C12 Profinet diagnostics during the entire life cycle of production lines at AUDI - Bernd Kremer,...
-
Upload
the-profibus-group -
Category
Engineering
-
view
139 -
download
2
Transcript of C12 Profinet diagnostics during the entire life cycle of production lines at AUDI - Bernd Kremer,...
PROFINET Network Diagnostics at Audi Neckarsulm, Germany
Bernd Kremer, Softing Industrial Automation
PI UK Conference 23/24 June 2015
The Stratford Manor Hotel
Photo: Audi AG
© Softing 2014 / Page 2 of 20
PROFINET and German Automobile Industry
About Audi
PROFINET at Audi Neckarsulm
Network Diagnostics Requirements at Audi
About the Solution
Résumé
© Softing 2014 / Page 3 of 20
PROFINET and German Automobile Industry
AIDA - Automation Initiative of
German Car Manufacturers
► Founded 2003
► Development of mutual positions on automation topics
(e.g. harmonization / standardization of technologies)
► 2004 decision for using PROFINET
► Setting requirements for every PROFINET component
being used in Automotive production
– Integrated safety (PROFIsafe)
– CC B (RT) or CC C (IRT)
– Fast Start-Up (FSU)
– Media redundancy
– PI-Certification
Support of network management services
PROFINET and standard Ethernet through
common port
Connectivity via copper as well as fiber optics
Integrated switch for line and ring topologies
Photo: Shutterstock
© Softing 2014 / Page 4 of 20
About Audi
Facts and Figures
► Member of Volkswagen (VW) Group
► More then 73,000 employees
► Over 1,5 million cars sold (49 models)
► #1 sales position with Premium Cars
in Europe and China
► 2 digit growth in main export markets
USA, China and Great Britain
► 11 Production Sites
► Ingolstadt and Neckarsulm responsible for installation of production
lines at other sites
► „one name, one standard, everywhere“
Photo: Audi AG
© Softing 2014 / Page 5 of 20
About Audi
Neckarsulm Plant
► More then 15,000 employees
► Over 275,000 built
► 1st place J.D. Power Award for best assembly quality
in Europe and Africa
► Site with broadest product variety
(19 models)
► 10.8 Million ft2 production floor space
New pressing plant
One aluminum-steel frame and body construction facility
Two pure aluminum frame and body construction facilities
One paint spray line
Multiple assembly lines
► Lead for production sites
Changchun and Foshan, China
Aurangabad, India
Lamborghini, Italy
Photos: Audi AG
© Softing 2014 / Page 6 of 20
PROFINET at Audi Neckarsulm
Network Composition
► First PROFINET installations proving high speed
communication capabilities and robustness in 2006
(A8 Project)
► 1 GBit/s Uplink from Network Cabinet to Access Switch
► Network structure laid-out for up to 8 cells
► Cells based on PROFINET with some Ethernet
components
► Cu-wiring of Facility and Cell networks with PROFINET
Type B cables only
► Field installations of cells (CC-C / IRT) as redundant
POF-rings
– Max. 40ea subscribers plus max. 10ea on branches
– Exceeding subscribers as extra ring on additional
IRT-switch
► Each cell as own Class C network (256 IP-Addresses)
► One network diagnostics interface TH LINK PROFINET
per cell (own IP-address)
Graphics: Audi AG
© Softing 2014 / Page 7 of 20
Network Diagnostics Requirements at Audi
Body Shop Production Planning
► Tool for effective and efficient support of
installation quality assurance,
plant asset management ,
and maintenance across
entire lifecycle of the facility
► Automation network diagnostics must:
cover all subscribers (PROFINET and standard Ethernet)
– summarize from entire network all information about:
– diagnostics,
– system, and
– devices including
– their individual diagnostics history
be suitable to support through facility lifecycle at:
– installation,
– commissioning,
– acceptance, and
– maintenance
offer report functionality incl. comparison with previous status
provide continuous monitoring capabilities
support SNMP (IT acceptance) Photos: Audi AG
© Softing 2014 / Page 8 of 20
Network Diagnostics Requirements at Audi
Final Assembly
► Tool for effective and efficient support of
network management,
maintenance, and trouble shooting
► PROFINET diagnostics and monitoring tool must:
fit in flow of work
relieve maintenance resources
work independent from brand of network components
offer hot plug-in without PLC project modification
provide little hardware footprint for cabinet installation
not require any additional components, e.g. data base PC
provide functionality offering:
– topology discovery,
– different breakup views,
– inventory information about components
– detection of sporadic failures
Photos: Audi AG
© Softing 2014 / Page 9 of 20
About the Solution
Three interlocking Components
► Network monitoring and analyzing software (TH SCOPE)
– Consolidation of data from all TH Links
– Network overview and topology information in different views
– Network statistics and history of network quality
– Status and bandwidth information for network infrastructure
– Inventory list with related network and device details, such as device type,
firmware version and, IP configuration
– Detailed information about communication failures
– Generation of reports respectively acceptance protocols
– Comparison with filed reference measurements (previous status)
– Data export functionality (e.g. Reference Measuring, Inventory List)
– Web Server
– SNMP agent for handing over diagnostics information from automation networks to IT
with central network monitoring
► Network diagnostic hardware interface (TH LINK PROFINET)
– Network access
– Monitoring communication and device status
– Passive “listening” and active communication (PROFINET, Ethernet)
– Data collection for processing through specific diagnostics algorithm
► Training
– 1 day, regularly performed at customer´s site
– Content (Ethernet, PROFINET) and methodology (hands-on) defined jointly with customer
© Softing 2014 / Page 10 of 20
About the Solution
Protocols and Services used for the
Diagnostics Algorithm
Device Detection
&
Device Identification
Device Diagnostics
&
Network Statistics
Configuration
&
Communication
Failures
Network
Topology
PROFINET
(Communication & Services) X X X X
PROFINET Diagnostics Services X X
ARP (Address Resolution Protocol) X X
Ping X X
SNMP X X X
DCP / DHCP X X
LLDP X X
© Softing 2014 / Page 11 of 20
About the Solution
Outcome
► All network diagnostics requirements of customer met
► Solution specified for all future body-shop facility projects
managed / coached by Audi Neckarsulm
► Step by step integration into existing assembly lines
► Solution provides:
– Maximized availability of all facilities
– High use efficiency through consistent user interface
( one solution / tool for multiple maintenance tasks)
– Assurance of consistently high communication quality
– Hot plug-in capability
– Independence from availability of IT department capacities
Photo: Audi AG
© Softing 2014 / Page 12 of 20
About the Solution
Course of Project
► 2012 initial contact with Softing / Trebing + Himstedt IC
(at first “Body Shop Production Planning” only)
► Test phase for target-performance comparison bringing up
differing and additional mandatory requirements, e.g.:
– Acceptance Report
– Usability (e.g. sequence of work)
– Topology views at different detail levels
► Realization of enhancements and changes with standard products
► 2013 Acceptance
► 2014 first deliveries
► 2015 Equipment of assembly lines for three models and new
body shop facilities
► …
Photo: iStock
© Softing 2014 / Page 13 of 20
Roundup
Conclusions
► Ethernet-based industrial communication offers the opportunity for
realizing networks utilizing multiple technologies in parallel
► Existing requirement for dedicated network diagnostics tools
► PROFINET leveraging numerous standard Ethernet technologies
and protocols hence provides the prerequisite condition for a
consistent hence beneficial network diagnostics of real life industrial
Ethernet installations
► PROFINET is providing the functionality for highly effective and
efficient network management and maintenance meeting the
challenging demands of a leading premium car manufacturer
OSI-Layer PROFINET
7a Application
IO Services & Protocols
7b RPC
6 Presentation --
5 Session
4 Transport UDP
3 Network IP, ARP, SNMP, DHCP
2 Data Link CSMA/CD, VLAN, DCP, MRP, MRRT, LLDP
1 Physical 100BASE-TX, 100BASE-FX
Photos: Audi AG
© Softing 2014 / Page 14 of 20
About Softing Industrial
Competence in Industrial Communication
► 35 years of experience in industrial communication between
devices, controllers and host systems based on international
standards
► Integration of fieldbus technologies, industrial Ethernet and OPC
for Factory and Process Automation
► Ready to use hardware and software products for data integration,
network diagnostics and Plant Asset Management
► Effective May 1st, 2014 Softing Industrial took over the Industrial
Communication business of Trebing + Himstedt including the
solution presented
Photos: Shutterstock
© Softing 2014 / Page 15 of 20
Thank you very much!
Bernd Kremer
Head of Channel Sales International
Softing Industrial Automation GmbH
+49 172 93 99 808
http://industrial.softing.com/en/