PROFINET Network Diagnostics at Audi Neckarsulm, Germany

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1 PROFINET Network Diagnostics at Audi Neckarsulm, Germany Bernd Kremer, Softing Industrial Automation PI UK Conference 23/24 June 2015 The Stratford Manor Hotel Photo: Audi AG

2 PROFINET and German Automobile Industry About Audi PROFINET at Audi Neckarsulm Network Diagnostics Requirements at Audi About the Solution Résumé Softing 2014 / Page 2 of 20

3 PROFINET and German Automobile Industry AIDA - Automation Initiative of German Car Manufacturers Founded 2003 Development of mutual positions on automation topics (e.g. harmonization / standardization of technologies) 2004 decision for using PROFINET Setting requirements for every PROFINET component being used in Automotive production Integrated safety (PROFIsafe) CC B (RT) or CC C (IRT) Fast Start-Up (FSU) Media redundancy PI-Certification Support of network management services PROFINET and standard Ethernet through common port Connectivity via copper as well as fiber optics Integrated switch for line and ring topologies Photo: Shutterstock Softing 2014 / Page 3 of 20

Integrated safety (PROFIsafe) CC B (RT) or CC C (IRT) Fast Start-Up (FSU) Media redundancy PI-Certification Support of network management services PROFINET and standard

4 About Audi Facts and Figures Member of Volkswagen (VW) Group More then 73,000 employees Over 1,5 million cars sold (49 models) #1 sales position with Premium Cars in Europe and China 2 digit growth in main export markets USA, China and Great Britain 11 Production Sites Ingolstadt and Neckarsulm responsible for installation of production lines at other sites Photo: Audi AG one name, one standard, everywhere Softing 2014 / Page 4 of 20

markets USA, China and Great Britain 11 Production Sites Ingolstadt and Neckarsulm responsible for

5 About Audi Neckarsulm Plant More then 15,000 employees Over 275,000 built 1 st place J.D. Power Award for best assembly quality in Europe and Africa Site with broadest product variety (19 models) 10.8 Million ft 2 production floor space New pressing plant One aluminum-steel frame and body construction facility Two pure aluminum frame and body construction facilities One paint spray line Multiple assembly lines Lead for production sites Changchun and Foshan, China Aurangabad, India Lamborghini, Italy Photos: Audi AG Softing 2014 / Page 5 of 20

8 Million ft 2 production floor space New pressing plant One aluminum-steel frame and body construction facility Two pure aluminum frame

6 PROFINET at Audi Neckarsulm Network Composition First PROFINET installations proving high speed communication capabilities and robustness in 2006 (A8 Project) 1 GBit/s Uplink from Network Cabinet to Access Switch Network structure laid-out for up to 8 cells Cells based on PROFINET with some Ethernet components Cu-wiring of Facility and Cell networks with PROFINET Type B cables only Field installations of cells (CC-C / IRT) as redundant POF-rings Max. 40ea subscribers plus max. 10ea on branches Exceeding subscribers as extra ring on additional IRT-switch Each cell as own Class C network (256 IP-Addresses) One network diagnostics interface TH LINK PROFINET per cell (own IP-address) Graphics: Audi AG Softing 2014 / Page 6 of 20

PROFINET Type B cables only Field installations of cells (CC-C / IRT) as redundant POF-rings Max. 40ea subscribers plus max.

7 Network Diagnostics Requirements at Audi Body Shop Production Planning Tool for effective and efficient support of installation quality assurance, plant asset management, and maintenance across entire lifecycle of the facility Automation network diagnostics must: cover all subscribers (PROFINET and standard Ethernet) summarize from entire network all information about: diagnostics, system, and devices including their individual diagnostics history be suitable to support through facility lifecycle at: installation, commissioning, acceptance, and maintenance offer report functionality incl. comparison with previous status provide continuous monitoring capabilities support SNMP (IT acceptance) Photos: Audi AG Softing 2014 / Page 7 of 20

information about: diagnostics, system, and devices including their individual diagnostics history be suitable to support through facility lifecycle at: installation, commissioning,

8 Network Diagnostics Requirements at Audi Final Assembly Tool for effective and efficient support of network management, maintenance, and trouble shooting PROFINET diagnostics and monitoring tool must: fit in flow of work relieve maintenance resources work independent from brand of network components offer hot plug-in without PLC project modification provide little hardware footprint for cabinet installation not require any additional components, e.g. data base PC provide functionality offering: topology discovery, different breakup views, inventory information about components detection of sporadic failures Photos: Audi AG Softing 2014 / Page 8 of 20

PLC project modification provide little hardware footprint for cabinet installation not require any additional components, e.g.

9 About the Solution Three interlocking Components Network monitoring and analyzing software (TH SCOPE) Consolidation of data from all TH Links Network overview and topology information in different views Network statistics and history of network quality Status and bandwidth information for network infrastructure Inventory list with related network and device details, such as device type, firmware version and, IP configuration Detailed information about communication failures Generation of reports respectively acceptance protocols Comparison with filed reference measurements (previous status) Data export functionality (e.g. Reference Measuring, Inventory List) Web Server SNMP agent for handing over diagnostics information from automation networks to IT with central network monitoring Network diagnostic hardware interface (TH LINK PROFINET) Network access Monitoring communication and device status Passive listening and active communication (PROFINET, Ethernet) Data collection for processing through specific diagnostics algorithm Training 1 day, regularly performed at customer s site Content (Ethernet, PROFINET) and methodology (hands-on) defined jointly with customer Softing 2014 / Page 9 of 20

firmware version and, IP configuration Detailed information about communication failures Generation of reports respectively acceptance protocols Comparison with filed reference measurements (previous

10 About the Solution Protocols and Services used for the Diagnostics Algorithm Device Detection & Device Identification Device Diagnostics & Network Statistics Configuration & Communication Failures Network Topology PROFINET (Communication & Services) X X X X PROFINET Diagnostics Services X X ARP (Address Resolution Protocol) X X Ping X X SNMP X X X DCP / DHCP X X LLDP X X Softing 2014 / Page 10 of 20

Network Topology PROFINET (Communication & Services) X X X X PROFINET Diagnostics Services X X ARP

11 About the Solution Outcome All network diagnostics requirements of customer met Solution specified for all future body-shop facility projects managed / coached by Audi Neckarsulm Step by step integration into existing assembly lines Solution provides: Maximized availability of all facilities High use efficiency through consistent user interface ( one solution / tool for multiple maintenance tasks) Assurance of consistently high communication quality Hot plug-in capability Independence from availability of IT department capacities Photo: Audi AG Softing 2014 / Page 11 of 20

facilities High use efficiency through consistent user interface ( one solution / tool for multiple maintenance tasks) Assurance of consistently

12 About the Solution Course of Project 2012 initial contact with Softing / Trebing + Himstedt IC (at first Body Shop Production Planning only) Test phase for target-performance comparison bringing up differing and additional mandatory requirements, e.g.: Acceptance Report Usability (e.g. sequence of work) Topology views at different detail levels Realization of enhancements and changes with standard products 2013 Acceptance 2014 first deliveries 2015 Equipment of assembly lines for three models and new body shop facilities Photo: istock Softing 2014 / Page 12 of 20

g. sequence of work) Topology views at different detail levels Realization of enhancements and changes with standard products 2013 Acceptance

13 Roundup Conclusions Ethernet-based industrial communication offers the opportunity for realizing networks utilizing multiple technologies in parallel Existing requirement for dedicated network diagnostics tools PROFINET leveraging numerous standard Ethernet technologies and protocols hence provides the prerequisite condition for a consistent hence beneficial network diagnostics of real life industrial Ethernet installations PROFINET is providing the functionality for highly effective and efficient network management and maintenance meeting the challenging demands of a leading premium car manufacturer OSI-Layer PROFINET 7a IO Services & Protocols Application 7b RPC 6 Presentation -- 5 Session 4 Transport UDP 3 Network IP, ARP, SNMP, DHCP 2 Data Link CSMA/CD, VLAN, DCP, MRP, MRRT, LLDP 1 Physical 100BASE-TX, 100BASE-FX Photos: Audi AG Softing 2014 / Page 13 of 20

life industrial Ethernet installations PROFINET is providing the functionality for highly effective and efficient network management and maintenance meeting the challenging demands of a leading

14 About Softing Industrial Competence in Industrial Communication 35 years of experience in industrial communication between devices, controllers and host systems based on international standards Integration of fieldbus technologies, industrial Ethernet and OPC for Factory and Process Automation Ready to use hardware and software products for data integration, network diagnostics and Plant Asset Management Effective May 1 st, 2014 Softing Industrial took over the Industrial Communication business of Trebing + Himstedt including the solution presented Photos: Shutterstock Softing 2014 / Page 14 of 20

Ready to use hardware and software products for data integration, network diagnostics and Plant Asset Management Effective May 1 st, 2014 Softing

15 Thank you very much! Bernd Kremer Head of Channel Sales International Softing Industrial Automation GmbH Softing 2014 / Page 15 of 20

Softing Industrial Automation GmbH +49 172 93 99 808

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