PROFINET: The Industrie 4.0 Network

Industrie 4.0 Initiatives Worldwide

Industrie 4.0 initiatives are driving the future of manufacturing globally. Key examples include:

• USA: Industrial Internet Consortium
• United Kingdom: Catapult Programme
• Sweden: Production 2030, Smart Industry
• Finland: FIMECC
• France: Association pour l'Industrie du futur
• Italy: Fabbrica Intelligente
• European Union: Vanguard Initiative
• South Korea: Manufacturing Industry Innovation 3.0 Strategy
• Austria: Productivity 4.0
• China: Made in China 2025
• India: Make in India
• Singapore: Digitalization and Smart City, Smart Nation

Powerful Networks for Different Levels

PROFINET provides robust networking solutions across various levels of an automation system:

• Corporate Level: Focuses on Cloud integration and broad bandwidth.
• Production Level: Supports Energy/Asset management and real-time data.
• Field Level: Enables Condition monitoring and high-speed communication.

PROFINET is presented as a single standard that meets all these requirements.

What is PROFINET?

PROFINET is the open Industrial Ethernet standard developed by PROFIBUS & PROFINET International (PI). It is:

• Vendor neutral.
• Based on Industrial Ethernet.
• Utilizes TCP/IP and IT-Standards.
• A Real-Time Ethernet solution with cycle times as fast as 31.25µs.
• Enables seamless integration of fieldbus systems, protecting investments.

Traditional vs. Modern Automation Structures

Historically, automation systems relied on proprietary fieldbus systems. These often presented challenges such as network separation, requiring additional training, indirect access to field devices (leading to higher costs), inflexible controller-to-controller communication, difficult diagnostics integration, lack of wireless integration at the device level, limited fieldbus access, and no clear topological view.

PROFINET, as part of digitalization concepts, offers significant advantages:

• Web Access for flexible remote service with no additional cost.
• Integrated Safety and Wireless capabilities, supporting standards like CB/T.
• Enhanced Firewall and Security integrated within the TIA Portal.
• Integrated Diagnostic and Asset Management with free diagnostic tools available.
• Increased flexibility through modular machine concepts and flexible network structures (star, ring, line).
• Support for Cloud Services.
• High bandwidth suitable for Big Data applications.
• Readiness for Industrie 4.0 and IIoT.
• Fast Controller-Controller communication (1440 Bytes within 1ms) in real-time.
• Support for open profiles like PROFIsafe, PROFIenergy, and PROFIdrive.
• OPC-UA integration in the field, making PROFINET multiprotocol capable.

In contrast to classic automation pyramids where communication systems often only reach the IO-level and complex field devices, IO-Link provides the simplest interface to reach the actuator/sensor level, closing the communication gap and enabling bi-directional data transfer for intelligent sensors and actuators.

PROFINET Architecture and Features

PROFINET offers a flexible architecture supporting various network topologies including Tree, Star, Line, and Redundant Ring Networks, as well as Wireless communication (IWLAN).

Key features and benefits include:

• Flexibility: Industrial Wireless LAN (even Real-Time), Safety Integrated, Flexible Topologies (integrating existing Fieldbus Systems), Open Standards, Web-Tools, and easy expandability with new standards like OPC-UA.
• Efficiency: One cable for all purposes, comprehensive device/network diagnosis (free tools, apps), Multimaster System, easy cabling, and fast device replacement.
• Additional Functionality: I-Device (PLC as Intelligent IO-Device), Redundancy (MRP – Media Redundancy Protocol), Advanced Web Programming (AWP) with User-defined Web Pages, and PROFIenergy.
• Increased Diagnostic: Proven Fieldbus diagnostics, Standard-Ethernet-Diagnostic (SNMP), integration into Plant Asset Management, and free diagnostic tools like PRONETA and smartphone apps. Enhanced error localization via Topological View and web diagnostics.
• Device Naming: PROFINET requires meaningful device names, often set as the IP Address by engineering, facilitating easier management than traditional PROFIBUS address settings. Assignment can be done via TIA-Portal or PRONETA, with controllers assigning names based on known topology.

Installation Rules

PROFIBUS Installation Guidelines:

• Maximum 32 stations per copper segment (RS 485); repeaters count as devices.
• Each segment must be terminated (first and last node).
• Ensure proper shielding on connectors and when routing cables into cabinets.
• Maintain a 10cm distance between cables carrying over 110V and other cables, especially if not isolated with a grounded metal plate; use fiber optic (FO) if necessary.
• On high Baudrates, avoid spur lines and ensure cables are not shorter than 1 meter.
• Segment length is dependent on the Baudrate.

PROFINET Installation Guidelines:

• A maximum distance of 100 meters from the switch to the end device is an IEEE802.3 rule.

IO-Link: Expanding Communication to the Field Level

IO-Link technology extends communication down to the actuator/sensor level, closing the gap in automation systems. It enables intelligent sensors and actuators to be accessible for communication and supports bi-directional transfer of cyclic and acyclic data.

The IO-Link Association has seen rapid growth, with over 230 member companies from the automation and communications industry. It is positioned within the PNO (PROFIBUS user organization), fostering collaboration among specialists and technology providers. IO-Link is a standard (IEC 61131-9) and is independent of fieldbus.

There are over 7000 IO-Link products available, including master modules for more than 15 fieldbus systems, central masters, and a wide variety of sensors (over 35 technologies) and actuator technologies. The growth in installed IO-Link units demonstrates its increasing adoption.

PROFINET Gateways and MultiFieldbus Interfaces

PROFINET Gateways facilitate integration of various communication protocols, including Modbus TCP, PROFIBUS, OPC UA, MQTT, Ethernet-IP, CAN/open, SAE J1939, M-Bus, and DALI, across control, field, and infrastructure/building technology levels.

Siemens SIMATIC ET 200 series offers MultiFieldbus interfaces:

• ET 200MP IM: IM155-5MF ST
• ET 200SP IM: IM156-6MF HF
• ET 200eco PN: "Next generation" modules.
• PN/MF Coupler: Enables easy configuration of deterministic data exchange across network boundaries between SIMATIC and third-party controllers, and simple integration of SIMATIC controls into existing machines/plants.

These interfaces support PROFINET, EtherNET/IP, and Modbus TCP, allowing simultaneous communication with multiple protocols to modules via a single cable. Engineering is facilitated by the MultiFieldbus Configuration Tool (MFCT), and the Shared Device function allows allocation of a station to several controllers, providing high flexibility and cost/planning savings.

SIMATIC ET 200 Product Highlights

• SIMATIC ET 200eco PN: The next generation of rugged I/O in IP65/67. Offers modules with high channel density (e.g., 64-channel digital modules), new features like S2-Redundancy, Shared Device, and high supply current. Benefits include easier mounting, less planning effort, cost savings, greater transparency, flexibility, and higher availability.
• SIMATIC ET 200SP for Lighting Control: Simple integration of lighting controls. Features include support for DMX 512 (Digital Multiplex 512) for stage and show lighting, and CM 1 x DALI Multi-Master for connecting DALI bus systems. Benefits include cost-effectiveness, space savings, and engineering time savings.
• SIMATIC ET 200SP (CAN integration): Modules for integrating CAN/CANopen nodes in confined spaces, such as AGV systems and eCar charging stations, offering compact and cost-effective solutions with time savings in engineering.
• SIMATIC S7-1500 / ET 200MP New Products: Features modules with high channel density (64-channel digital, 16-channel analog) and active backplane bus with hot-swapping capabilities. These offer optimized price-performance, minimum footprint, tool-free assembly, and high machine/system availability.

Engineering with TIA Portal

The Totally Integrated Automation Portal (TIA Portal) serves as the central engineering tool. It provides:

• Common data management across all automation tasks.
• A uniform and integrated operating concept for HMI, IPC, Controllers, Distributed I/O, Motion Control, and Drives.
• Common, central services including Security Integrated, Safety Integrated, Diagnostics, and Energy Management.

Additional SIMATIC Tools

Siemens offers specialized tools to support automation tasks:

• PRONETA: For configuration of PROFINET devices (IP address, device name, mass operations), offline/online comparison, and IO testing (signal logging, diagnostics).
• SINETPLAN: For simulation of network load based on topology and nodes, offering detailed reporting, validation of planning guidelines, online scanning, and seamless integration via API and standards like AutomationML and STEP7/TIA Portal projects.

PROFINET: The 100% Ethernet Backbone for Industrie 4.0

PROFINET is a robust, 100% Ethernet-based communication system that serves as the backbone for Industrie 4.0. It offers:

• Seamless integration of fieldbus systems and investment protection.
• Support for OPC UA, Big Data, and integrated diagnostic and energy profiles for plant transparency.
• A unified standard for various applications:
• Safety Applications (PROFIsafe)
• Energy Management (PROFIenergy)
• Drive Applications (PROFIdrive)

PROFINET is designed for Factory Automation, Process Automation, Drives, and Safety applications.