Implementation of Fully Integrated Automation with PROFIBUS

Chen Meicheng Fang Yanjun

Department oI Automation Department oI Automation
Wuhan University Wuhan University
Wuhan, 430072 Wuhan, 430072
CHINA CHINA
cmeicheng263.net vffang263.net
Xu Jun
Department oI Automation
Wuhan University
Wuhan, 430072
CHINA
xuhuman163.com
-This paper presents an integrated approach for
implementing fully automation with Profibus technology. We
studied the frame of Profibus protocol and the communication
model for Profinet components. A scheme for developing
Profibus slave was proposed. Aiming at the interoperation
between Profibus devices and other fieldbus devices, a scheme
for designing fieldbus protocol conversion gateway was also
presented. Other kinds of fieldbus devices can connect with
Profibus network via the gateway. Profibus devices can be
directly encapsulated in Profinet components, and through a
gateway, other kinds of fieldbus devices can also be encapsulated
with Profinet.
I. INTRODUCTION
Fieldbus technology enables the changeover Irom central to
decentralized automation systems. Nowadays, due to the high
commercial interests involved, there are many Iieldbuses
coexisting as ProIibus, Hart, CAN and some others |1|. A
modern enterprise is likely to adopt a Iew diIIerent kinds oI
Iieldbus technologies in its control systems, which will lead to
incompatible problems.. How to Iorm an eIIicient solution Ior
theses problems is a current hot spot in the research Iield on
industrial automation.
Today, ProIibus International has more than 1100 active
members worldwide; many results have shown its reliability
and high eIIiciency. ProIibus technology is mainly used in
manuIacture and process automation. It includes three
compatible editions: ProIibus-DP (Decentralized
Periphery) ProIibus-PA (Process Automation) and
ProIibus-FMS (Field Message SpeciIication). ProIibus-DP is
mainly used in high-speed data communication between
automatic control systems and dispersive I/Os or Iield
intelligent devices. ProIibus-DP protocol adopts the
normative model oI ISO/OSI; includes only the Iirst, second
layer and the user interIace; it doesn`t include the third to the
seventh layer, Ior the purpose oI high-speed data
communication. Other Iieldbus devices can also be integrated
in ProIibus network through protocol conversion gateway and
act as ProIibus devices, so they can also be encapsulated in
ProIinet components.
II. DESIGN OF PROFIBUS MODULES
SIEMENTS Corporation provides development kits Ior
ProIibus modules design. In addition, kinds oI protocol chips
are available Ior implementation oI diIIerent editions oI
ProIibus protocol. With the development kit and the protocol
chip, it is very convenient to design ProIibus components.
A. Profibus-DP protocol
ProIibus-DP protocol adopts the normative model oI
ISO/OSI; includes only the Iirst, second layer and the user
interIace; it doesn`t include the third to the seventh layer, Ior
the purpose oI high-speed data communication.The physical
layer oI ProIibus-DP is accord with the EIA criterion.
Physically, ProIibus is an electrical network based on a
twisted pair or an optical network based on a Iiber optic cable.
The data link layer describes the normal Iormation, security
mechanism and available communication services oI data
transmission messages. The only task oI the ProIibus-DP is to
deIine how the user data transmit Irom one station to another
through Iield bus, without the evaluation oI the data. The
direct data link map (DDLM) program supports the accessing
right to the second layer. The user interIace deIines
application Iunctions oI devices based on ProIibus-DP and the
characteristics oI all kinds oI systems or Iield devices.
Architecture oI ProIibus protocol is shown as Fig.1.
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According to OSI normative model, the second layer
deIines the bus accessing control, the data transmission
security, the management oI communication protocol and
messages. The second layer is called FDL (Field Data Link)
layer and its services are shown in Fig.1as below. All oI the
services are executed the SAPs (Service Access Points)
412 0-7803-9252-3/05/$20.00 2005 IEEE
through the upper protocol. ProIibus-DP only uses the
subclass oI the services, namely SRD and SDN service. In
ProIibus-DP, every SAP is deIined with a deIinite Iunction.
The deIault SAP is Ior data exchange.
SRD is used Ior all the ProIibus-DP Iunctions that involve
data transmission between master and slaves, such as cyclic
data exchange, diagnostic, parameterization, acyclic read and
write, etc. SDN is a non-conIirmed connectionless service that
is used Ior issuing global control commands Irom master to
slave. DDLM uses SDN service to implement the
DDLMglobalcontrol Iunction and uses SRD service to
implement other Iunctions. SDN is the only FDL service that
can address a group oI stations.
B. Profibus slave design
ProIibus is the network Ior the cell and Iield area in the
open, heterogeneous communication systems. ProIibus allows
comprehensive networking oI the management, cell and Iield
levels along with Industrial Ethernet and the AS-InterIace
(AS-I). In actual use in Iield area, about 90 oI the slaves are
based on ProIibus-DP.
The DP masters communicate with DP slaves through a
series oI messages. These messages include the services oI
SRD (send and require responsive data) and SDN (send
no- responsive data). The DP master sends data to DP slaves
and receives the data Irom DP Slaves within the DP polling
cycle time. To increase the reliability oI the data transmission
process, there are mandatory services Ior the master class 1
and optional services Ior the master class 2.
A ProIibus slave can be divided into two parts, i.e. a
communication board Ior implementation oI ProIibus protocol
and an I/O interIace board Ior handling peripheral signals`
input or output. The communication board and the I/O
interIace board can be connected through a Ilat cable. Frame
oI a ProIibus slave is shown as Fig.4.
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The SPC3 is an intelligent communication chip Ior slave
applications. It enables connection to the ProIibus-DP Iield
bus. The IM 183-1 interIace module is implemented with the
SPC3. The SPC3 has a 1.5Kbyte message Irame memory. It
can handle all communications tasks oI the ProIibus-DP
protocol completely independently. This accelerates protocol
handling and reduces the scope oI the soItware in the
microprocessor oI the interIace module. Bus access is
hardware driven. Data transIer takes place via a 1.5Kbyte
RAM. The interIace to the application is a data interIace.
ThereIore, the data can be transIerred independent oI the bus
circle. The maximum transmission rate is can reach 12Mbit/s.
The main board provides chip selecting signals, data bus,
address bus, and some control signals Ior the slave board. The
slave board can be easily connected to the main board through
a Ilat cable, thus it can process the corresponding signals. This
doing assures the convenience Ior the slave module`s Iuture
Iunction extending.
The I/O interIace board is used Ior signal acquisition and
outputting. It can be designed with the corresponding
Iunctions according to practical requirements. Many chips can
be selected to process peripheral signals. MAX197 can be
used Ior analog signal sampling, and TLV5618 can be used Ior
outputting analogsignals. 74LS244 and 74LS573 can handle
the switch signal inputting and outputting respectively.
III. INTERCONNECTION OF HETEROGENEOUS
FIELDBUS DEVICES
Interconnection oI heterogeneous Iieldbus devices is an
excellent way to exert each Iieldbus technology`s advantages.
As most Iieldbus are quite diIIerent Irom each other at the
physical layer and the data link layer, the protocol conversion
task can be IulIilled only through gateways.
A. Fieldbus protocol conversion model
As heterogeneous Iieldbuses deIine quite diIIerent
standards at each layer oI their protocols, protocol conversion
can be realized only through gateways |5|. In addition,
adopting the compound protocol conversion method will
optimize the design schemes. Fieldbus protocol deIines a user
interIace above its application layer, thus the gateway must try
to call the deIined SAPs (Service Access Points) to transIer
services Irom the upper entity to the lower entity. Fig.5 shows
the communication model between Iieldbus devices.
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Fig. 5. Communication model between Iieldbus devices
B. Fieldbus gatewav design
A good example oI the Iieldbus gateway design can be
implemented between Modbus and ProIibus-DP. Modbus is
another widely used Iieldbus technology, which is actually the
standard Ior industry communication since 1979. Though
ProIibus-DP and Modbus both can use RS-485 bus at the
physical layer, their data link layer and user
interIace/application layer are quite diIIerent Irom each other.
Gateway must be adopted to implement the interconnection oI
the two diIIerent networks. Protocol conversion adopts
layer-by-layer mode, namely Irom the lower layer to the upper
layer. The lower layer supports the upper layer and the upper
layer calls the services provided by the lower layer.
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Protocol chip SPC3 is adopted Ior the implementation oI
ProIibus-DP protocol. Single chip processor 89C52 provides
serial interIace Ior Modbus and protocol chip SPC3 provides
ProIibus-DP with RS-485 interIace. Fame oI the gateway
between ProIibus-DP and Modbus is shown as Fig.6.
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Through the way, a Modbus device can implement all oI the
Iunctions oI ProIibus-DP, and act as a node in the ProIibus-DP
network. Similarly, gateway Ior protocol conversion between
ProIibus and other Iieldbus can be designed.
III. PROFINET TECHNOLOGY
ProIinet technology supports the modularization oI plants
and machines through the distribution oI automation and
intelligent Iield devices. This technological modularization is
a key characteristic oI distributed automation systems and
simpliIies the reuse and standardization oI plant and machine
parts.
A. Profinet component
The Iunction oI an automatic plant or machine is perIormed
through the deIined interaction oI mechanical,
electrical/electronics and control logic/soItware. Working on
this principle, ProIinet |6,7| deIines the parts 'mechanical,
'electrical/electronics and 'control logic/soItware in
Iunctional terms to Iorm a technological module. A simple
ProIibus-DP network with several masters and slaves can also
be encapsulated in a ProIinet device.
A typical model oI a ProIinet component is shown as Fig.7.
It represents a technological module in the system-wide
engineering. It encapsulates its automation Iunctionality in a
soItware component, and Irom the technological point oI view,
has an interIace containing the variables required Ior
interacting with other components.
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Fig. 7. ProIinet component model
ProIinet components are based on the open communication
COM. The interIaces can be easily connected in the ProIinet
connection editor. The component model enables objects oI
various origins through deIined interIaces.
B. Engineering with Profinet
A ProIinet component created and conIigured in ProIinet
Engineering will perIorm the automation Iunctionality in
runtime |8|. The component description must be created with
the respective vender speciIic programming and conIiguration
tools. Use oI the vendor-speciIic tool presupposes that it
includes the component generator, which enables the ProIinet
speciIic XML Iile oI the ProIinet components to be created.
The concrete system is described through the conIiguration oI
ES-Autos. Component interconnection during conIiguration
results in some major advantages compared to programming a
system with Iunctionality. The topological structure oI the
automation system, on the other hand, is created in the
network view. The Iield devices and programmable
controllers are assigned to communication or bus system and
the device addresses are Iixed in accordance with the rules oI
the underlying bus system.
C. Real-time performance analvsis
The analysis oI various TCP/IP implementations has
revealed that considerable running times are needed with
standard communication stacks to manage the data packets. It
is possible to optimize these running times, but the required
TCP/IP stack is no longer a standard product but a proprietary
implementation |9|. The same is true when using UDP/IP
implementations.
An eIIicient solution is created in ProIinet Ior real-time
applications which are typically Iound in production
automation and whose update or response times are at least in
the range oI 5-10ms. The update time is created in a device
application, is then send to a partner device through the
communication systems, and is subsequently made available
to the application again at this partner device. Such a solution
greatly minimizes throughout times in the communication
stack and results in enhanced perIormance in terms oI the
update rate oI automation data. On the one hand the
elimination oI several protocol levels reduces message length;
on the other hand it takes less time beIore the data to be
transmitted are ready Ior sending and the application is ready
Ior processing.
IV. CONCLUSIONS
The scheme oI adopting ProIibus technology to implement
Iully integrated automation inside an enterprise is an eIIicient
way to raise the eIIiciency and save the costs. A successIul
application example has shown that the Iully integrated
automation with ProIibus saves 15 oI a system`s overall
costs. Moreover, such a system-wide and vender-independent
engineering project will provide the users with a high degree
414
oI clarity and transparency, thus it will Iinally contribute a lot
to the improvement oI the qualities oI a intelligent control
system. It can be Ioreseen that the application oI ProIibus
Iieldbus technology will become more attractive in the Iuture.
V. REFERENCES
|1| Yang Xianhui, Filedbus Technologv and Its
Application, Beijing: Qinghua University Press, 1999,
pp.101-103.
|2| A. N. Expert, A Book He Wrote, His Publisher, 1989.
Yang Changkun. Fieldbus Technologv Handbook on
PROFIBUS, Chinese PROFIBUS Organization, 2001.
|3| Tang JiYang, Guidance of The Application of Profibu-,
Chinese PROFIBUS Organization, 2001.
|4| ManIred Popp, Introduction to PROFIBUS on Industrial
PC. SIEMENS AG, 1997.
|5| Cai Jianxin, Theory and application oI HART modern
HT2012.Electricaltechnologvapplication,1994(4),pp.43-
46.
|6| Gu Hongjun, Industrv Ethernet and Fieldbus Technologv,
Beijing: Renmin Youdian Press, 2002, pp.96-99.
|7| GeoII Brown, 'Bring Together Drivers and Fieldbus
Technologv, Control and Instrumentation, vol 8, pp.
35-37, May 2000.
|8| GeoII Brown, 'Bring Together Drivers and Fieldbus
Technologv, Control and Instrumentation, vol 8, pp.
35-37, May 2000.
|9| PADABIS, Plant Automation Based on Distributed
svstem ,http://www.pabadis.org.
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