Presentation HETES 8/06/2015, Ghent (Belgium)

Transcription

1 Presentation HETES, Ghent (Belgium) 1 2 1

2 3 PROFIenergy Why use PROFIenergy What is PROFIenergy? How does PROFIenergy work? Measurement example Work in progress 4 2

3 Why use PROFIenergy? 5 Why use PROFIenergy? 6 3

4 Why use PROFIenergy? We need a way to reduce industrial energy consumption! Source: European Environment Agency ( 7 Why use PROFIenergy? How to reduce energy consumption: 1. Reduce consumption during production Often not possible Expensive (new hardware) Consumption workweek Time 8 4

5 Why use PROFIenergy? How to reduce energy consumption: 2. Reduce consumption in idle-time =>Problem: Shutdown of factory automation is complicated Consumption workweek Time 9 Why use PROFIenergy? How to reduce energy consumption: Solution?? Consumption workweek Time 10 5

6 Why use PROFIenergy? Example: How can consumption during idle-time be reduced? DC 24V 11 Why use PROFIenergy? Example: Traditional way: Manual switches DC 24V 12 6

7 Why use PROFIenergy? Example: Traditional way: Manual switches Additional Hardware expensive Manual switching for each group Time intensive Room for error No complex routines possible NOT OFTEN IMPLEMENTED 13 Why use PROFIenergy? Example: Automated way: Additional controller DC 24V 14 7

8 Why use PROFIenergy? Example: Automated way: Additional controller Additional Wiring expensive Additional Hardware/controllers expensive A device can still only be switched completely off/on NOT OFTEN IMPLEMENTED 15 Why use PROFIenergy? Example: How can consumption during idle-time be reduced? => Better methods are needed! DC 24V 16 8

9 PROFIenergy 17 What is PROFIenergy? First requested by German automobile manufacturing industry (AIDA) a PI working group set up in 2009 A profile based on PROFINET Offers a standardized way for energy management Power saving mode(s) Energy measurements 18 9

10 What is PROFIenergy? Typical Use Cases: Energy Saving during short pauses (~minutes) Energy Saving during longer pauses ( ~hours/days) Energy Saving during an unplanned pause ( time?) Measuring and visualization of the load/flow of energy 19 What is PROFIenergy? Case 1&2: Energy saving during pauses; A trigger starts the pause (Pre-defined) Devices will be put into stand-by or switched off if possible o Different levels of stand-by /energy usage o Some devices can t be switched off (safety, long startup times, ) Coordinated starting and stopping 20 10

11 What is PROFIenergy? Case 1&2: Energy saving during pauses; 21 What is PROFIenergy? Case 1&2: Energy saving during pauses; A trigger starts the pause (Pre-defined) Devices will be put into stand-by or switched off if possible o Different levels of stand-by /energy usage o Some devices can t be switched off (safety, long startup times, ) Coordinated starting and stopping 22 11

12 What is PROFIenergy? Case 1&2: Energy saving during pauses; 23 What is PROFIenergy? Case 1&2: Energy saving during pauses; 24 12

13 What is PROFIenergy? Case 1&2: Energy saving during pauses; A trigger starts the pause (Pre-defined) Devices will be put into stand-by or switched off if possible o Different levels of stand-by /energy usage o Some devices can t be switched off (safety, long startup times, ) Coordinated starting and stopping 25 What is PROFIenergy? Case 1&2: Energy saving during pauses; Discharge Feed 26 13

14 What is PROFIenergy? Case 3: Energy saving during an unplanned pause; The duration is unknown A low level standby state by default (little energy conservation). User can put devices in higher level of energy conservation 27 What is PROFIenergy? Case 3: Energy saving during an unplanned pause; 28 14

15 What is PROFIenergy? Case 4: Measuring and visualization of the load Logging and visualizing the Consumption Energy Management System 29 What is PROFIenergy? PROFIenergy offers: Different energy levels for different times; in longer breaks where the device has more time to switch off and on, more energy can be saved it is possible to retrigger the device to another level (fast startup, ) Energy information, e.g. active power (P), apparent power (S) and power factor (cos φ), can be read out independently from manufacturer or device 30 15

16 PROFIenergy Why use PROFIenergy? What is PROFIenergy? How does PROFIenergy work? Measurement example Work in progress 31 How does PROFIenergy work? I I 0 0 I 0 DC 24V 32 16

17 How does PROFIenergy work? 33 How does PROFIenergy work? Start_Pause Timer End_Pause 34 17

18 Why use PROFIenergy? What is PROFIenergy? How does PROFIenergy work? Measurement example Work in progress PROFIenergy 35 Measurement example A PROFIenergy study commissioned by PI at Daimler s Sindelfingen plant and at Volkswagen Commercial Vehicles in Hannover Measurements on typical production cells Goal: quantify the benefits that could result from using PROFIenergy

19 Measurement example Continuous recordings were taken over a seven day period, at one second intervals. 37 Measurement Example base load during non-productive periods can be at least 50% of the total energy consumed 38 19

20 Measurement Example Generally agreed that a transition to energy saving modes is economically feasible for idle times lasting 5 minutes or more 39 Measurement example Based on the study, following estimations were made for the savings potential: 70% possible savings during idle time Potential saving of 33% of the total energy consumption 40 20

21 PROFIenergy Why use PROFIenergy? What is PROFIenergy? How does PROFIenergy work? Measurement example Work in progress 41 Work in progress PROFIenergy Setup for measurements 42 21

22 Lab Visit & Questions? 43 22

23 Presentation HETES, Ghent (Belgium) PROFINET as introduction to PROFIenergy 1

24 Content Introduction to automation Introduction to PROFINET Device and technology classes Network topology Ethernet fundamentals Device description 2

25 Non-automated processes Disadvantages High staff cost Human errors Less accurate No global monitoring possible ON OFF Automated process Check the process with sensors level sensors Change the process with actuators pump Control the process with a controller PLC (Programmable Logic Controller) 3

26 Sensor Check the process Measure water level Actuator Influence the process Change water flow Pump 4

27 Controller Control the process control pump depending on sensor value Pump OUT IN Controller Programmable Logic Controller (PLC) Adjustable algorithms More complex algorithms possible 5

28 Cabling A multicore cable from sensors and actuators to controller: Too much copper needed Engineering design Construction Maintenance Not flexible Pump OUT IN Cabling: fieldbus 1 cable from all sensors / actuators to controller 4 Pump Remote IO

29 Cabling Digital serial communication system Fieldbus / fieldnet Connection between sensors and actuators One cable for multiple sensors / actuators Less cables needed Remote IO needed Connect multiple sensors / actuators in the field Specialised tools needed for Diagnostics Monitoring Content Introduction to automation Introduction to PROFINET Device and technology classes Network topology Ethernet fundamentals Device description 7

30 What is PROFINET? PROcess FIeld NET It s NOT PROFIBUS over Ethernet! Open Industrial Ethernet standard Compatible with standard Ethernet Uses UDP/IP and other IT standards Is real-time Ethernet Modular concept 15 History of PROFINET 1976: the idea of Ethernet 1980: open fully-specified 10 Mbps system 1985: IEEE : twisted pair replaces the old and more expensive coax cables 1995: Fast Ethernet Alliance (for 100 Mbps) 2003: PROFINET CBA coupled with PROFIBUS 2004: real-time Industrial Ethernet 2005: PROFINET starts in Field 16 8

31 Specification history Specification PN V1.0 Whitepaper PN V1.3 PN V2.0 PN V2.1 PN V2.2 PN V2.3 Function Enhancements Basic Functionality Simple device exchange Network configuration Switch Integration Fiber Optics Fast Start Up Network diagnosis Topology Media Redundancy Time synchronization Maintenance NE107 Performance Optimization Fiber Optic Enhancements PROFINET in PA Basic functions Applications Standard Robots Highest Speed / Process PROFINET IO Interfacing of distributed I/O same goal as PROFIBUS or other industrial field busses Specifies: Data exchange Parameterisation Diagnostics / alarm processing 18 9

32 Content Introduction to automation Introduction to PROFINET Device and technology classes Network topology Ethernet fundamentals Device description Device classes IO-Supervisor IO-Parameter Server IO-Controller Network components IO-Device 20 10

33 Device classes IO-controllers Programmable controller Executes the automation program IO-devices Distributed field devices: sensors, actuators, drivers, IO-supervisors HMI, PCs, diagnostic devices IO Parameter Server Loading and saving configuration data records Network components Switches, access points for wireless communication 21 Technology classes Copper wire FOC: Fibre Optic Cable Wireless: WLAN Bluetooth 22 11

34 Complete network 23 Content Introduction to automation Introduction to PROFINET Device and technology classes Network topology Ethernet fundamentals Device description 12

35 Star Limited environmental extension Central located switch Switch is weak point single point of failure 25 Tree Star topology 26 13

36 Tree Weakness caused by high network load 27 Line Integrated switches 1 failing device can interrupt large piece of network PROFINET device with integrated switch 28 14

37 Ring Redundant path Redundancy manager 29 Depending on: Plant layout Used topology Consequences of a network failure (costs, risks, ) Timing constraints Mix of topologies Whether or not redundant 30 15

38 Content Introduction to automation Introduction to PROFINET Device and technology classes Network topology Ethernet fundamentals Device description The 100 Mbps Ethernet signal The physical layer 32 16

39 Ethernet signal decoding Real IO-data Real PLC data (as can be seen in monitor mode) 4B/5B-coding Scrambling Descrambling MLT 3 Physical signal 33 4B/5B-coding Raw IO-data: possible loss of synchronisation For long series of 0 : possible loss of synchronisation between transmitter and receiver 4 data bits = 5 bits on the line Extra signalling codes possible Effective data bandwidth = 125 MHz 34 17

40 4B/5B-coding Data (Hex) (Binary) 4B/5B Code D E F Scrambling To reduce the radiated emission obtain EMC, avoid EMI Using pseudo-random code Original data isn t readable from the scope screen using the signal levels 36 18

41 Scrambling Signal before switch Same signal after switch 37 MLT 3 Multi-Level Transition 3 Reduces the maximum signal frequency

42 Device addressing MAC address IP address Device name 39 MAC addresses Fixed hardware address 48 bit unique number (worldwide) 24 bit Organisationally Unique Identifier (OUI) 24 bit hardware identifier Transmission of MAC address Highest byte of address is sent first Least significant bit is sent first OUI Hardware ID Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte

43 IP address Independent of used hardware 4 bytes (xxx.xxx.xxx.xxx) in decimal notation Contains 2 parts network ID and station ID 2 parts are divided by subnet mask by bitwise and -ing IP address and subnet mask 41 Used for PROFINET Device name Must be unique for every PN device Names in configuration = real names! When device names in configuration differ from the real names no communication possible Even when IP-addresses are correct Name contains different labels Names with a real meaning are possible 42 21

44 Content Introduction to automation Introduction to PROFINET Device and technology classes Network topology Ethernet fundamentals Device description Device model of an IO-device Description of all field devices modular and non-modular devices Used structures Slots Subslots Index Bus Interface (DAP) API 1 API 2 Subslot 1 Channel 0 Channel 1 Channel 2 slot 0 slot 1 slot 2 Subslot 2 Channel 0 Channel 1 Channel

45 Thanks for your attention 23