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 / of 20

PROFINET and German Automobile Industry

About Audi

PROFINET at Audi Neckarsulm

Network Diagnostics Requirements at Audi

About the Solution

Résumé


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


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


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


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



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



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


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


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


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


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


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


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


Thank you very much!

Bernd Kremer

Head of Channel Sales International

Softing Industrial Automation GmbH

+49 172 93 99 808

[email protected]

http://industrial.softing.com/en/

C12 Profinet diagnostics during the entire life cycle of production lines at AUDI - Bernd Kremer,...

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