PROFINET in Automotive Part 2
Hunter Harrington PROFINET Consulting Eng PROFI Interface Center Agenda 2 Why PROFINET? Industrial Ethernet PROFINET Industrial protocol and design Environment Automation Requirements What is PROFINET? Minute PROFINET intro Determinism with PROFINET Unique Features Diagnostics, Network mgmt, Proxies, Shared and I-Device, Fast startup Application profiles PROFIenergy, PROFIsafe Network installation Installation,Topologies, Redundancy
www.us.profinet.com Agenda 3 Why PROFINET? Industrial Ethernet PROFINET Industrial protocol and design Environment Automation Requirements What is PROFINET? Minute PROFINET intro Determinism with PROFINET Unique Features Diagnostics, Network mgmt, Proxies, Shared and I-Device, Fast startup Application profiles PROFIenergy, PROFIsafe Network installation Installation,Topologies, Redundancy
www.us.profinet.com Why (PROFINET)? 4 Why are we here?
Or Rather, Why are we here talking about Ethernet, TCP/IP and now PROFINET? Ethernet has been out since the 70‟s and TCP/IP shortly after!
TCP/IP was not designed with automation and control in mind, Ethernet was, but doesn‟t provide the entire solution
PROFINET was designed from the ground up with advanced Industrial Ethernet Automation capabilities To cover weaknesses for automation in existing protocols (ex: TCP/IP, client / server model, timeouts, determinism, smaller vs larger packets, etc..)
www.us.profinet.com Industrial Ethernet Requirement: Environment 5
Office Area Production and Field Areas
Moderate Temperatures Extreme temperatures Low Dust burden High dust burden No moisture Moisture possible Virtually no vibrations Vibrating Machines Low EMC burden High EMC burden Low mechanical danger Danger of mechanical damage Low UV radiation UV burden in outer area Virtually no chemical danger Chemical burden from oily or aggressive atmospheres
www.us.profinet.com Industrial Ethernet Requirements 6 Speed Microseconds to over 100 milliseconds Determinism (repeatable message delivery) Jitter from <1microsecond to 10 milliseconds
Standard Factory Motion Control Communication Automation Application
100ms+ 10ms+ 1-10ms <1ms <1ms <1µs TCP/IP Real-Time IRT
www.us.profinet.com Shielded vs. Unshielded 7 Reference measurement
Shielded Twisted Pair (STP) vs. 800 692 Unshielded Twisted Pair (UTP) 700 600 Data transfer rate: 100 Mbit/s 500 Bus load 81% 400 300 200 180 Packet length: 346 bytes 200 Duration: 30 s 100 10
0 Number of faulty Number of packets faulty Result 2 kV 2,5 KV An UTP cable is totally unsuitable Noise voltage for noisy environment Shielded TP UTP Cord Even noise voltages of 1 kV can lead to a breakdown in communication
Shielding has nothing to do with the protocol! It’s all about your environment
www.us.profinet.com Shielding 8 TCP/IP has methods in place to resend telegrams when lost But the timing is not acceptable for industrial use! There is no such thing as a protocol protection against noise The need for shielding is independent of the protocol used PROFINET Installation Guideline has details
If you used shielded cable with DeviceNet or PROFIBUS use shielded cable with Industrial Ethernet as well!
www.us.profinet.com Agenda 9 Why PROFINET? Industrial Ethernet PROFINET Industrial protocol and design Environment Automation Requirements What is PROFINET? Minute PROFINET intro Determinism with PROFINET Unique Features Diagnostics, Network mgmt, Proxies, Shared and I-Device, Fast startup Application profiles PROFIenergy, PROFIsafe Network installation Installation,Topologies, Redundancy
www.us.profinet.com What is PROFINET? (got a minute?) 10 Some short one minute videos to help us get started
www.us.profinet.com 5 steps to determinism 11
Switch
Port1 Port2 Port4
Port1
Controller
Port2 Port1
Port1 Fast ForwardingPort1
31.25µsec DFP Fragmentation
Motion Control DeviceScheduling x Device y Device z (IRT)
IRT Bandwidth Standard channel High Speed IO Reservation channel (IRT) Cycle 1
Real-time Layer 2 (RT) HTTP PROFINET SNMP … Standard 1 2
data 3
time time
TCP/UDP -
-
Isochr. Real Configuration TCP/IP Real IP TCP/IP RT/RT IRT IRT = Isochronous Real-time DFP = Dynamic Frame Packing Ethernet www.us.profinet.com PROFINET and TCP/IP 12
PROFINET DOES NOT USE STANDARD TCP/IP
PROFINET uses TCP/IP where it makes sense: Diagnostics Non time critical data Communicating with higher level IT systems PROFINET real-time coexists with TCP/IP without restrictions
31.25µsec Scheduling Bandwidth Real-Time TCP/IP www.us.profinet.com Why not use TCP/IP for real-time? 13 Because it‟s not fast enough and it‟s not deterministic enough. Here‟s why:
T1 T5 Server Client Data
T2 TCP/IP TCP/IP T4 Suite Suite
T3 Ethernet Ethernet UNWELCOME DELAYS
31.25µsec Scheduling Bandwidth Real-Time TCP/IP www.us.profinet.com Ethernet doesn‟t cause delays 14
100m 100m Switched 100Mbps 64-byte Ethernet packet Propagation Node A Node B 0.5
Transmission 5.12
Node time Switch latency Network 330 10
Transmission 5.12
Propagation 0.5 All times in µs
Source: University of Michigan, Industrial Ethernet Book, 31.25µsec “Performance Metrics for Industrial Ethernet” Scheduling Bandwidth Real-Time TCP/IP www.us.profinet.com PROFINET RT (Real Time) 15 The device determines which path the telegram takes
Ethernet Frame
InterFrame Pre- Sync MAC MAC EtherVLAN- Ether- Frame Cycle Data- Trans FCS Data Gap amble type type ID Counter Status Status
12 Byte 7 Byte 1 Byte 6 Byte 6 Byte 2 Byte2 Byte 2 Byte 2 Byte 40*…1440 Bytes 2 Byte 1 Byte 1 Byte 4 Byte
RT Data
Ethertype (type of protocol): Ethertype (PN): 0x8892 Ethertype (IP): 0x0800 EtherType (ARP): 0x0806 EtherType (IPV6): 0x86DD …
HTTP SNMP Socket PROFINET
TCP / UDP
time - IEEE EtherType IEEE EtherType 0x0800 IP Real 0x8892
31.25µsec Ethernet
InterFrame Pre- Sync MAC MAC Ether- VLAN Ether- Frame Data Cycle Data- Trans FCS Scheduling Gap ambel type type ID Counter Status Status 12 Byte 7 Byte 1 Byte 6 Byte 6 Byte 2 Byte 2 Byte 2 Byte 2 Byte 40*…1440 Bytes 2 Byte 1 Byte 1 Byte 4 Byte Bandwidth Real-Time TCP/IP www.us.profinet.com When you try to use all layers… 16
Industriale.g. Industrial Application WEB SNMP Socket Application WEB SNMP Socket PROFINET Layer EtherNet/IPProtocols Layer Protocols
Transport Layer TCP / UDP Transport Layer TCP / UDP
Internet Layer IP Internet Layer IP
Network Access Network Access Layer Ethernet IEEE 802.3 Layer Ethernet IEEE 802.3
31.25µsec Scheduling Bandwidth Real-Time PROFINET is the enabling factor to achieve www.us.profinet.com TCP/IP speed and determinism When you try to use all layers… 17
Industriale.g. Industrial Application WEB SNMP Socket Application WEB SNMP Socket PROFINET Layer EtherNet/IPProtocols Layer Protocols
Transport Layer TCP / UDP Transport Layer TCP / UDP
Internet Layer IP Internet Layer IP
Network Access Network Access Layer Ethernet IEEE 802.3 Layer Ethernet IEEE 802.3
16 ms Less than 100µs 8 ms Jitter
Source: University of Michigan, Industrial Ethernet Book, 31.25µsec “Performance Metrics for Industrial Ethernet” Scheduling Bandwidth Real-Time PROFINET is the enabling factor to achieve www.us.profinet.com TCP/IP speed and determinism Bandwidth Reservation for PROFINET IRT 18 IRT = Isochronous Real Time Communication system scheduling Exact cycle synchronization Separate time domains for Real-time and non-Real-time IRT IRT IRT Standard channel Standard channel channel channel channel
Cycle 1 Cycle 2 Cycle n
e.g. 1 ms position controller clock cycle
Synchro- Isochronous (IRT) Real-time (RT) Open standard nization Data Data communication
IRT-Data RT - Data TCP/IP-Data
31.25µsec Scheduling Bandwidth Real-Time TCP/IP www.us.profinet.com Scheduling for PROFINET IRT 19 Every IRT device knows, when data arrives and where to send it Switch schedule Rec. Dest. Arrive Frame Departure port port 1 t1 1 t1+∆t 4 1 t2 2 t2+∆t 4 1 t3 3 t3+∆t 2 2 - - - -
Switch
Port4 Port1 Port2 3*) - - - -
Port1 4*) - - - -
Frame Frame3 12
Frame 123 Controller
Frame 1
Port2 Port1
Port1 Port1
Frame 1 Frame 2 Frame 3 *) 100% free for TCP/IP Device x Device y Device z
31.25µsec Scheduling Bandwidth Switch must be IRT-aware Real-Time TCP/IP www.us.profinet.com 31.25 microsecond cycle 20
31.25µsec Scheduling Bandwidth Real-Time TCP/IP
www.us.profinet.com Summary 21 PROFINET achieves industry requirements for speed and determinism using standard Ethernet by using these 5 steps 1. Using TCP/IP where appropriate 2. Skipping it when necessary 3. Reserving bandwidth for higher performance 4. Scheduling traffic to ensure motion control needs 5. Fast Forwarding, Dynamic Frame Packing, and Fragmentation to achieve 31.25µsecond cycle times
www.us.profinet.com Agenda 22 Why PROFINET? Industrial Ethernet PROFINET Industrial protocol and design Environment Automation Requirements What is PROFINET? Minute PROFINET intro Determinism with PROFINET Unique Features Diagnostics, Network mgmt, Proxies, Shared and I-Device, Fast startup Application profiles PROFIenergy, PROFIsafe Network installation Installation,Topologies, Redundancy
www.us.profinet.com Unique PROFINET Functionalities for Automotive 23 B E N E F I T Function(s) Application PROFINET PROFINET device Diagnostics of PROFINET Maintenance and Diagnostics diagnostics supports devices diagnostics quick error localization IT Integration in Standard IT tools and Devices support LLDP, Network Management for PROFINET know how can be used HTTP (web server), SNMP configuration/diagnostics Topology Clear and simple Read the network topology Configuration, / presentation of network and monitor / Diagnostics and Redundancy status / Redundancy Redundant network documentation Simple Fast and easy device Automatic name Device replacement Device replacement and assignment by means of Commissioning Replacement commissioning configured topology IP 65/67 devices Proxy concept Specifications for legacy Connect Legacy networks to IO / CBA (peer to peer) network data mapping to PROFINET Communication to legacy PROFINET data systems Shared Device Application enhancement Multiple controllers can Standard and safety for IO devices control IO device application I-Device Application enhancement Can be IO device and Standard and safety for IO controllers controller at the same time applications Application profiles Support of a variety of Safety, Energy savings, PROFIsafe, PROFIenergy, applications and devices common device profiles PROFIdrive Fast Start Up Supports fast application Fast startup of I/O devices Example: Tool change
after power on (500 ms) www.us.profinet.com Unique PROFINET Functionalities for Automotive 24
B E N E F I T Function Application PROFINET PROFINET device Diagnostics of PROFINET Maintenance and Diagnostics diagnostics supports devices diagnostics quick error localization IT Integration in Standard IT tools and Devices support LLDP, Network Management for PROFINET know how can be used HTTP (web server), SNMP configuration/diagnostics Next section Topology Clear and simple Read the network topology Configuration, presentation of network and monitor Diagnostics and status documentation Simple Fast and easy device Automatic name Device replacement Device replacement and assignment by means of Commissioning Replacement commissioning configured topology IP 65/67 devices Proxy concept Specifications for legacy Connect Legacy networks to IO / CBA (peer to peer) network data mapping to PROFINET Communication to legacy PROFINET data systems Shared Device Application enhancement Multiple controllers can Standard and safety for IO devices control IO device application I-Device Application enhancement Can be IO device and Standard and safety for IO controllers controller at the same time applications Application profiles Support of a variety of Safety, Energy savings, PROFIsafe, PROFIenergy, applications and devices common device profiles PROFIdrive Fast Start Up Supports fast application Fast startup of I/O devices Example: Tool change after power on (500 ms) www.us.profinet.com About PROFINET Proxies 25 Proxies are like gateways in that they connect disparate networks, BUT unlike gateways they are defined in the PROFINET spec, so data mapping is always the same.
Controller
XX55
CE
Allen-Bradley
IO-Link PROFIBUS PA FF DeviceNet PROFIBUS DP AS-i also Interbus, HART, CC-Link, Modbus
www.us.profinet.com PROFINET Shared Device 26 PROFINET offers shared device functionality Two Controllers can access the same device Flexible assignment of modules to different controllers
IO controller IO controller 1 2
PROFINET
Shared IO Device
Shared device results in reduced costs, simplified architectures, can save on cabinet space, allowing optimized solutionswww.us.profinet.com
PROFINET IO I-Device How do I integrate machines? 27
An IO controller can also be operated IO controller 1 as an IO device CPU1 With IO controller functionality on the same interface PROFINET IO device 1 Controller-Controller communication with simple IO access, without TCP/IP CPU2 I-Device telegrams or proprietary methods IO controller 2 Allow local controllers in a modular architecture to communicate to a higher level station (main controller)
IO device 2
I-Device – . Simple and familiar IO interfacing of CPUs . Interfacing of CPUs in different projects simple and . Integration among different controllers (manufacturers) fast solution . Transmission of cyclic data (RT, IRT)
www.us.profinet.com Application Profiles 28 Agreement within a device family on how to use the PROFIBUS / PROFINET data by adding data structures, cyclic / acyclic services, behavior, parameterization, diagnosis, integration, etc. Engineering
Host/Master Field Device/Slave
Profile
7 7 2 2 1 IEC 61158 1
www.us.profinet.com Application Profiles 29
"Best Practice Patterns" Application Profiles "Common Profiles" Profile Guidelines
Cooperation with other organizations I&M Functions IEC 62390 e.g. OPC, DriveCom, VDMA, OpenPLC, etc. Redundancy Data types Training (UML, Safety, Models, etc.) Time Stamp Diagnosis Tools PROFIsafe Models
Remote Water/ PA intellig. I/O Laboratory Robot PROFI Fluid waste SEMI Encoder Devices Pumps for Devices /NC drive Power water PA ? ?
SEMI FF, Interbus, IEC 61804 CAN, etc.
Low Ident Weighing Voltage PROFI (Bar- & IO-Link Trains ...... code, Switch- energy Dosage RFID) gear ? www.us.profinet.com PROFINET IO PROFIenergy Energy Management Application Profile 30
Definition: PROFIenergy is an application profile based on PROFINET which permits coordinated and centrally controlled switching-off of loads in pauses independent of the vendor and device.
An overview of Use Cases
• UC 1: Disconnection and connection during pauses
• UC 2: Disconnection and connection on the weekend
• UC 3: Load-dependent machine control
• UC 4: Pausing auxiliary process under threat of load spike
www.us.profinet.com PROFINET Fast Startup 31
Main Control CPU End of Arm Tooling Tool Model “A”
Robot Controller Tool Docking system Tool Model “B”
Robot Tool Model “C”
PROFINET IO CP 1616 Flexible Robot Cell must I/O connect to End of Arm Tooling based upon Work in Process
After power on, startup times of 500ms or less can be achieved using PROFINET Fast Startup www.us.profinet.com
Agenda 32 Why PROFINET? Industrial Ethernet PROFINET Industrial protocol and design Environment Automation Requirements What is PROFINET? Minute PROFINET intro Determinism with PROFINET Unique Features Diagnostics, Network mgmt, Proxies, Shared and I-Device, Fast startup Application profiles PROFIenergy, PROFIsafe Network installation Installation,Topologies, Redundancy
www.us.profinet.com PROFINET Guidelines 33 Design Guideline With network load tool Installation Guideline Commissioning Guideline
All at http://www.profibus.com/nc/downloads/downloads/profinet-installation-guide/display/ and on CD.
www.us.profinet.com Suggested Topologies 34
Engineering Station HMI
Peer-to-Peer
max. 10 switches with 1ms Line architecture update time Tree architecture
www.us.profinet.com What you should keep in mind… 35
PC (unknown traffic) !
! Jitter / Delays > 10 switches > 1ms update time
! ! Vision system HMI Panel (unknown traffic!) (unknown traffic!) video stream
www.us.profinet.com PROFINET networks: Ring Topology 36 PROFINET supports the ring topology for high availability (redundancy) For example, if a cable or device fails, then the system will automatically segment itself to a „line‟ topology keeping the rest of the system active
www.us.profinet.com Redundancy 37 Office Requirements Spanning Tree Rapid Spanning Tree Industrial Requirements Media Redundancy Protocol IRT Media Redundancy
Recovery Time
www.us.profinet.com Spanning Tree & Rapid Spanning Tree 38 Media redundancy through loop formation Detection and breakup of loops Reconfiguration time Spanning Tree: protocol- & timer-based minutes Rapid Spanning Tree: event-controlled seconds Note: STP and RSTP assume structured cabling, in which there are never more than 8 switches between terminals. RSTP is downward-compatible to STP; an STP network component in the network forces STP throughout the entire network.
www.us.profinet.com Media Redundancy Protocol (MRP) 39 Media Redundancy Manager (MRM) sends test frames to Media check ring network Redundancy If MRM does not receive it‟s own Manager ! test frame = network failure! MRM informs Media Redundancy Clients about Media network failure Redundancy The network is segmented back Clients to a working line configuration by the MRM Network continues to operate until failure is repaired failure
www.us.profinet.com With MRP recovery time drops to <300ms for 50 switcheswww.us.profinet.com IRT media redundancy 40
Bumpless Redundancy Devices send telegrams through Media both redundancy ports Redundancy All transmitting nodes forward Manager telegrams but do not learn addresses Receiver does not forward frames Receiver Receiver checks for most recent frame and uses that information In case of failure a frame will still arrive at the receiver Sender All Nodes in ring must support this feature failure
www.us.profinet.com Data is still there in case of a failure! Zero recoverywww.us.profinet.com time! PROFINET over wireless backbones 41 PROFINET runs over these standard wireless technologies: IEEE 802.11 (b,g,a,h,n) – Wireless LAN IEEE 802.15.1 – Bluetooth Wireless is part of the PROFINET specification Many vendors Some IO devices have wireless built in PROFIsafe is safety-certified over wireless using PROFINET as the transport mechanism
www.us.profinet.com Questions? 42
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