Opensafety – the Key to Your Safety Solution
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April 2010 / Issue 1 The Magazine for the Industrial Ethernet Standard Volume 5, Volume FACTS openSAFETY – the key to your safety solution openSAFETY: the first open and bus-independent safety standard for all Industrial Ethernet solutions Save time and expenses: how everyone benefits from openSAFETY openSAFETY over SERCOS III, EtherNet/IP, Modbus-TCP, POWERLINK, and your fieldbus www.open-safety.org 2 Special 1/2010 openSAFETY: the first open and bus- independent safety standard for all Industrial Ethernet solutions The data transfer protocol that carries safety frame traffic has no bearing at Highlights at a glance: all on the functionality of the safety protocol. This is called the Black Chan- nn one single, uniform standard for all leading fieldbuses nel principle: all safety-oriented mech- nn maximum productivity due to efficient cross- anisms are exclusively implemented on communication the application level, which enables total independence from the underlying nn reduced commissioning and maintenance time transport layer. A brief look at the basic nn automatic safe parameterization structure of data transfer protocols may serve to illustrate the principle. nn perfectly suited to safe modular machine concepts nn sole 100% open safety solution nn Transport and Application Layers nn fastest IEC 61508 SIL3 communication solution nn no risk involved in investment: TÜV certified The standardized OSI (“Open Systems conformance test Interconnection”) data communication model is the reference scheme for nn perfectly suited to back-plane buses today’s most common non-proprietary data transfer protocols. This system is comprised of seven layers that enable the processing of data in a hierarchically With openSAFETY, the EpSG has intro- communication solutions. The EpSG structured way. Every layer represents duced the world’s first 100% open provides active support for imple- a stage determined by protocols in safety protocol. In fact, openSAFETY menting openSAFETY on top of any and which data transfer tasks are carried is open not only in terms of its legal all data transfer protocols, and also out according to specific rules. The basis, but also literally open in techni- offers help e.g. for certification and two fundamental, low-level layers are cal respects: given the protocol’s bus- conformance tests. The open source the so-called physical layer and the independence, openSAFETY can be license of this TÜV-certified protocol Data link layer, which are also jointly used with all fieldbuses, Industrial stack ensures that the technology is a referred to as physical layers. These Ethernet solutions, or industry-specific very secured investment for all users. layers define the physical interface to Choose your certification authority: IEC 61508 certification by TÜV Rheinland and TÜV Süd Special 3 Das Magazin zum Standard FACTS im Industrial Ethernet All logos are registed trademarks of the corresponding vendor organization. They solely represent the associated technology and the related possible application. openSAFETY is independent from every fieldbus association. the transmission medium, and provide a format that higher-level applications anisms implemented in this layer test functions to check whether an can digest, and ensures syntactically enable safety-oriented decoding and actual connection between a sending correct data exchange. Other tasks encoding of payload data pertaining to and a receiving device is established carried out in the presentation layer specific safety-sensitive applications. at all. Ethernet only specifies these two include data compression and data For the sake of simplicity, the blue area low-level physical layers. Also referred encryption. The top layer in the OSI in the center of this illustration covers to as “transfer layers,” the third and model is the Application layer. For this all the transport-oriented layers 2 fourth layer handle the timing and layer, no strict definition of a task or through 6. The choice of transport logical order of data transfer as well as range of tasks is applicable. It provides medium, or, more precisely, of a specific data attribution to applications. Com- various services to actual applications data transfer protocol, is of marginal prising all transport-oriented services, that operate outside the scope of this importance. these four layers combined can be said model. Inspired by the OSI model, to constitute no more than the traffic the illustration below highlights that medium for application data, which, in openSAFETY exclusively specifies the the OSI model, is attributed to the upper high-level, application-oriented layers layers. These high-level layers include of the protocol stack. The safety mech- the Session layer and presentation layer. These two are often grouped with the Application layer, since all programs and applications directly access all three of them. The Session Inspired by the OSI model, layer administers the organization and layer 7 Your Application this schematic view of synchronization of data exchange be- openSAFETY’s general tween applications. E.g. if a connection implementation illustrates layer 6 is interrupted, services on this layer that the open safety protocol ensure that communication is resumed CAN Modbus EtherNet/Ip exclusively specifies the from the point of interruption once the layer 5 appli cation-oriented layer – connection is back in operation. layer the basic prerequisite to enable 6, the presentation layer, translates EtherCAT Your Fieldbus Black Channel operation. system-specific representations into layer 4 profinet layer 3 pOWERlINK Sercos Wireless layer 2 layer 1 Ethernet RS485CAN USB … lVDS 4 Special 1/2010 Save time and expenses: how everyone benefits from openSAFETY “Competition is good for business” – nn Rising development potential was sizable. The entry of this free market maxim is almost costs for communication Ether net technology into industrial data always true, since healthy competition systems communications marked the next stage stimulates continual product improve- of development, one that was widely ments regarding quality as well as cost- A brief review of the history of bus-based associated with the expectation that, effectiveness. However, safety-oriented automation may serve to illustrate how finally, a universal standard would software and hardware development is investment risk has been increasing in prevail. However, as different manu- a special case where this rule may not line with growing complexity. Ten years facturers chose strongly divergent apply, because manufacturers in a after the introduction of the first field- approaches to enable real-time per- market economy are faced with a high bus, the market was full of different, form ance with this techno logy, what investment risk: there are considerable competing systems. Infighting over followed was the fieldbus war all over development costs, but there is only the standardization of the technology again. Amongst a multitude of systems, comparatively small sales potential. ensued. Until the present day, industry about half a dozen have been able to Hence, the automation sector has long experts know this phase as the “field- claim major portions of the market: been calling for a universal safety bus war,“ which only seemed to end profinet, Modbus-TCp, EtherNet/Ip, protocol, i.e. one that would give all with the introduction of the IEC61158 – which all provide soft real-time per form manufacturers a solid economic base a weak compromise because still, even ance, and the hard real-time systems for all further development of safety- this conclusion do not bring any overall pOWERlINK, EtherCAT, and SERCOS III. oriented products. The introduction system compatibility. Still, even this There was a moderate increase of de- of openSAFETY marks the first time a conclusion did not bring about overall velopment costs for In dus trial Ethernet standard of this kind has become system compatibility. It should be solutions in comparison to conventional available that can be used license noted, though, that development costs fieldbuses. At the same time, the sales free by anyone. for first generation buses were com- potential could not be increased in the paratively low, whereas their market same proportion. Development effort Integrated safety technology Industrial Ethernet These graphs visualize how Fieldbuses investment risk increases as development becomes more and more complex. Sales potential Special 5 Das Magazin zum Standard FACTS im Industrial Ethernet Save time and expenses: how everyone benefits Plant automation “one safety standard for your entire production plant” from openSAFETY openSAFETY constitutes a universal safety standard for an entire production line, irrespective of the control system manufacturer and fieldbus standard used in it. plC Supplier 1 plC Supplier 2 plC Supplier 3 plC Supplier 4 The bus-independent openSAFETY standard therefore reduces costs as well as commissioning time for production facilities as a whole. Machine 1 Machine 2 Machine 3 Machine 4 nn Safety technology – nn The solution: a special case openSAFETY Benefits for plant operators Things look markedly different, however, A tried and tested, non-proprietary sys- for the development and certification tem, openSAFETY resolves this situation nn a single, consistent safety standard for an entire effort required to make products de- in a way that benefits both manufactur- line or plant signed for use in safety-sensitive areas, ers and users. Thanks to the Black