Profinet implementation and testing - Dave Tomlin and Xing Ye
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This document discusses testing industrial ethernet networks like PROFINET. It defines different types of network tests: verification tests check cabling, qualification tests check signal quality, and certification tests check the entire network. The challenges of testing these networks are also examined, such as complex device configurations, bandwidth competition causing packet loss, and time pressures of on-site commissioning. Solutions discussed include portable network testers that can simplify testing and identify issues through features like one-touch health checks, cable verification, and performance monitoring.
Profinet implementation and testing - Dave Tomlin and Xing Ye
- 1. A quick way to address field network issues effectively The Field Test Challenge of PROFINET Industrial network commissioning & testing
- 2. 2PROFIBUS UK 2Editable name of event Guidelines1 Test types2 Designers Responsibilities3 Network Diagrams4 Commissioning and testing5 © 2017 Agenda
- 3. 3PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Installation & Commissioning Guidelines © 2017
- 4. 4PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Examples of test results Test types - definition of terms Verification (simple line test)* Basic cabling structure test Check for correct wiring Qualification (functional test)* Identifying performance of data transmission Certification (acceptance test)* Classical network acceptance tests Assessment according to defined standards (e.g. IEC11801 or in our case PROFINET Commissioning Guidelines) Troubleshooting Typical Ethernet problems * PROFINET Commissioning Guideline V1.36 PNO Dec. 2014 © 2017
- 5. 5PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Cable Verification in Practice Qualification and Verification – PROFINET Verification test – Wire test Confirm accurate wiremap from plug to plug Opens Shorts Crossed wires Measure length of cable Easy to use or cheap? Manual or automatic? © 2017
- 6. 6PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Qualification and Verification - PROFINET Qualification test – Functional test Determination of signal-noise-ratio (SNR) Noise sources: NEXT *, FEXT *, echo noise, environment noise BERT (Bit-Error-Rate-Test) or Packet-Error-Rate-Test Sends Ethernet frames with 100Mbit/s; okay if 10s without losing frames Evaluation based on Ethernet error tolerances according to IEEE 802.3. Determination of runtime difference between wire pairs Fastest pair is 0ns ** e.g. limit for 1000BASE-T: 50ns © 2017 * NEXT: near end crosstalk FEXT: far end crosstalk ** (PROFINET works with two wire pairs. In the ideal case both pairs should have the same runtime) Test line
- 7. 7PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Near end and Far end cross talk NEXT and FEXT Cross talk in UTP cables is caused by capacitive coupling between pairs. Signals on pair A cause noise signals on pair B, and often the cross talk noise proves to be the limiting factor Cross talk occurs in two ways. Nearend cross talk (NEXT) happens when a signal from a transmitter at one end of a cable interferes with a receiver at the same end of the cable. Far-end cross talk (FEXT) occurs when a signal interferes with a receiver at the opposite end of the cable from the transmitter © 2017
- 8. 8PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Test Report – Verification and Qualification Clear details of each cable Report for end customer or management © 2017
- 9. 9PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Certification (acceptance test)* Some of the Classical network acceptance tests Full System Inventory – does it match? Network Topology – does it match? Packet loss rate? Network Load © 2017
- 10. 10PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Designers Responsibilities © 2017
- 11. 11PROFIBUS UK 11PROFIBUS, PROFINET and IO-Link Seminar – June 2019 © 2017 Designers Responsibilities
- 12. 12PROFIBUS UK 12PROFIBUS, PROFINET and IO-Link Seminar – June 2019 © 2017 Designers Responsibilities 12 RGF1 17 RGF2 22 RGF3 27 RGF4 38 26 RGF15 31 RGF4 28 RGF4 24 RGF3 36 RGF3 23 RGF3 40 44 39 41 14 RGF1 34 RGF1 19 RGF2 35 RGF2 18 RGF2 13 RGF1 16 RGF1 21 RGF2 29 RGF4 Rep Seg 1 18m 5m 7m 5m 17m 10m 8m 7m 10m 17m 24m 56m 1m 5m 7m 4m 7m 16m 5m 9m 24m 3m 7m 45 9525 37 RGF4 16m 5m 25m
- 13. 13PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 The change from fieldbus to Ethernet The change - Communication link from Fieldbus to Industrial Ethernet Topology - linear daisy chain with limited node devices (126) to ring, star, liner mixture with unlimited of node devices linked. Media - Simple twisted copper pair to copper, fiber, wireless. Copper from one pair to four pairs Speed - Typical Kb/s to 100Mb/s or 1Gb/s Scale - Self contained to open flexible scaling Complexity - Simple RS485 serial protocol (244 bytes) to complex PROFINET protocol (1440 bytes) Control – Master/Salve to Provider/Consumer Device – Extra network devices (switch, router, Access Point, firewall etc.) © 2017 Controller I/O #1 I/O # N I/O #2 … … Controller SWITCH I/O #1 I/O # N I/O #2 AP
- 14. 14PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Time pressure on site commissioning test Longer time spend on commissioning test when the nodes and network getting bigger and complex More time required for trouble shooting when things go wrong due to the complexity Shortage of high skilled person Lack of knowledge and skilled person in shop floor to handle Ethernet (PROFINET) communication network Whole network access right and the risk of causing production line down Security concerns to share whole network access right with others Limited budget of monitoring tool Especially for the small network for fixed monitoring system Limited space or difficult position to access cabinet with laptop © 2017 The challenge - The field test of network communication (I) Access Right
- 15. 15PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Complex node device configuration and network trouble shooting in commissioning and maintenance stage vs fieldbus Multiple domains/Aspects to configure the Node Devices comparing fieldbus Physical layer involved different media – copper (multi cores 4-8 instead of two), fiber (bending, dirtying, mating connector and fusion), wireless access (coverage, interference, security) Ethernet Link/IP layer setup – speed, duplex, MTU, protocol, multiple switches, IP address, subnet mask, gateway, DNS etc. Multi vendors devices’ compatibility (monitoring system, interaction) and inter link communication Unknown/miss configured devices connected to the existing network Network bandwidth competition – abnormal node device behavior using extra bandwidth to compete with other © 2017 The challenge - The field test of network communication (II) IP address The complex node device & parameters
- 16. 16PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Packet loss mechanism The network device – Switch has a unique network behaviour. Each I/O has built-in switch Ethernet Link Key Performance Indicator (KPI) Bandwidth Delay (Latency) Jitter Packet Loss Network bandwidth competition – one of the common sources to cause packet loss, delay and jitter. Each switch will discard received errored packets based on FCS regardless the priority set of the traffic on packets Controller link is the bottle neck of the bandwidth competition causing KPI degradation. © 2017 The challenge - The bandwidth, packet error, delay & jitter relation Bandwidth Delay (Latency)Jitter Packet Loss When Buffer Full Rx Error Error Packets Dropped I/O 1 I/O 2
- 17. 17PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Current available tester solutions in market Reduce commissioning and trouble shooting time Network health checking with easy status indication – Traffic light Identify and locate the fault quickly Quantified link performance check – Bandwidth, Packet error, jitter, delay Long term monitoring error event – know when, where what error Comprehensive test report for the acceptance test Simplify the test procedure for low skilled users One key scan to know all the network status Pass/Fail with traffic light indication of each device Spot on the failed configuration or status location of device(s) easily without expert on site Risk control of limited network access right to free up specialist time Limited access control functions of network with monitoring only Handing over routing job to front line operators © 2017 The solution - Field tester requirements (I)
- 18. 18PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019 Current available test solutions in market Easy carry to access field test point with multiple functions Small form factor and light to access awkward access position of the production line easily. All in One – Multi-layers testing from physical layer copper, fiber & Wi-Fi to Link/IP and PROFINET protocol layer Non-intrusive test access via spare port or mirrored port of switch Support multi-protocol of industrial Ethernet production Affordable to the majority of the automation lines High price performance Easy operation with less or no training Used for multi production lines/plants Low total ownership cost using existing file storage system © 2017 The solution - The field tester requirements (II)
- 19. 19PROFIBUS UK How do I know which nodes are present in the network and their health status? The scanned node list using the traffic light system gives you the answer! Device list with individual health indication Total Nodes and Overall test status Test Scenarios – Example Field Maintenance Test – Network Health Status … Controller SWITCH I/O #1 I/O # N I/O #2 A tester view sample
- 20. 20PROFIBUS UK Test Scenarios – example Field Maintenance Test – Node Device change How can I configure the faulty replacement/wrong device quickly to resume the production without PC? Setup function allows device configuration without PC software instantly and no need for network specialists on site. … Controller I/O #1 I/O # N I/O #2 New I/O #2 o Flash LED to check right device to setup o Setup IP address, name, factory default o Scan the network again after replacement Sample of tester GUI SWITCH
- 21. 21PROFIBUS UK Test Scenarios – example Field Commissioning/Acceptance Test – Cable How can I verify that the PROFINET cable is made correctly in the field by installers? PROFINET wiremap test is assuring the quality of cable installed during the installation and checked in commissioning. … Controller I/O #1 I/O # N I/O #2 A B PROFINET cable under test #1 Remote M12 D or X coded Adapter Cable RJ45 M12 M12 D or X coded Adapter Cable M12 RJ45 SWITCH Sample of PROFINET cable test result
- 22. 22PROFIBUS UK Test Scenarios – example Field Commissioning Test – Network Comparison How can I find the new commissioned production line issues in the field quickly? The NetMAP comparison function makes verifying and troubleshooting new production line faster. Controller I/O #1 I/O # N I/O #2 Controller I/O #1 I/O # N I/O #2 Dismantle, ship and reassembly back in the plant NetMAP A NetMAP B … … (Ref) SWITCH SWITCH Sample of tester GUI
- 23. 23PROFIBUS UK Test Scenarios – example Field Commissioning Test – Bandwidth Usage 1 Controller I/O #1 I/O #N I/O #2 How do I know the bandwidth usage of individual device as well as where the network bottle neck is? Bandwidth measurement with PROFINET scan and mirror port link test gives you the insight. SWITCH … Mirror Port 1 to 8 1 8
- 24. 24PROFIBUS UK Test Scenarios – example Field Trouble Shooting – Event log Controller I/O #1 I/O #N I/O #2 How can I isolate the cause of the intermittent fault quickly in a PROFINET production line? Event log can assist you to identify what and when the error appeared on a specific device. SWITCH … Sample of tester GUI
- 25. 25PROFIBUS UK Test Scenarios – example Field Network Maintenance – Network Health Trend How can I do the preventive maintenance to minimise the down time and spare parts storage? The live network health status comparison gives you the insight of trend on any changes. Controller I/O #1 I/O # N I/O #2 Controller I/O #1 I/O # N I/O #2 A month later to test again on the same network Result May Result June … … May Test SWITCH SWITCH Production 7 Tested 2 May 2019 Production 7 Tested 2 June 2019 June Test
- 26. 26PROFIBUS UK How can I prove the network I commissioned is working correctly? The PDF and CSV formatted test reports meet both the direct filing and integrated to the project report. A sample of PDF test report summary page A sample of CSV formatted test report for easy Test Scenarios – Field Commissioning Test – Test Report example 1
- 27. 27PROFIBUS UK Test report sample of PDF detailed test items Test Scenarios – Field Commissioning Test – Test Report example 2 How can I trace back to the original network commissioned setup record on specific node devices? The comprehensive detailed test reports saves your time significantly to find a specific device’s setup.
- 28. 28PROFIBUS UK Q & A Thanks for your attention All of the Documents below are available to download on the PI Website* PROFINET Design Guidelines Network Load Calculation Tool Installation Guideline for Cabling and Assembly Commissioning Guidelines PROFIBUS Design Guidelines PROFIBUS Assembly Guidelines * You may need to be a member to access some documents Dave Tomlin Hitex UK Ltd 02476 692066 dtomlin@Hitex.co.uk www.hitex.co.uk UK Technical distributor for Softing Industrial Automation Tools. Xing Ye Ideal Networks Ltd Xing.Ye@idealnwd.com www.idealnetworks.net