Once again we get our teeth into
a myth about PROFINET!
A compilation of previous 'debunks' is available
conversation is also worth reading
does not use TCP/IP!
news to us! TCP/IP is part of the internet 'suite' that
all Industrial Ethernet solutions use and PROFINET is no
exception. However, TCP/IP has severe limitations in the
Real Time and high end Motion Control domains where time
critical functionality is required.
Any solution that depends on TCP/IP in these domains
is forcing it to do things it was never intended for! Any
TCP/IP based Real Time system, even a small one, is also
prone to traffic overloads and network storms.
on TCP/IP a lot - but only for the tasks for which it
was designed, e.g. enterprise connectivity and non-time
critical functions such as parameterization or diagnostics.
For Real Time, PROFINET by-passes TCP/IP to achieve far
superior performance! For Isochronous Real Time (that's
mainly Motion Control) it is enhanced still further by
the use of an ASIC switch that is embedded in end devices
and shares the Ethernet bandwidth.
But it's important
to remember that in both these time critical domains,
full Ethernet compatibility is guaranteed!. So, TCP/IP
functionality can be used simultaneously if desired.
In the case of Motion Control, never less than 50%
of the Ethernet bandwidth is available for TCP/IP-based
transmissions! That's at least 6MB of data in
tandem with up to 150 axes of Motion Control! TCP/IP
based solutions cannot get anywhere near this!
The ASIC also means
external switches and point-to-point connections can be
avoided and a multi-drop bus-like structure employed.
Think of the benefits that brings!
ASSEMBLY BRINGS FOCUS ON FUTURE: The
2006 PTO General Assembly meeting, held in Scottsdale in August,
was memorable for its User Experience presentations (see later)
as much as for the professionalism of its materials. More
than 50 members and representatives attended to listen to
the latest technical updates and the future strategy of the
PTO and its mother organization, PI. Chairman Mike Bryant
(above) opened proceedings with a look at progress, including
a rapid-fire list of PTO statistics for the past 12 months:
8000 phone calls fielded; 250,000 air miles logged; the PTO
web site has seen nearly 2,000,000 hits while the parent
web site at www.profibus.com
has seen 15,000,000 hits, roughly the same number as PROFIBUS
devices installed. New Board Director Thad Frost was welcomed.
On long term strategy Mike said that being market leader poses
some challenges: "We must watch out for new technologies
and paradigm shifts, and we must never forget that our competition
is always biting at our heels," he said. "Complacency
could be our biggest enemy." The broadening technical
scope of the organization - now ranging from sensors to IT
- means we have to adapt. "PROFIBUS will continue to
be the most successful fieldbus ever," he said, going
on to predict that 30,000,000 devices will be installed by
2011. "Nevertheless," he warned, "PROFIBUS
growth will flatten so we must face those challenges now."
He predicted a shakeout of Ethernet solutions within 5 years,
with just 3 serious contenders remaining and said that PROFINET
has moved from being a fieldbus technology to an 'automation
technology', with all that entails. He concluded by announcing
a new mission statement for PI, the international organization
of which PTO is part: "We are and will remain the world's
leading automation organization for communication solutions,
serving our users, our members and the press with the best
solutions, benefits and information."
For more details and less formality visit the PROFIblog
for Day 1 and the PROFIblog
for Day 2. There are also referrals to news items and
other blogs about the Meeting. There's even an experimental
podcast by Carl Henning - check out his PROFIcasthere
EXPERIENCES IMPRESS AT GENERAL ASSEMBLY:
End user presentations at the PTO General Assembly covered
applications in tobacco and, believe it or not, the theater.
Michael Darnell (left) of system integrator and PTO member
Prism Systems spoke enthusiastically about PROFINET's 'component
based' capabilities, which were put to good use in a plant
making hundreds of different cigar products. The plant is
highly automated mechanically but lacked 'electrical' automation,
so the owners had decided to bring things up to date and create
a 'show place' for the industry, all to a tight time scale.
The plant comprises many identical machines and was ideally
suited to the component-based approach, whereby one
functional module (it can be a machine, a fieldbus network
or a single device) is defined as a 'component', placed in
a computer library and then re-used as often as needed. Using
simple click and drag techniques components are placed into
an on-screen drawing and the communications paths are configured
by simply joining up the inputs and outputs on-screen. This
procedure saves huge amounts of engineering time and effort.
The plant uses 21 PLCs, with extensive PROFIBUS and AS-Interface
networks. The benefits, said Michael, are shown by simple
mathematics: using conventional programming, it takes 80 hours
to develop code for each machine and 4 hours to replicate
it for each other machine, resulting in over 300 hours of
effort for the 63 machines in the plant, plus a modification
time of 10 hours every time something has to be changed. Using
the component-based approach, the code takes the same time
but replication is reduced to minutes, giving a total of about
90 hours. Furthermore, each modification takes only minutes
and only has to be performed once because it is automatically
made available to all the others. Among the advantages are
easier project management and the ability to test and prove
programs off-site. The 4500 man-hour project was implemented
in 5 months and showed a reduction of 20% in labor hours and
30% in labor costs. "With component-based PROFINET,"
said Michael, "we were able to 'eat the elephant' easily!"
Jim Tomlinson (right) of the MGM Grand Hotel and Casino in
Las Vegas fascinated the audience with a detailed explanation
of the use of PROFIBUS in the Cirque du Soleil show "KA."
The show involves non-stop action, both on stage and front
of house, with complex motion of stage parts and flying apparatus.
32 PLCs, 186 drives and 206 coordinated axes of motion are
involved. Safety is tightly integrated via PROFIsafe. Once
begun, the show rarely stops even if a major problem develops
... "we just slow it down a bit until things come back
on track," said Jim, brilliantly demonstrating this when
his PC gave an unexpected 'low-battery' alarm: Jim's presentation
did not falter as he grappled to connect his power lead under
the desk! 12 months advance testing of the KA system took
place at a Canadian base before the show was set up in Las
Vegas. This user experience
was a stunning demonstration of the power of PROFIBUS and
we hope to bring you a more detailed case study shortly.
WELCOMED: The PTO has welcomed the joint announcement
by Emerson Process Management and Siemens Automation and Drives
that both companies are exchanging technology and providing
each other with engineering support. Siemens will be adding
interfaces to its SIMATIC PCS 7 process control system and
Process Device Manager (PDM) tool to support FOUNDATION Fieldbus
(FF) standards in addition to the PROFIBUS and HART standards
they support today. Emerson will be similarly expanding its
Delta V and Ovation control systems as well as its AMS Suite
with an interface for PROFIBUS DP and PROFINET in addition
to the FOUNDATION Fieldbus and HART standards. PI Chairman
Edgar Kuester said that the development is especially important
for PROFINET and PROFIBUS DP, particularly in view of the
global process automation market in which the American company
Emerson plays an outstanding role, as it provides an ideal
starting point for further disseminating open technologies.
In addition, collaboration will serve to speed up the use
of open technologies, expand the compatibility of automation
products and thus provide the customer with greater functionality.
It will also give PROFIBUS and PROFINET an ideal opportunity
to demonstrate their greatest asset, namely closely-coupled
implementation in both continuous and discrete automation
processes. It's in 'hybrid' applications that the fieldbus
combination of PROFIBUS DP and PA offers an especially decisive
advantage. PI will continue to develop its own technologies
under one roof. For PROFINET, work will continue on the communication-specific
requirements of process automation within the newly-founded
'DCS Requirements' working group and the findings will influence
the PROFINET specifications. PI member companies will continue
to consolidate the market position of PROFIBUS PA above all
in connection with PROFINET." Read the press releases here
WORKSHOP: The PTO has announced a free PROFINET Developer
Workshop on October 5, 2006 at the Hyatt Regency O’Hare in
Chicago, IL. The workshop will provide potential PROFINET
developers with a wide range of technical information including
PROFINET vendor presentations to help them select the best
tools to develop their PROFINET products, and is designed
for device developers, development managers and product marketers.
During the workshop, the ARC Advisory Group will provide a
market overview and industry expert Harry Forbes will speak
about the explosive growth of Industrial Ethernet. The PTO
will give an overview on PROFINET and the PROFI Interface
Center will provide a high-level look at various applications
and the types of tools available to address them. Presentations
will also be given by seven development tool providers who
will each talk about their specific PROFINET development tools.
Providers will also be available at exhibit tables for more
detailed discussions. Exhibiters include: Hilscher North America,
Inc., HMS Industrial Networks, Inc., Real Time Automation,
Siemens Energy & Automation, Softing North America, Grid Connect,
Inc. and Woodhead Industries. The PROFINET Developer Workshop
follows the 3rd International Industrial Ethernet Symposium
being held October 3-4 in Chicago. To register, visit www.us.profibus.com
or call 480-483-2456.
THERE'S STILL TIME
TO ATTEND A FREE TRAINING CLASS: Want to know more
about PROFIBUS? Want to know more about PROFINET? Want to
know why you should use a fieldbus of any kind? A recent ARC
Advisory Group survey revealed that one of the major factors
inhibiting adoption of a fieldbus was "lack of knowledge."
Remedy that by attending one of the free classes offered by
PTO and the PROFI Interface Center. There are still a few
of each class type remaining. There are no sales pitches but
you can visit with the exhibiting vendors during breaks, lunch,
and after the class at the hosted bar. If you register early
you'll be eligible for an onsite raffle for a $25 gift card.
We hope to see you in San Francisco, Richmond, Minneapolis,
St. Louis, Calgary, Los Angeles, Denver or Seattle. And remember
to watch the website for possible
additions to the scheduled cities, or visit
our North American events page. For up-to-the-minute reports
on these classes as they happen, visit the PROFIblog.
SYMPOSIUM FOR CHICAGO, OCTOBER:
The Third International Ethernet Symposium is slated for October
3-4 at the Westin Michigan Avenue Hotel in downtown Chicago.
This is the first time it will be held in the US, having been
previously hosted in Berlin and Amsterdam. The event will
be moderated by David Humphrey, Senior Analyst, ARC Advisory
Group, and is expected to attract more than 300 participants
from 20 countries. Collins Hemingway, former marketing director
of Microsoft and best-selling author, will provide the keynote.
The symposium will include two days of workshops covering
best practice examples of Ethernet in automation and feature
presentations from a wide variety of industry and technology
experts, industry analysts and 'best practice' customer case
histories. Alongside will be a 'Micro-fair' with interactive
exhibits of the latest Industrial Ethernet technology. Organized
by Siemens, participation and presentation opportunities are
nevertheless open to all industrial Ethernet organizations,
including competitors. panelists from five industrial Ethernet
consortia will present their views and answer questions from
the moderator and the audience. Registration and additional
details are available here.
Flash presentation follows below ... if you cannot see it,
please install a Flash plug-in to your browser.)
HIGH SPEED MEDIA REDUNDANCY
FOR PROFINET: The PROFIBUS Nutzerorganisation (PNO)
in Germany has concluded a licensing agreement with Hirschmann
and Siemens - co-owners of the rapid-recovery redundancy technologies
for Ethernet known respectively as HSR and HiPER-Ring - to
sub-license the technology to PNO member companies. The sub-license
covers PROFINET Controllers (e.g. PLCs) or PROFINET field
devices with integrated Controller Functionality having Redundancy
Manager status. Products with a Redundancy Client are granted
a free license. The deal is significant not just because it
is the first to provide a real time media redundancy service
for PROFINET networks (conventional Rapid Spanning Tree is
already available), but because of its relevance for automation
realtime. The basic HSR/ HiPER-Ring technology delivers 200-300ms
recovery time (an order of magnitude faster than RST) which
is suitable for PROFINET's TCP/IP activity. If ERTEC 200 or
400 chips are used in controller and field devices together
with Isochronous Real Time (IRT), recovery times of microseconds
can be achieved in motion control applications. The solution
is the first to be submitted to IEC as a Publically Available
Specification (PAS). The redundancy functionality will be
part of IEC 61158-5/6. In Class 2 applications, as defined
by the SC65C committee which is currently considering how
to standardize Industrial Ethernet redundancy, it can provide
recovery times in the millisecond range, sufficient for normal
automation realtime. For PROFINET Class 1 applications, recovery
times in the microsecond range are possible. The licensing
conditions are only available to members of the PNO Germany
at present. However, under the IEC's 'reasonable and non-discriminatory'
requirements, other vendors can negotiate separate agreements
with Hirschmann and Siemens.
MARKETING STARTED AT ACHEMA: The new PROFIBUS device
profile 'Lab Devices' is being specified especially to allow
seamless integration of laboratories into PROFIBUS networks
or, by means of OPC, also into other automation worlds. The
LabDevices profile is currently being worked out. The profile
was presented to the public the first time at the Achema fair
(Frankfurt, Germany) in May 2006. Information was provided
at the PI exhibition booth as well as at the booth of the
DIN Technical Committee Laboratory Devices through information
boards and an information flyer. Information was also available
from several device manufacturers (Julabo, Lauda, Sartorius)
who participated in the relevant TC 3 working group. Included
in the information was the function block approach (see right)
which makes the new profile similar to the existing 'PA Devices'
profile. However, three function blocks (Human Interface,
Ramp and Lab Control Unit) have been specifically developed
for the LabDevices profile. Contacts were established with
potential users and device manufacturers. The responses confirmed
the trend towards increased automation in laboratories and
showed a positive reaction to the trendsetting activity of
PI in specifying the new profile. But it became also evident
that the introduction of fieldbus technology into laboratories
will take more time compared with factory or process automation.
Marketing of the new profile will be continued the next months.
Large chemical and pharmaceutical companies and some key manufacturers
- including those of LIM systems - will be addressed.
Q: Is there a PROFINET network
with a ring structure? Are there any limitations regarding
A: One of the advantages of
PROFINET is that it enables the creation of flexible
network structures. The length, speed and topology depend
on the network components you choose for your network.
For example, in case of fiber optic with integrated
interfaces you can reach up to 300m between devices.
With external components, fiber optic distances of up
to 26km are possible, depending on the type of fiber
optic being used and the vendor. In an electrical network
the maximum distance between any two devices is 100m.
Q: Is it possible to connect a
standard Fast Ethernet Device (let's say, for example a
Fast Ethernet Controller which supports TCP/IP) to a PROFINET
network? I do not need Real Time support on these devices
but I'd like to hang some standard Ethernet devices on a
PROFINET network. Does a PROFINET Switch handle this? Is
there something special to be taken care of?
A: You can connect a standard
TCP/IP device into PROFINET: this device can't support
real time communication because it hasn't been supported
by the PROFINET protocol. Any standard TCP/IP device
can connect to PROFINET.
Q: I am new to PROFIBUS. Can a
slave be implemented using a micro-controller and RS-485
circuitry? Can anyone suggest a step by step approach to
developing a slave device.
A1: For PROFIBUS-Slave-Devices
you have to implement a uC communicating with additional
SLAVE-ASIC (SPC3 or VPC3+C) and a physical connection
to the PROFIBUS Network by optical isolated RS485 Line
Driver. PROFIBUS Communication is based on the firmware
you need for one of the ASICs above.
A2: Search with Google for
'FE-TP-0405.pdf'. This article from Prof. Max Felser
will give you an idea what you can do.
AROUND THE WORLD:
China: PROFINEWS 49 and 50 have been published in Chinese
and are available online here.
Cesar Cassiolato (pictured) is the new President of Association
PROFIBUS Brazil. Cassiolato is from Smar. Among his aims are
the expansion of RPA membership and making RPA Brazil the
best known Brazilian association for fieldbus protocols. He
also intends to form the first PICC (Competence Centre) in
Latin America. UK:
More than 100 delegates and speakers gathered at Coombe Abbey
(right) in June to attend the third PROFIBUS UK International
Conference, which this year focused on end user issues. Hands-on
'primers' and the case studies presented by users such as
AstraZeneca and Thamesport were in the program. The papers
can be downloaded
here. A similar Conference will take place around the
same time in 2007 and probably at the same location. JAPAN:
PROFIBUS Days were held in Tokyo, Osaka and Kita-Kyushu in
July, with over 240 delegates attending. JPO and six member
companies made presentations covering the advantages of PROFIBUS
and PROFINET (including PROFIsafe, etc), with application
examples and demonstration of both systems.
CLARIANT, a fluortelomers company from Gendorf, underwent
extensive modernization and interfaced a first section of
its plant to a process control system. CLARIANT, which specializes
in pre-treatment and finishing chemicals, decided to work
with a remote I/O technology system called Excom, developed
and manufactured by TURCK. The decision to opt for Remote
I/O in an Ex area was based on the long-standing experience
with TURCK and their excellent commercial and technical support.
The technical advantages of the system include: availability,
power and gateway redundancy, longer periods without interruption,
decentralized periphery system structure based on PROFIBUS
DP-V1 functionality. The Excom system is space saving due
to elimination of the need for multiple control cabinets.
Up to 128 binary or 64 analogue intrinsically safe channels
can be transferred via a single bus address. It also offers
installation in Zone 1 for connection of signals from Zone
0, and hot exchanges. By working with Excom, CLARIANT has
reduced its planning, installation and maintenance costs by
more than 23% and reduced future installation costs by 30%
to 40%. Excom, in Ex area with PROFIBUS DP-V1 functionality,
was implemented within 3 weeks. Contact: Jim Petersen on 800-544-7769
ON CHIP: Hilscher North America has released netX;
a System on Chip (SoC) for industrial networking connectivity.
netX can be a Master or Slave for PROFINET (Real Time & Isochronous
Real Time) and PROFIBUS. It has built-in peripherals and can
interface to virtually any network physical layer and protocol.
netX 500 offers four communication channels, two which may
be Ethernet or fieldbus, and the remainder fieldbus. The two
Ethernet Channels are interconnected with switch or hub functionality.
Development tools and kits are available. Hilscher
I/O: Lumberg has introduced LioN compact I/O modules
for PROFIBUS DP applications. It has two housing styles. Features
include universal I/O functionality, expanded diagnostics,
a diagnostic LED, optimized spacing between ports, flexible
mounting options and an Innovative un-potted design which
makes it possible to achieve the same shock and vibration
resistance that was until now only possible with potted modules,
resulting in lower weight. Lumberg
ADAPTER: The BradCommunications PROFIBUS USB adapter
provides the tools to quickly and easily create a reliable
connection between and PROFIBUS devices. PROFIBUS DP Master/Slave
DP-V0 Class 1 & 2 and DP Master DP-V1 Class 1 & 2 are supported.
FDT specification 1.2 is also supported and with baud rates
of up to 12Mbps it's possible to use the adapter for control,
configuration, set parameters, diagnose and trouble-shoot.
I/O: Designed for industrial in-cabinet use, the IP20
BradControl Block I/O system is an effective way to connect
industrial I/O devices to a PLC or PC controller over an industrial
network. Standard DIN rail mounting makes it convenient to
install and adds flexibility to the design. Legends and LED
indicators provide for easy setup and operational validation.
The system comprises a network adapter and up to 32 expansion
modules. Up to 512 channels of I/O are supported. Woodhead
UPDATE: ProfiTrace, the USB PROFIBUS analyzer, now
supports the recently defined I&M functions for DP-V1 and
PA devices and also has an improved PROFIBUS PA measurement
algorithm for the PA-Probe. A free update can be downloaded
The analyzer is an essential tool for troubleshooting, maintenance
and commissioning. It's claimed to eliminate downtime and
increase plant availability and is distributed in USA by Grid
VERSION TOOL: A new version of the CBA Engineering
Tool iMap for configuration of machine-machine communication
offers significantly improved ease of use. For example, users
in large projects benefit from a much clearer navigation with
the new 'plan view'. An important feature is the capability
to display several technological functions on a single device.
iMap V3.0 also offers greatly improved flexibility: in addition
to the activation and deactivation of individual functions,
it is easy to copy entire plant sections. It's also multi-lingual.
PROFINET: ProfinetCommander runs as a PROFINET IO controller
on a PC allowing engineers, maintenance personnel, integrators
and developers to test and build a PROFINET network quickly
and without PLC programming. The user can view the configuration,
I/O data, parameters, alarms, and diagnostic data, and change
the output data to the IO devices. This permits simple test
and setup of a PROFINET IO Device or system before putting
it into production, or in the case of device faults or alarm
conditions. For developers, the added benefits are simple
testing for correct operation and diagnostic function prior
to certification and final product release. More
IO: Ci-800DP Series Fieldbus devices offer application
specific Remote I/O such as Remote Process Cluster transmitters,
Remote Thermocouple Cluster transmitters, & Remote Digital
I/O. Each has a basic compact I/O module with an integrated
PROFIBUS DP Slave port. The Remote Process Cluster transmitter
is an 8 channel Universal Analog input module for migrating
from Analog transmitters to a fieldbus-based system. The Remote
Thermocouple cluster transmitter scans and converts sensor
signals for PROFIBUS DP. The Remote Digital I/O system is
a compact I/O module for discrete devices. All modules are
software configurable and expandable. Canopus
Ascon Corporation is pleased to introduce the DeltaDue temperature
modules with optional DX DIN rail mount PROFIBUS Gateway Manager.
The DX module can store a backup copy of all connected DeltaDue
module configurations and operator parameters. All DeltaDue
modules feature "hot swap" capability and true single loop
integrity. Thus, when a replacement DeltaDue module is inserted
in the system, the DX module can instantly download all configuration
and operator parameters to the new module without operator
or engineer intervention. Also, the DX module provides a selectable
Fieldbus output and allows for the connection of multiple
Master devices to the system. Ascon
Corporation or more
Automation Training has just added a 2 Day PROFIBUS DP course
to its offerings. This course is available on Siemens Step
7 as well as AB-ControlLogix Woodhead's SST communications
networks. Upon completion, the student shall be able to describe
the function and capabilities of PROFIBUS, Install simple
networks including interface modules, software and cables,
configure Remote IO, apply some communication blocks, and
troubleshoot and repair PROFIBUS networks. Automation
AFTER PROFIblog, WHAT NEXT?Why PROFIcast of course! PTO
Deputy Director Carl Henning has just experimented with a
Podcast of his PROFIblog material from the General Assembly
meeting. If you're wondering how to keep up to date with PTO
matters, then PROFIcast may be just the thing. Save time by
downloading it and listening in the car. Check out the blog
here, and the podcast