PROFINET. Applying the. Ethernet. Standard to. Industrial. Automation. Peter Thomas Control Specialists Ltd.

Transcription

1 PROFINET Applying the Ethernet Standard to Peter Thomas Control Specialists Ltd Industrial Automation Automation Seminar Coventry July 2014

2 Objectives 2 PROFINET - Applying the Ethernet Standard to Industrial Automation. A review of PROFIBUS PROFINET the natural evolution of PROFIBUS Connecting to existing Fieldbus systems Control System Configuration Network Monitoring Considerations

3 Review of PROFIBUS PROFIBUS is a multi-drop network where many devices are connected to one cable. Every PROFIBUS device must have a unique address which is set by the engineer during set up Up to 126 PROFIBUS devices can be connected together in a single network. However only 32 devices can be connected on a segment. Segments are formed using repeaters, hubs, optical links or couplers. DP devices run on RS485 cabling using shielded twisted pair cable terminated at the ends to stop reflections. PA devices run on Manchester Bus Powered (MBP) cable.

4 Review of PROFIBUS A PROFIBUS network must have a Class-1 master. The Class-1 master must be configured to communicate with its allocated slaves. Each device has a GSD file which describes its characteristics, options, diagnostics etc. A Class-2 master can optionally be connected to the network for engineering functions such as parameter setting, calibration or diagnostics etc. DP devices can run at a bit rate from 9.6kbit/s up to 12Mbit/s (all devices at the same bit rate). PA devices always run at 31.25kbit/s.

5 Review of PROFIBUS The protocol is a simple master slave communication with token passing between masters. Only one device can talk at a time and communicational is one way at a time (half duplex). Device start up is standardised and checks include: ID number, unique identification for each type of device (check configured ID=device ID) IO configuration (check modules present=modules configured) Standardised diagnostics. Communication errors and peripheral errors. Standardised profiles PA devices, drives, encoders, safety etc.

6 What is PROFINET? PROFINET is an open Industrial Ethernet standard developed by the PROFIBUS Organisation. It is NOT PROFIBUS over Ethernet. PROFINET uses completely standard modern Ethernet (IEEE802.3). However, some features of PROFINET require additional standards to operate. Ethernet is not a multi drop network. Each cable only connects two devices. Switches are used to branch from device to device with a maximum cable length between devices of 100m Ethernet uses four core twisted pair screened cable Termination (to stop reflections) is provided in every device and is no longer in the hands of the user.

7 PROFINET PROFINET is not a master/slave protocol. Full duplex communication is used which means that devices can read and write at the same time. PROFINET operates at 100Mbit/s or faster. PROFINET makes use of Existing IT standards but, unlike IT systems, is real-time and deterministic. PROFINET is very well thought out to meet all the requirements of automation and control systems incorporating: High speed time communication with a range of real-time performance classes. Standardised communication and peripheral diagnostics. Profiles for a wide range of applications.

8 PROFINET IO devices E.g. PLC running application program. (Compare with PROFIBUS Class-1 master) IO-Controller Ethernet PROFINET Supervisor E.g. PC or laptop running engineering tool application. (Compare with PROFIBUS Class-2 master) Configuration Control/monitoring Alarms IO-Device E.g. Field device with inputs/outputs (Compare with PROFIBUS Slave device) Diagnosis Status/Control Parameters

9 PROFIBUS and the OSI model FMS DP PA User layer FMS profiles DP profiles PA profiles application (7) Fieldbus Message Specification (FMS) DP basic functions DPV0 DP extensions DPV1, DPV2 OSI model (3) to (6) Not used data link (2) physical (1) Fieldbus Data Link (FDL) RS485/Fibre optic MBP interface MBP(IEC )

10 PROFINET and the OSI model Non time critical communications Real time communications User layer Profiles Profiles Application Layer (7) PROFINET Application Layer Presentation Layer (6) Session Layer (5) Not used Not used Transport Layer (4) Network Layer (3) Data Link Layer (2) Physical layer (1) TCP/UDP IP Standard fast Ethernet. PROFINET Real-time channel

11 PROFINET IO Many features that have been developed for PROFIBUS devices have been directly incorporated into PROFINET: Standardised module and channel-related diagnostics, Alarm and status information, Identification and Maintenance (I&M) functions, Time stamping, Device description file (GSD) with configuration data for the device and available modules PROFINET based on XML (called GSDML) Highly deterministic process cycle timing.

12 Real-Time Operation What does Real-Time mean? A real-time control system responds in a deterministic manner within a time which is short compared to the plant response time. i.e. it depends on the application! Standard communications (IT) requires a response in the order of ~100ms. Factory automation requires a response time in the order of 1 to 10ms. Multi axis motion control requires a response time in the order of 0.1 to 1ms with a jitter of less than 1µs.

13 Real-Time Operation PROFINET makes use of: TCP/IP for standard communications, achieving response times typically less than 100ms. A Real-Time, RT, channel for I/O communications, achieving cycle times between 1 and 10ms. Isochronous Real-Time, IRT, channel for highly deterministic performance (drives and servos), achieving cycle times down to 32µs with <1µs jitter. RT and IRT communications are totally compatible with TCP/IP. Because they are encapsulated inside a standard Ethernet frame.

14 Real-Time Operation PROFINET IRT complies with IEEE 1588 Precision clock synchronization protocol for networked measurement and control systems. However this not always good enough! PROFINET extensions to IEEE 1588 provide better accuracy with: Automatic determination and compensation of the network transmission time. Giving less than 1µs jitter.

15 Isochronous Real-Time Operation Cycle 1 Cycle 2 Cycle 3 IRT channel Non real-time channel IRT channel Non real-time channel IRT channel Non real-time channel Sync IRT RT NRT Open channel i.e. TCP/IP Cycle times down to 32µs possible

16 IRT traffic IRT traffic uses a reserved time slot at the beginning of each cycle. This is always delivered on time. RT traffic has higher priority than standard TCP/IP traffic. TCP/IP must wait for RT to finish. Overtaking lane IRT Reserved for IRT IRT RT RT TCP/IP RT TCP/IP RT RT TCP/IP RT RT TCP/IP RT TCP/IP Normal lane

17 IRT performance Central control with motion control and operator panel Open factory network E.g. 24 axes with 1000byte I/O Router PROFIdrive profile Multi-axis drives Single-axis drives Cycle time 1 ms, IRT phase less than 200µs, leaving ~80 % for RT and standard communication.

18 Functional Safety with PROFINET PROFINET also offers safety oriented communication that allows for integrating safety oriented components. A second 'safety fieldbus' is not necessary. PROFIsafe V2 can be used in functional safety systems up to EN954 cat 4, PL e or SIL3. PROFIsafe is a profile that can be used in PROFIBUS and PROFINET. However, PROFINET has a significant advantage that safe and standard IO can be mixed in a single device.

19 Functional Safety with PROFINET Safety application Standard application Safety application Standard application PROFISAFE layer Standard PROFINET I/O protocol PROFISAFE layer Standard PROFINET I/O protocol Ethernet PROFIsafe Profile PROFINET Blackchannel PROFIsafe V2 provides functional safety for both PROFIBUS and PROFINET systems. Suitable for use in SIL3 applications.

20 Other innovations on PROFINET Time synchronisation and time stamping. The IRT facilities allow accurate time stamping to be implemented using IRT clock synchronisation. Configuration in Run The ability to change the configuration of a device without stopping the control application. Standardised, scalable redundancy High availability using redundant ring architecture and standard Media Redundancy Protocol, MRP. Standardised energy saving using the PROFIenergy profile. Intelligent shutdown and start-up from power save.

21 Integration with Fieldbus Over 3000 different products are available on PROFIBUS from over 300 different manufacturers. There are currently far fewer devices available for PROFINET. So integration of PROFIBUS and PROFINET is very desirable. PROFINET provides a transparent interface with PROFIBUS via a standardised gateway or Proxy. The Proxy is a PROFINET IO device on one side and a PROFIBUS master on the other. PROFIBUS Configuration is integrated into the PROFINET configurator and is downloaded via Ethernet. PROFIBUS PROFINET

22 Integration with Fieldbus PROFINET PROXY PROFIBUS DP PROXY INTERBUS-S PROFIBUS PA PROXY Other fieldbusses: AS-i, Modbus, DeviceNet, and others being developed.

23 Hardware Configuration Configuring a PROFINET system is very similar to configuring a PROFIBUS system. The configuration is usually done using the programming tool of the hardware vendor e.g. Siemens Step 7 Rockwell RS Logix 5000 etc. Before you begin make sure that you have the GSDML files for each device on the network. For each device you add, you assign a user-friendly device name and an IP address.

24 Siemens Hardware Configuration 24

25 Network Diagnostics The use of PROFINET diagnostic tools and devices will allow you to monitor the live status of your PROFINET Network. During the design phase, careful consideration has to be given as to how these tools will connect to the network. Connecting a device or tool to the wrong point in the network can result in misleading, or even missing, diagnostic information.

26 Network Monitoring Considerations There are three preferred ways of connecting a diagnostic tool to a PROFINET network:- Via a Mirrored Port on a managed switch. Using a TAP in series with the with the IO Controller and its IO devices. Using a permanently connected diagnostic device. However, very often, the first two of these methods only allow communications in one direction, i.e. to the monitoring software. This can lead to certain functions of the tool not working.

27 Diagnostic Monitoring using a Managed Switch SIEMENS CP315-2 DPPN CPU MASTERRACKCPU E-8C-FE-75-E2 SIEMENS X208 8-PORT SWITCH (WEB) 00-0E-8C-9B-94-BD MOXA ETS PORT SWITCH E8-0C-B6-29 WAGO RACK03DEV E-8C-9B-94-BD SIEMENS ET200S RACK03DEV B-1B-25-B7-1D Let us consider the monitoring all PROFINET communications between the IO Controller and the 3 IO Devices by connecting to the 8-port switch. MURR IMPACT20 RACK03DEV F-9E-08-7F-DE

28 Ethernet Switches PROFINET networks make extensive use of switches. Simply plugging in a diagnostic tool into a spare port on the switch will not work because switches only send messages to the port to which the intended receiving device is connected. To overcome this we set up one port as a mirrored port (usually a feature of managed switches). But note, that some mirrored ports are NOT bi-directional which can prevent certain diagnostic functions working

29 Diagnostic Monitoring using a Managed Switch SIEMENS CP315-2 DPPN CPU MASTERRACKCPU E-8C-FE-75-E2 SIEMENS X208 8-PORT SWITCH (WEB) 00-0E-8C-9B-94-BD MOXA ETS PORT SWITCH E8-0C-B6-29 WAGO RACK03DEV E-8C-9B-94-BD SIEMENS ET200S RACK03DEV B-1B-25-B7-1D The solid line connects the laptop to a mirrored port the dashed line is a second connection to a spare port this is only required when the mirrored port is NOT bidirectional AND the diagnostic software needs to transmit data MURR IMPACT20 RACK03DEV F-9E-08-7F-DE

30 Softing EchoTap If you do not have a switch that supports port mirroring, an alternative is to use a TAP. Taps have two RJ45 ports and are connected in series with the device(s) that you want to monitor. The PC connects to the Tap via a USB interface. By definition, the installing of a tap requires you to disrupt the network when installing it. IN OUT USB

31 Diagnostic Monitoring using a Softing EchoTap SIEMENS CP315-2 DPPN CPU MASTERRACKCPU E-8C-FE-75-E2 SIEMENS X208 8-PORT SWITCH (WEB) 00-0E-8C-9B-94-BD MOXA ETS PORT SWITCH E8-0C-B6-29 WAGO RACK03DEV E-8C-9B-94-BD SIEMENS ET200S Connection to spare port RACK03DEV B-1B-25-B7-1D MURR IMPACT20 USB RACK03DEV F-9E-08-7F-DE

32 Permanent Monitoring Softing BC502 PN SIEMENS CP315-2 DPPN CPU MASTERRACKCPU E-8C-FE-75-E2 SIEMENS X208 8-PORT SWITCH (WEB) 00-0E-8C-9B-94-BD MOXA ETS PORT SWITCH E8-0C-B6-29 WAGO RACK03DEV E-8C-9B-94-BD SIEMENS ET200S Connection to web server RACK03DEV B-1B-25-B7-1D MURR IMPACT20 RACK03DEV F-9E-08-7F-DE

33 WireShark Wireshark is a network protocol analyser. It lets you capture and interactively browse the traffic running on a computer network. It is not dedicated to PROFINET and as such cannot be compared to ProfiTrace. It is free to download and available from

34 WireShark Wireshark can be used to capture and analyse the following PROFINET traffic:- Start-Up Checks / IP Assignment etc. Data Exchange Loss of Module Loss of Communications Duplicate Device Name SNMP / LLDP traffic

35 Using a Managed Switch with WireShark SIEMENS CP315-2 DPPN CPU MASTERRACKCPU E-8C-FE-75-E2 SIEMENS X208 8-PORT SWITCH (WEB) 00-0E-8C-9B-94-BD MOXA ETS PORT SWITCH E8-0C-B6-29 WAGO RACK03DEV E-8C-9B-94-BD SIEMENS ET200S RACK03DEV B-1B-25-B7-1D Connection to mirrored port MURR IMPACT20 RACK03DEV F-9E-08-7F-DE

36 Using an EchoTap with WireShark SIEMENS CP315-2 DPPN CPU MASTERRACKCPU E-8C-FE-75-E2 SIEMENS X208 8-PORT SWITCH (WEB) 00-0E-8C-9B-94-BD MOXA ETS PORT SWITCH E8-0C-B6-29 WAGO RACK03DEV E-8C-9B-94-BD SIEMENS ET200S Connection to spare port RACK03DEV B-1B-25-B7-1D MURR IMPACT20 USB RACK03DEV F-9E-08-7F-DE

37 Questions? 37 Peter Thomas Control Specialists Ltd LinkedIN Tel +44(0) Mob +44(0)