SNMP • DHCP... Configuration Diagnostics 1 User Data 2 TCP/UDP Real time IP RT IRT 2 3 3 Ethernet Real time ERTEC Pharmatex 2008

  31. 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 Pharmatex 2008

  32. 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, • Subslot 0 is representative for the module. PROFINET IO device Virtual IO device Virtuelles IO-Device Slot 0 Slot 1 Slot 2 Slot n Subslot 0 Subslot 0 Subslot 0 Subslot 0 PN Subslot 1 Subslot 2 Subslot 2 Subslot 2 Subslot n Subslot n Subslot n Subslot n Pharmatex 2008

  33. Components identify their neighbors Comfortable diagnosis with topology upload Pharmatex 2008

  34. Maintenance information in system transferred through standard interfaces to asset management systems Diagnosis with graphic view Pharmatex 2008

  35. Integrated diagnostics archive • PROFINET messages are stored on the control system. • Date/time • System • Device name (BMK, ...) • 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 • Device status • Available / not available • Error message is available • Diagnostics alarm • Maintenance alarm • Automatic device exchange is possible • Priority • Plain text description • Detailed information • Text output of the error cause Pharmatex 2008

  37. PROFINET IO PROFIsafe: V2 mode PROFIBUS DP PROFIsafe on PROFINET IO PROFIsafeon PROFIBUS and PROFINET • Increased performance demands • No separate safety bus needed • PROFIsafe on PROFIBUS and PROFINET Pharmatex 2008

  38. IRT Real-time Communication and PROFIsafe Synchronization Domain PROFIsafe can also be used with IRT without any restrictions Pharmatex 2008

  39. Status and prospects – Fieldbus integration Fieldbus-Integration Basics Existing Draft PROFINET Specifications Fieldbus-Integration Specific Fieldbus-Integration Devices INTERBUS PROFIBUS AS-interface IO LINK HART Fieldbus Foundation (FF) 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, ... 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. • 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. Pharmatex 2008

  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 Pharmatex 2008

  43. The proxy concept – Key to integration • The proxy is a representative for fieldbus systems to Ethernet. • It is an IO device in PROFINET and master for the fieldbus. Engineering system PROFINET Proxy 2 Proxy 1 SPS IO Fieldbus 1 Fieldbus 2 Pharmatex 2008

  44. PROFINET P Proxy Fieldbus D Device • Every fieldbus device is a module in the proxy • Every fieldbus module is a submodule in the proxy Compact illustration Modular illustration Transparent illustration Physical device Physical device Physical device P P P D D D D Logic device 3 Logic device 2 Logic device 3 Logic device 3 Logic device 1 Logic device 2 Logic device 2 Logic device 1 Logic device 1 All fieldbus devices are one module in the proxy Every fieldbus device is a “virtual“ PROFINET device Fieldbus integration in PROFINET – Scenarios Pharmatex 2008

  45. Fulfillment degree of the requirements • Selection of the modular integration concept for fieldbuses Pharmatex 2008

  46. IO controller IO controller configuration tool PROFINET device description (GSDML) PROFINET Import PROXY module Fieldbus Operation Configuration Configuration Pharmatex 2008

  47. Profiles and their effective application • The PROFIBUS profiles will be completed by a mapping for PROFINET. • Examples for this are PROFIdrive or PROFIsafe for PROFIBUS and PROFINET Pharmatex 2008

  48. PROFINET - wireless • 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) Pharmatex 2008

  49. PROFINET WLAN 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 Pharmatex 2008

  50. PROFINET • The comprehensive solution • Integration • Safety • Diagnostics • Performance Pharmatex 2008

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