Ethernet-based Industrial Communication

Protocols
Christoph Wimmer
Business Development Manager
Agenda
Why Ethernet-based Protocols
Overview of Ethernet-based Industrial Protocols
Adding Deterministic I/O to NI PACs
Agenda
Why Ethernet-based Protocols
Overview of Ethernet-based Industrial Protocols
Adding Deterministic I/O to NI PACs
4
Why Ethernet: Protocols
Modbus TCP/IP
Traditional Industrial
Protocols
PROFInet PROFIBUS
DeviceNet
EtherNet/IP
Modbus
Ethernet Physical
Layer
CanOPEN EtherCAT
Ethernet Adoption in Industrial
Total Market $630M
Ethernet Really Means:
Ethernet/IP
PROFInet
Modbus TCP/IP
Expected Trends in Type of Wireline Infrastructure Networks
being used in Industrial Facilities
Source: VDC 2006
Agenda
Why Ethernet-based Protocols
Overview of Ethernet-based Industrial Protocols
Adding Deterministic I/O to NI PACs
Industrial Ethernet and OSI Model
7. Application
6. Presentation
5. Session
4. Transport
3. Network
2. Data Link
1. Physical
Modbus TCP/IP
Ethernet/IP,
PROFInet, and
EtherCAT,
TCP & UDP
IP
Ethernet
Industrial Ethernet protocols are not all just
Ethernet, they add features for reliability and
determinism and the trade-off is compatibility
with standard Ethernet
Ethernet-based Industrial Protocols
Modbus TCP/IP
EtherCAT
Ethernet/IP
Profinet
Similarities
Reuse layer 1 and 2 of OSI model
What about the other 5 layers?
Define master (scanner) and slave (adapter)
devices
Address 1 or more target applications
Non Real Time
Real Time
Hard Real Time
Application Targets
Non Real Time
Uses standard TCP/IP or UDP/IP
Application: PLC to HMI or PLC to SCADA
Real Time
Provides added determinism w/ OTS hardware
Application: Control data
Hard Real Time
Adds specific hardware to deliver determinism
Application: Distributed Motion
Where Protocols Fit?
Modbus TCP/IP PROFInet (NRT)* Ethernet/IP
PROFInet (RT)** Ethernet/IP
EtherCAT
PROFInet (IRT)**
Ethernet/IP CIP
Sync
**Also PROFInet IO
*Also PROFInet CBA
Ethernet-based Industrial Protocols
Modbus TCP/IP
EtherCAT
Ethernet/IP
Profinet
Modbus TCP/IP Overview
First industrial protocol on Ethernet (introduced 1999)
Based on Modbus developed by Modicon in 1979
Widely adopted and open Ethernet standard
Advantages
Uses standard Ethernet (hardware and TCP/IP transport layer)
Open and relatively simple
Disadvantages
Not a hard real-time protocol
Does not deliver determinism
Modbus Data Items
Data Item Data Type
Modbus Modbus Slave
Description Example
Read Write Read Write
000001065535 Boolean value Yes Yes Yes Yes Accesses single-bit coils. 000001 = {000001}
100001165535 Boolean value Yes No Yes Yes Accesses single-bit discrete inputs. 100002 = {100002}
300001.1365535.16 Boolean value Yes No Yes Yes
Accesses individual bits of input registers and interprets
them as logical TRUE or FALSE values. The least
significant bit is 1. The most significant bit is 16.
300001.1 = {the first
bit of 300001}
300001365535
16-bit
unsigned
integer
Yes No Yes Yes
Accesses 16-bit input registers as unsigned integers
ranging from 0 to 65,535.
300001 = {300001}
400001.1465535.16 Boolean value Yes Yes Yes Yes
Accesses individual bits of holding registers and
interprets them as logical TRUE or FALSE values. The
least significant bit is 1. The most significant bit is 16.
400002.16 = {the
16th bit of 400002}
400001465535
16-bit
unsigned
integer
Yes Yes Yes Yes
Accesses 16-bit holding registers as unsigned integers
ranging from 0 to 65,535.
400002 = {400002}
Ethernet-based Industrial Protocols
Modbus TCP/IP
EtherCAT
Ethernet/IP
Profinet
EtherCAT Overview
EtherCAT - Ethernet Control Automation Technology
Managed EtherCAT Technology Group (ETG)
Open and based on standards, i.e. IEC 61158
Advantages
Hard Real Time industrial protocol
Extremely efficient and straightforward communication
Disadvantages
Addresses only hard real time (?)
Not designed for Standard TCP/IP packets and EtherCAT packets
Functional Principle: Ethernet On the Fly
Analogy Fast Train:
Train (Ethernet Frame) does not stop
Even when watching the train through a narrow window one sees the entire train
Car (Sub-telegram) has variable length
One can extract or insert single person (bits) or entire groups even multiple
groups per train
Master
Slave Slave
Slave Slave
18
Ethernet Frames
EtherCAT commands are transported in the data area of an Ethernet
frame and can be coded via a special Ether Type
Ether Type is limited to an Ethernet subnet (not relayed by routers)
Ethernet-based Industrial Protocols
Modbus TCP/IP
EtherCAT
Ethernet/IP
Profinet
EtherNet/IP Overview
Dominant bus for Rockwell Automation
Managed by Open Device Vendors Association (ODVA)
Extends DeviceNET concepts to Ethernet
Advantages
Uses Ethernet transport layer (TCP and UDP)
Disadvantages
Can overload networks with UDP messages if note correctly
configured, recommend managed switches with IGMP snooping
Device Classes
Slave
Only sends data if requested by a scanner
Supports explicit and implicit messaging
Adapter Class
Master
Initiate implicit and explicit communications
Scanner Class
Used for set-up or on-demand data transfer
Allows data transfer to be initiated by either
device.
Messaging Class
EtherNet/IP Add-ons
CIP Sync
Based on 1588
Provide shared clock to devices
CIP Motion
Builds on CIP Sync to perform distributed control for motion
Uses clock sharing not QoS
CIP Safety
Builds on DeviceNet Safety
Intelligent devices with time-out parameters
Ethernet/IP Terminology
TCP/IP
Used to set parameters and initiate
implicit communication
Explicit Messages
UPD/IP multicast
Used to communicate I/O data
Normally set-up for cyclical updates
Implicit Messages
Communication from LabVIEW to
ControlLogix PLCs
EtherNet/IP
Available for download from NI-Labs (ni.com/labs)
Ethernet-based Industrial Protocols
Modbus TCP/IP
EtherCAT
Ethernet/IP
PROFInet
PROFInet Overview
Dominate bus for Siemens
Application protocol that extends PROFIBUS to Ethernet
Managed by PROFIBUS&PROFINET International (PI)
Advantages
Supports both standard and deterministic Ethernet traffic
Uses IEEE-1588 and QoS to add determinism
Disadvantages
For RT/IRT managed switch with QoS is recommended
Switch with ERTEC ASIC for most challenging apps.
Three Levels
Non Real Time (NRT)
PROFINET CBA
For the commissioning of a plant
Range of 100ms
RT (Real-Time)
PROFINET CBA and PROFINET IO
IO applications
Up to 10 ms cycle times
IRT (Isochronous Real-Time)
PROFINET IO
Applications in drive systems
Cycles time of less than 1ms Source Wikipedia
PROFInet Network cycle
No Start Period message
Clock synchronization via IEEE 1588 & asynchronous
Red portion of the cycle (Isochronous)
Green portion of the cycle (Asynchronous) min 125 ms
Technology: IEEE-1588
Technology to synchronize distributed clocks
Accuracy based on clock jitter
Technology: IEEE-1588
HRT: Determinism and Performance
Organization Response Time
(for 100 axles)
Jitter Data Rate
EtherCAT ~ 0.1 ms < 0.1 us 100 Mbits/s
Sercos-III < 0.5 ms < 0.1 us 100 Mbits/s
Profinet-IRT < 1 ms < 1 us 100 Mbits/s
Ethernet Powerlink < 1 ms < 1 us 100 Mbits/s
Ethernet/IP ~ 1 ms < 1 us 100 Mbits/s
Table 1. Real-time comparison of the various real-time methods
Standards-Based Real Time Ethernet Now Off-the-Shelf, by Klaus Zwerina
Table 1. Real-time comparison of the various real-time methods
Standards-Based Real Time Ethernet Now Off-the-Shelf, by Klaus Zwerina
Agenda
Why Ethernet-based Protocols
Overview of Ethernet-based Industrial Protocols
Adding Deterministic I/O to NI PACs
Host Computer
(TCP/IP)
NI PXI System
with Ethernet Interface
NI cRIO-9074
NI 9144
NI System with Deterministic Distributed I/O
(EtherCAT)
(TCP/IP)
(EtherCAT)
NI cRIO-9074
NI PXI System
with Ethernet Interface
NI 9144
NI Master Controllers
Requirements
CompactRIO or PXI RT system with 2 Ethernet ports
NI-Industrial Communications for EtherCAT
NI 9144 Expansion Chassis
2 Ports for
Daisy-Chaining
8 Slots for
C Series
Rugged Chassis
-40 to 70C
9-30V Input
Hazloc
Shock/Vibe
LabVIEW Experience
{
{
CompactRIO
Chassis
NI 9144
Expansion
Chassis
Deterministic
Distributed I/O
Demo
C Series I/O Modules
EASY POWERFUL
OPEN
Over 30 analog and digital modules supported
All single-point measurements
No waveform support (NI 9233/9234)
Module-to-module and chassis-to-chassis
synchronization
Compatibility with different NI chassis
Questions