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Author / Title of the presentation
PROFIdrive
Benefits
Technology
Applications
Dr. Andreas Uhl
Siemens AG
Agenda
Technology
Applications
Case Study
Future Trends
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Dr. Andreas Uhl / PROFIdrive
Agenda
Benefits and technology of PROFIdrive
PROFIdrive application fields
Case study with a newspaper printing machine
Future development of drive and communication
Agenda
Technology
Applications
Case Study
Future Trends
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Benefit of Standardized Drive Interfaces
Definition of compatibility levels according to IEC TR 62390
Drive with PROFINET
Drive with PROFINET and PROFIdrive
Dr. Andreas Uhl / PROFIdrive
PI Standards for Drives and Motion Control
Device characteristics
Communication characteristics
Transmission
Technology (e.g. RS485)
Transmission
Technology Ethernet
Communication Protocol
PROFIBUS DP
IEC 61158
Communication Protocol
PROFINET IO
IEC 61158
Common Application Profiles (PROFIsafe, PROFIenergy)
Ro
bo
ts &
NC
PA
Devic
es
Weig
hin
g &
Do
sag
e
LV
SG
Tra
in A
pp
licati
on
s
…
PR
OF
Idri
ve
IE
C 6
18
00
-7
GB
/T 2
57
40
-201
3
En
co
der
Pro
file
…
Applications with
drives and motion control topic
Dr. Andreas Uhl / PROFIdrive
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5
The PROFIdrive Interface Model
Communication System
PROFINET / PROFIBUS
Controller
Application
Process
Controller Device
Parameter access
… HMI / Comm. tool / Maint.
Supervisor Device
Drive
Device
… Drive
Application
Process
Drive
Application
Process
Drive
Device
- Parameter channel (access)
- Parameter semantics
- Application parameter
Pa
ram
ete
r a
cces
s
Ala
rms
- Profile specific Alarms
- PROFIdrive Fault Codes
PROFIdrive
defines:
Ac
tua
l va
lue
s
Se
tpo
int
va
lue
s
- PROFIdrive Telegrams
related to
- 6 PROFIdrive
Application Classes (AC)
Dr. Andreas Uhl / PROFIdrive
Agenda
Technology
Applications
Case Study
Future Trends
Drive Applications – Application Classes
Variable Speed
Drives
• Pumps, fans
• Conveyor systems
Simple
Motion Control
Single Axis (Servo)
Positioning Drive
• PTP handling
Enhanced
Motion Control
Multi Axis (Servo)
Path Interpolation
• Robotics (RC)
• Machine tools NC)
• Handling (MC)
Application Class
AC1 Application Class
AC3 Application Class
AC4
PROFIdrive Profile
Standard Drives
Encoder Profile
Encoder (V1.1)
Class 1
Encoder (V1.1)
Class 2
Encoder (V4.1)
Class 3 Encoder (V4.1)
Class 4
PROFINET RT
PROFINET IRT
Dr. Andreas Uhl / PROFIdrive
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Agenda
Technology
Applications
Case Study
Future Trends
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Drive Applications – Control Systems
Standard Drives
Variable Speed
Drives
• Pumps, fans
• Conveyor systems
Simple
Motion Control
Single Axis (Servo)
Positioning Drive
• PTP handling
Enhanced
Motion Control
Multi Axis (Servo)
Path Interpolation
• Robotics (RC)
• Machine tools (NC)
• Handling (MC)
PLC NC, RC, MC
F-PLC
Dr. Andreas Uhl / PROFIdrive
Agenda
Technology
Applications
Case Study
Future Trends
Example: Standard Drive Application Fields 9
Pumps
Ventilating
Conveying
Transportation Compressors
Dr. Andreas Uhl / PROFIdrive
Agenda
Technology
Applications
Case Study
Future Trends
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Isochroneous Operation – What is This?
… in isochroneous operation the drive synchronizes itself to the bus cycle …
... Isochroneous operation assures a bus cycle with 1 ms precision …
… this therefore assures a closed-loop control quality and a setpoint response that are needed in high performance multi-axis motion control!
Controller
The cyclic data transfer on the bus line is scheduled and deterministic
Actual values and new setpoint values are sampled and activated at all devices at the same point in time
… new setpoint values are activated and new actual values are sampled at the same points in time Ti and To for all axes …
Dr. Andreas Uhl / PROFIdrive
Agenda
Technology
Applications
Case Study
Future Trends
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Example AC4: Packaging Machine
Isochronous Operation for Applications …
- Cam Disc
- Electronic Gearing
- Flying Saw
- Multi-Axis Path Interpolation (NC, RC)
Dr. Andreas Uhl / PROFIdrive
Agenda
Technology
Applications
Case Study
Future Trends
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Example AC4: Electronic Gear Application
Dr. Andreas Uhl / PROFIdrive
Agenda
Technology
Applications
Case Study
Future Trends
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Example AC4: Electronic Gear Application
Decentral
I/O
LED 2
Cam LED 1
X
X
SpeedL*
Gear Toothed
drive
belt
Encoder
sL*
Frequency
Converter
n1* s1
s2
s1*
s2* n2*
Servo Motor Encoder
Servo Motor Encoder
Elec-
tronic
gear
Elec-
tronic
gear
Clock synchronous operation
T_DC = 1 ms
Encoder Motion Controller Servo Drive
PROFIdrive AC4
Telegram 3
Encoder Class 3
Telegram 81
Dr. Andreas Uhl / PROFIdrive
Agenda
Technology
Applications
Case Study
Future Trends
Example: Machines with Isochronous Drives 14
Machine Tools
Robots
Productronic
Dr. Andreas Uhl / PROFIdrive
Case Study
Newspaper Printing
Machine
Agenda
Technology
Applications
Case Study
Future Trends
Offset Printing Technology
- Non image areas absorb
water
- Image areas are water-repellent
(chemical process)
Image areas (without
water) absorb ink
Pixel accuracy < 5 um
Paper speed up to 18 m/sec
❶ ❷
Ink is transfered to paper
Ink is transfered to
blanket cylinder
(smoothness, quality) ❸
❹
Dr. Andreas Uhl / PROFIdrive
Impression
cylinder
Material web
Rubber cylinder
Plate cylinder
Moisture applicator
(symbolic)
Inking unit
(symbolic)
Printing plate
Rubber coating
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Agenda
Technology
Applications
Case Study
Future Trends
Design of a Newspaper Printing Machine
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Dr. Andreas Uhl / PROFIdrive
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Agenda
Technology
Applications
Case Study
Future Trends
Roller bearers
and paper roll
Finisher
Turning unit
Folder superstructure
Turning bar
Printing tower
Copyright manroland web systems GmbH
Design of a Newspaper Printing Machine
Dr. Andreas Uhl / PROFIdrive
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Agenda
Technology
Applications
Case Study
Future Trends
The overall machine
is a series of
printing towers and
folders
Design and size is
very customer-
specific
Modularity helps to
respond quickly and
flexibly to customer
requests
Copyright manroland web systems GmbH
Design of a Newspaper Printing Machine
Dr. Andreas Uhl / PROFIdrive
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Agenda
Technology
Applications
Case Study
Future Trends
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Challenge - Industrial Communication
Highly complex machine – more than 1000 axes running in angular synchronism The highest reliability and redundancy are required Flexibility by being able to reconfigure while the printing machine is operational Extends over a wide area
widely distributed drives running in angular synchronism
widely distributed operating control panels
Dr. Andreas Uhl / PROFIdrive
Modular Control Topology
Control module, printing tower:
10 drives (angular synchronism)
8 auxiliary drives (unsynchronized)
Control module,
turning unit:
16 drives (angular synchronism)
Control module, folder:
16 drives (angular synchronism)
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Dr. Andreas Uhl / PROFIdrive
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Communication Topology
PN1
PN2
= 1. PROFINET interface (e.g. onboard interface)
= 2. PROFINET interface (e.g. CBE30-2)
SIMOTION
D4x5-2 SIMOTION
D4x5-2
S120 I/O I/O S120 S120 I/O
Local
network
Section network
PN2
PN1
Module Module
Dr. Andreas Uhl / PROFIdrive
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Module Communication Relationship
Isochronous drives.
Motion
TO
Motion
TO
… Motion
TO Application
PN-Devices
(Standard IO) …
PN IRT-Controller interface
Non-isochronous drives
PROFIdrive interface
PROFIdrive AC4 PROFIdrive AC1/3 …
Master axis
IRT sync master
PROFIsafe
PROFIsafe
Controller RT
F-Application
F-Control
Module
I-Device interface
Module network
IRT Sync-Slave
IRT-Module RT-Module
…
Shared Device capable
PN I-Device interface
Master axis …
Controller IRT
Higher-level
RT-Controller
Controller RT
Higher-level
RT-Controller
TCP/IP oder UDP
Master axis
Section network
Motion-Steuerung
Modul
Motion Controller
Section
Motion Control
Module
Dr. Andreas Uhl / PROFIdrive
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Agenda
Technology
Applications
Case Study
Future Trends
IRT Controller for Cascaded Coupling
Simotion CPU
Higher-level
Controller (IRT)
I-Device
PN CBE30-2
Controller
PN integrated
Device (IRT)
Sync-
Master
Sync-
Slave
Controlled
Sync-
Master
Sync-
Slave
Motion
TO
The synchronization of
the motion TOs to the
external sync-master
can be controlled by the
application program.
Dr. Andreas Uhl / PROFIdrive
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Example of Communication Topology
Section A
Section network
Module controller printing unit
Machine network
Section B Section controller
(two PNIO interfaces)
Module controller folder Module controller printing unit
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Agenda
Technology
Applications
Case Study
Future Trends
Media Redundancy for PROFINET IRT
PROFINET
Controller 1
Drive 2 Switch
Controller 2
Drive 1
Drive 3
Ring topology
Duplexed telegrams
send in both directions
of the rings
Seamless transition to
the second telegram in
case of fault
MRP support also
available for non-
realtime applications
As redundancy manager
Seamless Media Redundancy for PROFINET IRT MRPD
Dr. Andreas Uhl / PROFIdrive
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MRPD – Application Example
Section controller SCALANCE Switch
(MRP redundancy manager) (2 PNIO interfaces)
MRPD ring for seamless media redundancy
Redundancy in case
of component faults
One or multiple
consecutive print
units can be switched
off during operation
for maintenance or
conversion work
Dr. Andreas Uhl / PROFIdrive
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Future Trends
of Drive and
Drive Communication
Interface
Agenda
Technology
Applications
Case Study
Future Trends
Driving Forces for Future Trends 30
Value (V) =
F (Features) Ʃ
C (Costs) Ʃ
The principle of “Increasing Ideality” is characterized by the
“Tendency for an Increasing Value” of the system
Transfer to supersystem
Increasing coordination
Decreasing of number of components
When it comes to evolving systems for the future,
the general trend is to increase their ideality!
Dr. Andreas Uhl / PROFIdrive
Agenda
Technology
Applications
Case Study
Future Trends
Rationalization in the Drive Environment 31
Line
Energy
management
(Standby)
Motor
encoder Motor Torque
sensor
Condition
monitoring
Process
monitoring
STO
Safety
encoder
Sa
fety
su
pe
rvis
ion
Safety
supervision
Dr. Andreas Uhl / PROFIdrive
Communication for the Drive Supersystem 32
Motor
Switch
PHY PHY PHY
MAC
Drive
control
Condition
monitoring
Energy
control
Process
monitoring Drive-based
safety
Drive Device
Ethernet-based
automation bus
Kommunikationssystem
Protokoll und Services Communication system protocol and services
Independent and
autonomous
communication
channels and
services!
Needed to address
the drive trends of
the future:
Dr. Andreas Uhl / PROFIdrive
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The PI Drive Interface today
Technology control
Motion control
Drive
Control
Process Drive
Motion Controller
Technology Drive-Based
Safety
Application programm
for safety
F-Controller
Energy
Management
Application programm
for energy management
Energy Controller
M G
Web
Server
Standard IT
Must: All this on one Cable! PROFINET Real
switched
Ethernet
Shared Device PROFIdrive PROFIsafe
Controller
Cross Talk
C2C
PROFIenergy
Dr. Andreas Uhl / PROFIdrive
Summary
PROFIdrive enables the interoperability of drives connected through PROFINET and PROFIBUS PROFIdrive covers the whole range of drive applications in automation through its Application Classes Existing PROFIdrive applications can be migrated from PROFIBUS to PROFINET retaining full compatibility
PROFINET is future-proof and supports the future trend of the drive to get a drive supersystem
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Dr. Andreas Uhl / PROFIdrive