Validation of PROFINET plants

Size: px

Start display at page:

Download "Validation of PROFINET plants"

Esmond Williamson
8 years ago
Views:

1 PI Competence Center &PI Training Center Validation of PROFINET plants Paolo Ferrari & CSMT Gestione s.c.a.r.l. Facoltà di Ingegneria, Università di Brescia, Via Branze Brescia (Italy) Tel: fax: web: CSMT Gestione Scarl 1

Facoltà di Ingegneria, Università di Brescia, Via Branze 38-25123 Brescia (Italy) Tel:

2 CSMT scoreboard Overall count Number of networks Number of centralized architecture Number of distributed controller architecture Number of controllers Number of redundancy rings Number of devices Independent networks Some networks may have multiple rings Smallest network with 4 devices, largest with 450 Not only automotive! CSMT Gestione Scarl 2

devices 329 296 23 623 228 20446 Independent networks Some networks may have multiple rings

The procedure for the plant validation The procedure designed by CSMT for the plant validation of PROFINET networks has been divided in two phases 1.

3 The procedure for the plant validation The procedure designed by CSMT for the plant validation of PROFINET networks has been divided in two phases 1. Self-declaration of the OEM and test of a sample line Self-evaluation checklist has been prepared CSMT verify the checklist is in accordance with which has been implemented in the sample line (OEM audit) 2. Audit validation of the entire plant CSMT verifies and measures the performance of the entire plant once it has been realized CSMT Gestione Scarl 3

Self-declaration of the OEM and test of a sample line Self-evaluation checklist has been prepared CSMT verify the checklist is

4 PHASE 1: Self-declaration and PROFINET checklist Every OEM that builds plants must fill in a PROFINET checklist prepared by CSMT following the guidelines of PROFIBUS International and the rules of the final user. The objective of the PROFINET Checklist is to help OEM to produce plant which are tested and compliant. The PROFINET Checklist is composed of Questions to be answered by the OEM Information that the OEM must give for easing final validation The checklist is a formal OEM declaration that the plant is compliant with PROFIBUS International guidelines CSMT executes one Audit for each OEM in order to Verify compliance with the realized plant Help OEM on critical points CSMT Gestione Scarl 4

The PROFINET Checklist is composed of Questions to be answered by the OEM Information that the OEM must give for easing final validation The checklist is a formal OEM declaration

5 PHASE 1: Example of Checklist YES NO n.a. OK Grade Cable laid according to plan and schematics? Y A Network topology observed? Y A Cable type according to planning? Y A Is the cable a PROFINET copper cable (100Base-TX with 2x2 wires)? Y B Cable parameters verified? Y A Correct answer Importance of the question Last version of the checklist contains about 120 questions Checklist is multilanguage CSMT Gestione Scarl 5

Y A 1 3 1 Is the cable a PROFINET copper cable (100Base-TX with 2x2 wires)? Y B 1 3 2 Cable parameters verified?

6 PHASE 2: Validation of the entire plant CSMT is in charge to verify the performance of the entire plant The Checklists e the Audit of the OEMs guarantee that any single part of the plant is compliant with the building guidelines CSMT verified sample parts of the plant to check accordance between Checklist and implemented network. CSMT estimated the performance of all the parts of the plant from the PROFINET IO point of view CSMT Gestione Scarl 6

guidelines CSMT verified sample parts of the plant to check accordance between Checklist and implemented network.

7 PHASE 2: Validation of the entire plant Checklist and self declarations A B OEM A OEM B OEM A C D OEM D OEM C Validation of the entire plant Final report on the plant Plant site CSMT Gestione Scarl 7

D OEM C Validation of the entire plant Final report

8 The network topology Generally plants are composed of several separate Ethernet networks Each network is connected to the plant Ethernet by means of a gateway (e.g. a dedicated CP card in the PLC) The PROFINET IO is transported only in the lower level networks. Factory network and gateways out of scope of the validation Gateway Gateway Gateway Gateway Gateway Automation island networks in scope CSMT Gestione Scarl 8

Factory network and gateways out of scope of the validation Gateway Gateway Gateway Gateway Gateway Automation island networks in scope

9 Validation steps In each network the following validation steps must be done 1. Visual inspection of cabinets (limited scope, the OEM already signed the Checklist) 2. Determine the number of active PROFINET devices 3. Collect the frame errors (physical) in all the network links connected to PROFINET ports using SNMP 4. Record traffic load of network (measured in series to each IOcontroller) 5. Record traffic load of the redundancy ring (recorded in the first link after the Redundancy Manager) 6. Record traffic load during ring redundancy switch over 7. Test network cables belonging to a specific list chosen by final user (e..g. redundancy rings) 8. Test network cables with error greater than the imposed threshold CSMT Gestione Scarl 9

Record traffic load of network (measured in series to each IOcontroller) 5. Record traffic load of the redundancy ring (recorded in the first link after the Redundancy Manager) 6.

10 Immediate feedback on validation An immediate feedback is provided at the OEM. 1. All the cable tests must show pass 2. The traffic load in any of the tested link must be under the imposed level 3. The redundancy switch over must not block the network The OEM is required to fix all the problems ASAP. If fixing is done quickly, the test can be repeated immediately. This way to proceed is very appreciated by the OEM that can close the validation step in a short period of time CSMT Gestione Scarl 10

The redundancy switch over must not block the network The OEM is required to fix all the problems ASAP.

11 Specific software for validation CSMT developed a specific software that guides the engineer through the validation activities CSMT Gestione Scarl 11

12 Traffic load at IO-Controller during switchover NOTE: it is an example! Ring open elsewhere PLC software error CSMT Gestione Scarl 12

13 Finding out the faulty link Scouting the network for errors with SNMP CSMT Gestione Scarl 13

14 Locating the fault in the plant Topology view CSMT Gestione Scarl 14

15 Experience and proper tool/procedure are important Overall improvement in the same project 7.0 lines/day 4.8 lines/day 3.7 lines/day 8.6 lines/day 2.5 lines/day 7.9 lines/day CSMT Gestione Scarl 15

16 Design and maintenance rules in PROFINET plant Rule #1 : Use ONLY managed switch (CC-B or CC-C) Rule #2 : Be sure to follow rule # CSMT Gestione Scarl 16

CSMT Gestione Scarl -Centro di Competenza PROFIBUS e PROFINET www.csmt.it

CSMT Gestione Scarl -Centro di Competenza PROFIBUS e PROFINET www.csmt.it 1 Un caso virtuoso di PROFINET applicato all industria di processo Paolo Ferrari Dipartimento di Ingegneria dell Informazione, Università di Brescia Via Branze 38-25123 Brescia (Italy) CSMT Gestione Scarl