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 38-25123 Brescia (Italy) Tel: +39-030-6595111 fax: +39-030-6595000 e-mail: profibus@csmt.it, profinet@csmt.it paolo.ferrari@ing.unibs.it web: http://www.csmt.it/it/profibus-profinet.html 2004-2013 CSMT Gestione Scarl 1
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 329 296 23 623 228 20446 Independent networks Some networks may have multiple rings Smallest network with 4 devices, largest with 450 Not only automotive! 2004-2013 CSMT Gestione Scarl 2
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. 2004-2013 CSMT Gestione Scarl 3
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 2004-2013 CSMT Gestione Scarl 4
PHASE 1: Example of Checklist YES NO n.a. OK Grade 1 1 0 Cable laid according to plan and schematics? Y A 1 2 0 Network topology observed? Y A 1 3 0 Cable type according to planning? 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? Y A Correct answer Importance of the question Last version of the checklist contains about 120 questions Checklist is multilanguage 2004-2013 CSMT Gestione Scarl 5
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. 2004-2013 CSMT Gestione Scarl 6
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 2004-2013 CSMT Gestione Scarl 7
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 11 10 1 9 2 8 3 7 4 5 6 1 2 3 4 11 10 1 9 2 8 3 7 4 5 6 1 2 3 4 1 2 3 4 11 5 11 5 11 5 10 9 8 7 6 10 9 8 7 6 10 9 8 7 6 2004-2013 CSMT Gestione Scarl 8
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 2004-2013 CSMT Gestione Scarl 9
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. 2004-2013 CSMT Gestione Scarl 10
Specific software for validation CSMT developed a specific software that guides the engineer through the validation activities. 2004-2013 CSMT Gestione Scarl 11
Traffic load at IO-Controller during switchover NOTE: it is an example! Ring open elsewhere PLC software error 2004-2013 CSMT Gestione Scarl 12
Finding out the faulty link Scouting the network for errors with SNMP 2004-2013 CSMT Gestione Scarl 13
Locating the fault in the plant Topology view 2004-2013 CSMT Gestione Scarl 14
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 2004-2013 CSMT Gestione Scarl 15
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 #1 2004-2013 CSMT Gestione Scarl 16