PROFINET in Automotive

Part 2

Hunter Harrington PROFINET Consulting Eng

PROFI Interface Center

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Agenda

Why PROFINET? Industrial Ethernet

PROFINET Industrial protocol and design

Environment

Automation Requirements

What is PROFINET? Minute PROFINET intro

Determinism with PROFINET

Unique Features Diagnostics, Network mgmt, Proxies, Shared and

I-Device, Fast startup

Application profiles PROFIenergy, PROFIsafe

Network installation Installation,Topologies, Redundancy

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2

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Agenda

Why PROFINET? Industrial Ethernet

PROFINET Industrial protocol and design

Environment

Automation Requirements

What is PROFINET? Minute PROFINET intro

Determinism with PROFINET

Unique Features Diagnostics, Network mgmt, Proxies, Shared and

I-Device, Fast startup

Application profiles PROFIenergy, PROFIsafe

Network installation Installation,Topologies, Redundancy

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3

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Why (PROFINET)?

Why are we here? Or Rather, Why are we here talking about Ethernet, TCP/IP and now PROFINET?

Ethernet has been out since the 70‟s and TCP/IP shortly after!

TCP/IP was not designed with automation and control in mind, Ethernet was, but doesn‟t provide the entire solution PROFINET was designed from the ground up with advanced Industrial Ethernet Automation capabilities

To cover weaknesses for automation in existing protocols (ex: TCP/IP, client / server model, timeouts, determinism, smaller vs larger packets, etc..)

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Industrial Ethernet Requirement: Environment

Office Area Production and Field Areas

Moderate Temperatures Extreme temperatures

Low Dust burden High dust burden

No moisture Moisture possible

Virtually no vibrations Vibrating Machines

Low EMC burden High EMC burden

Low mechanical danger Danger of mechanical damage

Low UV radiation UV burden in outer area

Virtually no chemical danger Chemical burden from oily or

aggressive atmospheres

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Industrial Ethernet Requirements

Speed Microseconds to over 100 milliseconds

Determinism (repeatable message delivery)

Jitter from <1microsecond to 10 milliseconds

6

Factory Automation

Motion Control Application

Standard Communication

TCP/IP

<1ms 1-10ms 100ms+

Real-Time IRT

<1µs <1ms 10ms+

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Shielded vs. Unshielded

Reference measurement Shielded Twisted Pair (STP) vs.

Unshielded Twisted Pair (UTP)

Data transfer rate: 100 Mbit/s

Bus load 81%

Packet length: 346 bytes

Duration: 30 s

Result An UTP cable is totally unsuitable

for noisy environment

Even noise voltages of 1 kV can

lead to a breakdown in

communication

7

10

180200

692

0

100

200

300

400

500

600

700

800

2 kV 2,5 KV

Noise voltage

Nu

mb

er

of

fau

lty

packets

Shielded TP UTP Cord

Shielding has nothing to do with the protocol!

It’s all about your environment

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Shielding

TCP/IP has methods in place to resend

telegrams when lost But the timing is not acceptable for industrial use!

There is no such thing as a protocol protection

against noise The need for shielding is independent of the protocol

used

PROFINET Installation Guideline has details

8

If you used shielded cable with DeviceNet or PROFIBUS

use shielded cable with Industrial Ethernet as well!

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Agenda

Why PROFINET? Industrial Ethernet

PROFINET Industrial protocol and design

Environment

Automation Requirements

What is PROFINET? Minute PROFINET intro

Determinism with PROFINET

Unique Features Diagnostics, Network mgmt, Proxies, Shared and

I-Device, Fast startup

Application profiles PROFIenergy, PROFIsafe

Network installation Installation,Topologies, Redundancy

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9

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What is PROFINET? (got a minute?)

Some short one minute videos to help us get started

10

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5 steps to determinism

Configuration

Real-time

High Speed IO

TCP/IP

Layer 2 (RT)

Bandwidth

Reservation

(IRT)

Cycle 1

IRT

channel Standard channel

Motion Control Scheduling

(IRT)

PROFINET HTTP

SNMP

…

IP

Ethernet

TCP/UDP

Standard data

1

TC

P/I

P

Real-

tim

e

2

RT

Iso

ch

r.

Real-

tim

e

3

RT/ IRT

31.25µsec Fast Forwarding

DFP

Fragmentation

IRT = Isochronous Real-time

DFP = Dynamic Frame Packing

Device z Device y

Controller

Switch

Port1

Po

rt1

Po

rt1

Po

rt2

Po

rt1

Po

rt2

Po

rt4

Po

rt1

Device x

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PROFINET and TCP/IP

PROFINET uses TCP/IP where it makes sense:

Diagnostics Non time critical data Communicating with higher level IT

systems

PROFINET real-time coexists with TCP/IP without restrictions

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PROFINET DOES NOT

USE STANDARD

TCP/IP

Real-Time

Bandwidth

Scheduling

TCP/IP

31.25µsec

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Why not use TCP/IP for real-time?

Because it‟s not fast enough and it‟s not deterministic enough. Here‟s why:

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T4

T5

T2

T1

T3

TCP/IP

Suite

Ethernet

Server

TCP/IP

Suite

Ethernet

Client Data

UNWELCOME

DELAYS

Bandwidth

Scheduling

TCP/IP

31.25µsec

Real-Time

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Ethernet doesn‟t cause delays

Node time

330

Propagation

0.5

Transmission

5.12

Switch latency

10

Transmission

5.12

Propagation

0.5

Network

14

Node A

Switched

100Mbps

Ethernet

Node B

100m 100m

64-byte

packet

Source: University of Michigan, Industrial Ethernet Book,

“Performance Metrics for Industrial Ethernet”

All times in µs

Bandwidth

Scheduling

TCP/IP

31.25µsec

Real-Time

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PROFINET RT (Real Time)

The device determines which path the telegram takes

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Data

40*…1440 Bytes

InterFrame

Gap

12 Byte

Pre-

amble

7 Byte

Sync

1 Byte

MAC

6 Byte

MAC

6 Byte

Ether-

type

2 Byte

VLAN

2 Byte

Ether-

type

2 Byte

Frame

ID

2 Byte

Cycle

Counter

2 Byte

Data-

Status

1 Byte

Trans

Status

1 Byte

FCS

4 Byte

Ethernet Frame

Ethertype (type of protocol):

Ethertype (PN): 0x8892

Ethertype (IP): 0x0800

EtherType (ARP): 0x0806

EtherType (IPV6): 0x86DD

…

RT Data

HTTP PROFINET

Rea

l-tim

e

SNMP Socket

IP

TCP / UDP

Ethernet

IEEE EtherType

0x8892

IEEE EtherType

0x0800

Data

40*…1440 Bytes

InterFrame

Gap

12 Byte

Pre-

ambel

7 Byte

Sync

1 Byte

MAC

6 Byte

MAC

6 Byte

Ether-

type

2 Byte

VLAN

2 Byte

Ether-

type

2 Byte

Frame

ID

2 Byte

Cycle

Counter

2 Byte

Data-

Status

1 Byte

Trans

Status

1 Byte

FCS

4 Byte

Bandwidth

Scheduling

TCP/IP

31.25µsec

Real-Time

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When you try to use all layers…

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Internet Layer

Network Access

Layer

Application

Layer

Transport Layer

Socket SNMP WEB

IP

Ethernet IEEE 802.3

TCP / UDP

Industrial

Protocols PROFINET

Internet Layer

Network Access

Layer

Application

Layer

Transport Layer

Socket SNMP WEB

TCP / UDP

Industrial

Protocols

IP

Ethernet

e.g.

EtherNet/IP

IEEE 802.3

PROFINET is the enabling factor to achieve

speed and determinism

Bandwidth

Scheduling

TCP/IP

31.25µsec

Real-Time

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When you try to use all layers…

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17

Internet Layer

Network Access

Layer

Application

Layer

Transport Layer

Socket SNMP WEB

IP

Ethernet IEEE 802.3

TCP / UDP

Industrial

Protocols PROFINET

Internet Layer

Network Access

Layer

Application

Layer

Transport Layer

Socket SNMP WEB

TCP / UDP

Industrial

Protocols

IP

Ethernet

e.g.

EtherNet/IP

IEEE 802.3

PROFINET is the enabling factor to achieve

speed and determinism

8 ms

16 ms

Less

than

100µs

Jitter

Source: University of Michigan, Industrial Ethernet Book,

“Performance Metrics for Industrial Ethernet”

Bandwidth

Scheduling

TCP/IP

31.25µsec

Real-Time

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Bandwidth Reservation for PROFINET IRT

Communication system scheduling Exact cycle synchronization

Separate time domains for Real-time and non-Real-time

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Cycle 1 Cycle 2

Cycle n

IRT

channel Standard channel

e.g. 1 ms position controller clock cycle

Isochronous (IRT) Data

Open standard communication

IRT

channel Standard channel

IRT

channel

Real-time (RT) Data

TCP/IP-Data RT - Data IRT-Data

Synchro- nization

IRT = Isochronous Real Time

Scheduling

TCP/IP

31.25µsec

Real-Time

Bandwidth

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Scheduling for PROFINET IRT

Every IRT device knows, when data arrives and

where to send it

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Controller

Switch

Device z Device y Device x

Port1

Po

rt1

Frame 3

Frame 2

Frame 1

Switch schedule

Rec.

port Arrive Frame Departure

Dest.

port

1 t1 1 t1+∆t 4

1 t2 2 t2+∆t 4

1 t3 3 t3+∆t 2

2 - - - -

3*) - - - -

4*) - - - -

*) 100% free for TCP/IP

Po

rt1

Po

rt2

Po

rt1

Po

rt2

Po

rt4

Po

rt1

Frame 1 Frame 2 Frame 3

Frame 1

Frame 1

Frame 2 Frame 3

Switch must be IRT-aware

TCP/IP

31.25µsec

Real-Time

Bandwidth

Scheduling

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31.25 microsecond cycle 20

TCP/IP

Real-Time

Bandwidth

Scheduling

31.25µsec

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Summary

PROFINET achieves industry requirements

for speed and determinism using standard

Ethernet by using these 5 steps 1. Using TCP/IP where appropriate

2. Skipping it when necessary

3. Reserving bandwidth for higher performance

4. Scheduling traffic to ensure motion control

needs

5. Fast Forwarding, Dynamic Frame Packing,

and Fragmentation to achieve 31.25µsecond

cycle times

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Agenda

Why PROFINET? Industrial Ethernet

PROFINET Industrial protocol and design

Environment

Automation Requirements

What is PROFINET? Minute PROFINET intro

Determinism with PROFINET

Unique Features Diagnostics, Network mgmt, Proxies, Shared and

I-Device, Fast startup

Application profiles PROFIenergy, PROFIsafe

Network installation Installation,Topologies, Redundancy

www.us.profinet.com

22

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Unique PROFINET Functionalities for Automotive

B E N E F I T Function(s) Application

PROFINET

Diagnostics PROFINET device

diagnostics supports

quick error localization

Diagnostics of PROFINET

devices

Maintenance and

diagnostics

IT Integration in

PROFINET Standard IT tools and

know how can be used

Devices support LLDP,

HTTP (web server), SNMP

Network Management for

configuration/diagnostics

Topology

/

Redundancy

Clear and simple

presentation of network

status / Redundancy

Read the network topology

and monitor /

Redundant network

Configuration,

Diagnostics and

documentation

Simple

Device

Replacement

Fast and easy device

replacement and

commissioning

Automatic name

assignment by means of

configured topology

Device replacement

Commissioning

IP 65/67 devices

Proxy concept Specifications for legacy

network data mapping to

PROFINET data

Connect Legacy networks to

PROFINET

IO / CBA (peer to peer)

Communication to legacy

systems

Shared Device Application enhancement

for IO devices

Multiple controllers can

control IO device

Standard and safety

application

I-Device Application enhancement

for IO controllers

Can be IO device and

controller at the same time

Standard and safety

applications

Application profiles Support of a variety of

applications and devices

Safety, Energy savings,

common device profiles

PROFIsafe, PROFIenergy,

PROFIdrive

Fast Start Up Supports fast application Fast startup of I/O devices

after power on (500 ms)

Example: Tool change

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Unique PROFINET Functionalities for Automotive

B E N E F I T Function Application

PROFINET

Diagnostics PROFINET device

diagnostics supports

quick error localization

Diagnostics of PROFINET

devices

Maintenance and

diagnostics

IT Integration in

PROFINET Standard IT tools and

know how can be used

Devices support LLDP,

HTTP (web server), SNMP

Network Management for

configuration/diagnostics

Topology Clear and simple

presentation of network

status

Read the network topology

and monitor

Configuration,

Diagnostics and

documentation

Simple

Device

Replacement

Fast and easy device

replacement and

commissioning

Automatic name

assignment by means of

configured topology

Device replacement

Commissioning

IP 65/67 devices

Proxy concept Specifications for legacy

network data mapping to

PROFINET data

Connect Legacy networks to

PROFINET

IO / CBA (peer to peer)

Communication to legacy

systems

Shared Device Application enhancement

for IO devices

Multiple controllers can

control IO device

Standard and safety

application

I-Device Application enhancement

for IO controllers

Can be IO device and

controller at the same time

Standard and safety

applications

Application profiles Support of a variety of

applications and devices

Safety, Energy savings,

common device profiles

PROFIsafe, PROFIenergy,

PROFIdrive

Fast Start Up Supports fast application Fast startup of I/O devices

after power on (500 ms)

Example: Tool change

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Next section

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About PROFINET Proxies

Proxies are like gateways in that they

connect disparate networks, BUT unlike

gateways they are defined in the PROFINET

spec, so data mapping is always the same.

25

Controller

PROFIBUS PA FF

Allen-Bradley

XX55

CE

DeviceNet PROFIBUS DP AS-i

also Interbus, HART, CC-Link, Modbus

IO-Link

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PROFINET Shared Device

PROFINET offers shared device functionality Two Controllers can access the same device

Flexible assignment of modules to different controllers

IO controller

1

PROFINET

IO controller

2

Shared

IO Device

Shared device results in reduced costs, simplified architectures,

can save on cabinet space, allowing optimized solutions

26

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Simple and familiar IO interfacing of CPUs

Interfacing of CPUs in different projects

Integration among different controllers (manufacturers)

Transmission of cyclic data (RT, IRT)

I-Device –

simple and

fast solution

An IO controller can also be operated

as an IO device

With IO controller functionality on the

same interface

Controller-Controller communication

with simple IO access, without TCP/IP

telegrams or proprietary methods

Allow local controllers in a modular

architecture to communicate to a

higher level station (main controller)

IO controller 1

IO device 2

PROFINET

IO controller 2

CPU2 I-Device

IO device 1

CPU1

How do I integrate machines?

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27

PROFINET IO

I-Device

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Application Profiles

Agreement within a device family on how to use

the PROFIBUS / PROFINET data by adding

data structures, cyclic / acyclic services,

behavior, parameterization, diagnosis,

integration, etc.

28

1

2

7

1

2

7

Host/Master Field Device/Slave

Engineering

IEC 61158

Profile

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Application Profiles 29

Ident (Bar-

code,

RFID)

Robot

/NC

Profile Guidelines

"Common Profiles" Application Profiles

Cooperation with other organizations

e.g. OPC, DriveCom, VDMA, OpenPLC, etc.

Training (UML, Safety, Models, etc.)

Tools

Redundancy

FF,

IEC 61804 Interbus,

CAN, etc.

Models

"Best Practice Patterns"

Diagnosis

Data types

IEC 62390

Encoder PROFI

drive

Fluid

Power

SEMI

I&M Functions

Time Stamp

PROFIsafe

......

PA

Devices

Water/

waste

water

intellig.

Pumps SEMI

Remote

I/O

for

PA

Laboratory

Devices

Weighing

&

Dosage

Low

Voltage

Switch-

gear

IO-Link Trains

?

PROFINET IO

? ?

PROFI

energy

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An overview of Use Cases

• UC 1: Disconnection and connection during pauses

• UC 2: Disconnection and connection on the weekend

• UC 3: Load-dependent machine control

• UC 4: Pausing auxiliary process under threat of load spike

PROFIenergy Energy Management Application Profile

Definition:

PROFIenergy is an application profile based on PROFINET which permits

coordinated and centrally controlled switching-off of loads in pauses independent of

the vendor and device.

30

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PROFINET Fast Startup

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Tool Model “B”

Tool Model “C”

Tool Model “A”

Robot

PROFINET IO

Robot

Controller

Main Control

CPU End of Arm Tooling

CP 1616 I/O

Flexible Robot Cell must

connect to End of Arm

Tooling based upon Work in

Process

After power on, startup times of 500ms or less can be achieved using PROFINET Fast Startup

Tool Docking system

31

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Agenda

Why PROFINET? Industrial Ethernet

PROFINET Industrial protocol and design

Environment

Automation Requirements

What is PROFINET? Minute PROFINET intro

Determinism with PROFINET

Unique Features Diagnostics, Network mgmt, Proxies, Shared and

I-Device, Fast startup

Application profiles PROFIenergy, PROFIsafe

Network installation Installation,Topologies, Redundancy

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32

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PROFINET Guidelines

Design Guideline With network load tool

Installation Guideline

Commissioning Guideline

33

All at http://www.profibus.com/nc/downloads/downloads/profinet-installation-guide/display/ and on CD.

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Suggested Topologies 34

HMI

max. 10

switches

with 1ms

update time

Engineering

Station

Tree architecture

Peer-to-Peer

Line architecture

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What you should keep in mind… 35

HMI Panel

(unknown traffic!)

Jitter / Delays

> 10 switches

> 1ms update

time

PC

(unknown traffic)

Vision system

(unknown traffic!)

video stream

!

!

!

!

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PROFINET networks: Ring Topology

PROFINET supports the ring topology for high

availability (redundancy) For example, if a cable or device fails, then the

system will automatically segment itself to a „line‟

topology keeping the rest of the system active

36

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Redundancy

Office Requirements Spanning Tree

Rapid Spanning Tree

Industrial Requirements Media Redundancy Protocol

IRT Media Redundancy

37

Recovery Time

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Spanning Tree & Rapid Spanning Tree

Media redundancy through loop formation Detection and breakup of loops Reconfiguration time

Spanning Tree: protocol- & timer-based minutes Rapid Spanning Tree: event-controlled seconds

Note: STP and RSTP assume structured cabling, in which there are never more than 8 switches between terminals. RSTP is downward-compatible to STP; an STP network component in the network forces STP throughout the entire network.

38

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Media Redundancy Protocol (MRP)

Media Redundancy Manager

(MRM) sends test frames to

check ring network

If MRM does not receive it‟s own

test frame = network failure!

MRM informs Media

Redundancy Clients about

network failure

The network is segmented back

to a working line configuration by

the MRM

Network continues to operate

until failure is repaired

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39

Media

Redundancy

Manager

Media

Redundancy

Clients

failure

With MRP recovery time drops to <300ms for 50 switches

!

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IRT media redundancy

Bumpless Redundancy

Devices send telegrams through

both redundancy ports

All transmitting nodes forward

telegrams but do not learn

addresses

Receiver does not forward frames

Receiver checks for most recent

frame and uses that information

In case of failure a frame will still

arrive at the receiver

All Nodes in ring must support this

feature

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40

Media

Redundancy

Manager

Sender

Receiver

Data is still there in case of a failure! Zero recovery time!

failure

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PROFINET over wireless backbones

PROFINET runs over these standard

wireless technologies: IEEE 802.11 (b,g,a,h,n) – Wireless LAN

IEEE 802.15.1 – Bluetooth

Wireless is part of the PROFINET

specification Many vendors

Some IO devices have wireless built in

PROFIsafe is safety-certified over wireless

using PROFINET as the transport

mechanism

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Questions? 42

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©2013 PI North America The PROFINET and PROFIBUS Logos are registered trademarks. Members of PI are entitled to use the logos in all their written or electronic publications and

promotional material. The use of the PROFINET Logo in connection with PROFINET products is allowed only under the conditions of the PROFINET Runtime Software license. All other trademarks

and registered trademarks are the property of their respective owners.