Friday, June 8, 2007

Profibus - An Introduction

Profibus is currently the most popular type of fieldbus, that became part of the IEC 61158 standard in 2000.

The Master/Slave Concept
Profibus networks are made up of two types of devices connected to the bus - master devices and slave devices.
It's bidirectional, so a master can send a request to the slave, and the slave can send back a response. Bus contention isn't an issue as only only master can control the bus at a time.

Each device on the network has an assigned address, where the address is assigned using rotary switches or DIP switches or set across the bus using a configuration tool.
Addresses 0 to 127 are supported, with 126 and 127 having special uses.
Address 0 is typically used as a default address for configuration tools attached to the bus.

Device and System Startup
The user specifies which slave devices the master should find on the bus and the information that should be transferred to the slave during startup. This information is generated by the configuration tool and given to the master device.
All configuration tools share common functionality - one for configuring a cyclic I/0 operation must do the following:

  • process GSD (device description) file and maintain a hardware catalog of devices to be configured on the bus
  • allow PROFIBUS device address to be specified
  • allow the specification of input and output data to be transferred between master and slave
  • allow startup parameters to be selected in order to activiation specific operating modes/features of the device
  • allow selection of system baud rate
  • generate the database file so it can be used by the master.

Each slave device has it's own GSD file developed by the vendor.

Cyclic I/O Data Exchange
After the bus system has been started up, the normal interaction between the master and it's slaves is to exchange I/O data.
The master (e.g. PLC with Profibus interface) sends out output data to the slave device, who responds with its input data. This concept typically maps to the input and output data sections of PLC memory.
Multi master systems exists, where each master is given control of the bus for a short time.

Device Diagnostic Reporting
PROFIBUS overs the capability to diagnose an operations problem all the way down to a broken wire on an output. During the data exchange cycle the slave can indicate to the master that it has detected a diagnostic condition. In the next cycle, the master gets the diagnostic information from the slave.
Four diagnostic information report format exist - standard diagnostics, device-releated diagnostics, module-releated diagnostics and channel-releated diagnostics.

  • Standard Diagnostics
    Six bytes, that every slave device is required to report contains information that is generally related to startup problems. E.g. I/O configuration that was set up in the configuration tool does not match what the slave expects, it will report a configuration fault.
    This is used to report faults that are common across all slave devices.
  • Device-Related Diagnostics
    Reports information that may be specific to a particular device or application area, that isn't covered by standard, module or channel diagnostics. The format is defined by the vendor, so you'll have to check the devices documentation.
  • Module-Related Diagnostics
    Reports diagnostics for a modular slave i.e. one that consists of an "intelligent" head module plus plug-in modules. So the head module can report that a plugin module has a diagnostic.
  • Channel-Related Diagnostics
    Reports that an individual channel of a specific module has a problem (e.g. short circuit, wire break, overvoltage). This allows diagnostics down to the wire level.


Fail-Safe Operation
Fail-safe operation is an optional feature available for implementation in a slave device. This feature allows you to specify the states of slave outputs in the case of bus failure (master failure, break in the bus). Non-fail-safe devices normally clear their outputs to zero, where fail-safe devices set their outputs to states that you define during the configuration phase.

That's just a brief introduction to Profibus. There's a lot more information available on the internet.
Here are some links about it, along with some general fieldbus links:

The Sensor Web

http://www.sensorsmag.com/sensors/article/articleDetail.jsp?id=328918

The Sensor Web is a distributed sensing system in which information is globally shared and used by all networked platforms. It's already been deployed long term in different environments and is opening up new avenues for distributed sensing and control.

Thursday, May 31, 2007

Programmable Automation Controllers

This whitepaper (PDF from automation.com) about Programmable Automation Controllers (PACs) finding their use in the industry. A PAC is a hybrid of a Programmable Logic Controller (PLC) and a PC.

Tuesday, May 29, 2007

Tutorials: learn.automationdirect.com

learn.automationdirect.com has a lot to offer for those looking to learn more about automation.

With videos and webinars on PLC Hardware, Sensors, Drives/Motors and Operator Interfaces, it's full of useful and relevant information.

You'll need Flash installed to play the videos.

Monday, May 28, 2007

Tutorials - The Basics Of Industrial Automation

I found this really useful siteon the web recently, the consists of loads of slides about the basics in Industrial Automation.
You can find it here - http://lamspeople.epfl.ch/kirrmann/slides_ia.htm

It goes through an Introduction and then onto PLCs, Field Buses and other important topics.

Safety - The Movie

This is very interesting - http://trailer.safetythemovie.com/

I wouldn't have thought Safety in Automation would have a movie in it, but apparently it does. While you'd expect this to be a DVD, I was very surprised to find they've made a full-screen, HD movie.

You can register online for some events - if anyone knows any more about this, I'd be interested to find out more.


SafetyEYE - The worlds first safe 3D camera system

Pilz has announced SafetyEYE - the worlds first safe camera system. You can read about it at the Pilz SafetyEYE web site.

This entry in the unofficial Mercedes-Benz, discusses the system further, which was developed by Pilz, in cooperation with DaimlerCrysler.

I've been lucky enough to see the demo of the SafetyEYE running, and it's amazing what it can do.
A camera, with three sensors is placed above an area that requires monitoring. Using a configuration tool, that connects to the controller over Ethernet, the user can take a snapshot of the scene and create detection zones around areas that the user shouldn't go.
When someone (or something) walks into this area, the output device reacts, and depending on what you've programmed, the system will slow/shut down.

The configuration tool looks really nice, with 2D and 3D views of the detection zones created.

The SafetyEYE won the Automation Award 2006 at the SPS/IPC/Drives fair.

We're likely to hear a lot more about this product over the next few months, as it approaches the official release.

Welcome to JIASource

The aim of JIASource is to give a quality Industrial Automation resource, that's easy to understand for people without the traditional background.

One of the main things I want to do is provide tutorials to help the understanding of Industrial Automation from the very beginning.
Some podcasts and useful links will probably be included.

So if you're trying to get your head around IA and would like something in particular covered, post a comment.

James