The PROFIblog

Last fall I went a little crazy about social media in industrial automation.  I felt there was not enough time to do all that stuff.  But now that there are automation and mainstream comics about it, it must really have arrived.  I really like this cartoon at automation.com.  The gray-haired, balding boss behind the big desk says: “We need to attract young engineers to take the place of upcoming retirees.  My grandkids keep talking about something called a We(?), their facebook pages and following tweets.  As near as I can tell, we need to figure out who ‘we’ are, get that book, and start bird watching.”  Speaking of birds, check out these B.C. comic strips.  I especially like the pun in the May 27 strip.

I have the hairline of the boss in the automation.com cartoon… and the grandkids.  But I also have a Wii (where my Mii has that same hairline), a Facebook page (but I just use it to keep up with the grandkids), and I tweet on twitter.  You can follow me on Twitter at http://twitter.com/chenning (although I’m kind of at a loss as to why you would want to).  I’m also on LinkedIn.  (But you have to register to see my profile.)

As I examine the Tweeters on Twitter, I see editors and bloggers, but not many users.  I guess there is still not enough time for all that stuff.

No more time to blog, tweet, or Link In now.  Time to get stuff ready for the Vancouver PROFINET class and Grand Rapids PROFIBUS class.

I was in Newark with Manny two weeks ago for the PROFIBUS in the Process Industries one-day training class.  We’ve been doing these classes for over 7 years now and it is amazing that we still get new questions.  In Newark we got a couple misconceptions that need to be addressed.  One attendee could not understand why exceeding the bend radius of a PROFIBUS cable would cause communications problems.  It started with Torsten’s anecdote about the coil of PROFIBUS cable that was visible to a manager.  He didn’t like the looks of it so instructed maintenance to fix it.  Rather than cut and reconnect the cable, they crimped it; that is, they flattened the coil, tightly tie-wrapped it, and stuffed it into the wire duct.  This caused the network to stop working.  The cable has requirements for resistance, inductance, and capacitance to avoid degrading the signal.  When the cable’s minimum bending radius is exceeded, those characteristics change.  In this case, they changed so drastically that the network stopped working.  Something like 80% of network problems are related to improper installation.  Sadly, this is true for ANY communication network.  There’s a “right” way to make the installation look good… and keep working.  For PROFIBUS and PROFINET, we offer Installation Guides so you can do it right.  The PROFI Interface Center also offers one-day, on-site installation and troubleshooting classes.

On a Course Evaluation form, one attendee thought that you had to use a single platform to get any benefit from asset management and that it was a large investment.  Well, it IS an investment.  But like any investment you expect a return on it.  The return you get on an investment in asset management is uptime.  Depending on the cost of your downtime, this could be a huge return.  PROFIBUS does not “do” Asset Management – it “enables” Asset Management by providing access to the kind of information that Asset Management software can use.  There are two technologies for providing this – EDDL and FDT/DTM.  We support both.  We are also working to unify the technologies in cooperation with Fieldbus Foundation and HART Communication Foundation.

For more about the technologies, Gary Mintchell (famous Automation World blogger) has a podcast devoted to each: EDDL and FDT/DTM.  Jim Cahill had a post today at Emerson Process Experts on the topic as well.

Oh, and that “limited to a single platform” notion – not correct.  PROFIBUS and PROFINET support for asset management is massively multi-vendor.

Other comments from the Course Evaluations:

“More on FDT/DTM and EDDL.” [See resources above.]

“Very thorough course.”

“Excellent presentation.”

“More quiz questions.”  [We decided this year to summarize each section using a quiz instead of PowerPoint bullets.  Apparently that was a good idea.]

“Very good information.  Would like to see a PROFINET seminar.”  [We would like everyone to see one.  You’ll find a list of them here.  If we are not coming to a city close to you, try the archived webinars instead.]

Speaking of PROFINET seminars, our next PROFINET one-day training class is in Vancouver on June 2.  I’ll be there.  Manny will be in Grand Rapids on that same day for a PROFIBUS one-day training class.  See you there?

I started this on the plane back from Jacksonville and I’m finishing it on the plane to Newark for the Process one-day training class.  (It’s tomorrow, May 14, at the Newark airport.  We have arranged for free parking at the hotel.)  In between I had to put the finishing touches on PROFInews North American Edition issue 26.

Jacksonville was one of our most interactive classes with more questions than ever.  It was good to see some IT folks in attendance.  In fact, one of them was having a firewall problem that Hunter was able to pinpoint for him.

The course evaluations were interesting, as usual.

Apparently we did not do a great job with the CBA Demo.  Maybe we tried to show too much, but the significance of CBA (Component Based Automation) is high.  CBA is the peer-to-peer integration technique for connecting even disparate controllers using a graphical configuration tool.  We will fine tune the demo for our next class.

You may recall that I occasionally get “called out” for beating up the competition.  I’ve been good lately.  But apparently the competition is creating even more outrageous FUD, at least according to the tales told in this class.  I stick to the facts.  That led to this comment on a course evaluation: “Great class. I gained a lot of information, especially in regard to dispelling myths.”  I was even admonished to “Compare to Ethernet/IP in greater detail since it is the primary competitor in the US.”

We always encourage viewing the archived webinars on Industrial Ethernet Basics, especially for those unfamiliar with Ethernet.  This is obviously the right thing for us to encourage, as this comment reveals: “Great class and introduction to the technology.  I did benefit from watching the webinars prior to attending – would have been rough without.”

There were no negative comments, other than about the CBA demo, and some very positive ones, like these:

“For a one-day course I thought it was perfect.”

“Superb course.  Questions were taken and handled well.”

I hope to see you in one of our free one-day training classes soon.  If you can’t make it to one of our venues, check out the webinars.

The section of the booth devoted to the PI Competence Centers featured an outline of the PROFINET Design Process.

A number of Development Tool providers were represented in the booth and at the fair: Hilscher, Siemens, HMS, NEC, KW-Software, IXXAT, and Molex among them.  Here is Molex’s panel in the PI booth (next to PTO member Northwire).

And some of the others here.

Molex updated me on their development kits including stacks for controllers and devices.  Their device stack has been used in situations where another Ethernet protocol was already implemented in a standard Ethernet controller.  They are currently working with a large (un-named) device manufacturer in the US.

KW-Software had a panel in the PI booth and I also visited their booth in Hall 9.  They have been working on a chip-based solution.  They had been calling it the “Tiger chip,” but apparently that was just a code name as their literature calls it “TPS-1.”  This chip is for PROFINET IO devices only.  They felt that when the cost of auxiliary devices was included, the TPS-1 would be half the price of other solutions that cover both device and controller.

There are lots of tool choices when it comes to adding PROFINET to devices.  One of PTO’s main purposes is to help device manufacturers through the selection process.  Just ask.

This concludes my report from Hanover.  Next week I’m off to Jacksonville for a PROFINET one-day training class.  If you are in that area please plan to attend.  There are more details and a link to registration online.   And all the free courses are listed here.

In addition to the new PROFIsafe products I mentioned several posts ago, there were other new products as well.

First up, a Phoenix Contact PROFIBUS Proxy with built-in 4-port switch, highlighted in green here.

Shown among many other PROFINET devices from Phoenix Contact.

Siemens also introduced its new PLC, the S7-1200.  Karsten Schneider (former manager of the PROFI Interface Center) proudly showed off the new software which provides an integrated development environment with a common database between PLC and HMI.  For me, the presence of green cable as the native network connection was the attraction.  Purple cable will likely be supported in an add-on card in the future.

[Green = PROFINET; purple = PROFIBUS]

HMS, another PTO member, also had something new – an OPC server for their Anybus gateway.  It has a couple of nice benefits, price being the first one.  (It’s free with the gateway.)  It also allows the run from the gateway in the field to the control room to use standard Ethernet infrastructure.  And one server supports multiple gateways and therefore multiple buses.

And finally a new “product” from PI, a successor book to the popular Rapid Way to PROFINET by Manfred Popp.  The new book by the same author, Industrial Communication with PROFINET, goes beyond the bits and bytes to provide a good introduction to PROFINET.  I’ve skimmed it once and am now reading it in detail.  Definitely recommended.

There was news of progress in a number of technology areas: IO-Link, wireless, PROFIBUS, and PROFINET.

IO-Link products are appearing more rapidly.  IO-Link is not a fieldbus, but allows digital communications over the device’s cable.  This led me to characterize it as “HART for discrete.”  Conventional devices can be interchanged with IO-Link devices easing the transition for users.  You can find more details at the IO-Link website.

Wireless for process automation is already well along in cooperation with HART Communication Foundation and Fieldbus Foundation.  The Working Group (WG) is specifying connectivity between HART and PROFIBUS and PROFINET.  Now the Working Group for wireless in factory automation has made some progress as well.  Why are there different Working Groups?  Because the requirements are different.  In the process environment think of a level switch on a tank that updates in intervals measured in seconds (or more) and compare that with a proximity switch on a production line that updates in milliseconds.  The former can be battery powered and move minimal data.  The latter needs more power because it is essentially always on.  Naturally the WGs are coordinating their activities to ensure they play well together and that they don’t interfere with existing WiFi communications used by PROFINET and other standard Ethernet technologies.  The factory automation protocol will be IO-Link over IEEE802.15.1.

PROFIBUS PA Profile 3.02 was being demonstrated on the PROFIBUS PA wall.  I have a short video of the demo from Christian Walter of Endress+Hauser: PROFIBUS PA 3.02 Video
The differentiator from Fieldbus Foundation technology is that no configuration software is required on a device change.  The change can involve a different brand of instrument or even an older instrument.

PROFINET products are required to be certified by PITLs – PI-certified Test Labs.  There are three conformance classes of PROFINET devices with the most feature-laden classified as Conformance Class C.  The complete test specification for Class C was just completed and already three products from two vendors have been certified.  Here PNO Director Dr. Peter Wenzel celebrates with representatives from Siemens and Hilscher.

The PROFIsafe wall gets longer with every fair.  Befitting its longevity, I suppose. 

PROFIsafe began over 10 years ago.  Through last year there were 630,000 PROFIsafe nodes installed.  Based on the ARC report that the total number of bus-capable safety devices is 700,000, PROFIsafe has a 90% market share.  PROFIsafe is the only bus-based safety technology that covers discrete, process, and motion control applications.  The take-away: PROFIsafe is long-established and often-used, making it a safe choice today in any application.

Dr. Wolfgang Stripf was once again present and updated me on new advances with PROFIsafe.  Five new safety controller suppliers are developing products with Phoenix Contact showing theirs at their booth.  Siemens extended their safety controller line to include a PC-based safety controller.  This was unexpected since the technical challenges that needed to be overcome in order to achieve approval were substantial.  PROFINET contained the magic ingredient that made this possible.

Dr. Stripf also noted that a revision is ready for release for PROFIsafe for PROFIdrive and for PA.  The revisions clarify the behaviors that should result when PROFIsafe commands are received.

This is my first post on the Fair; I’ll introduce you to the fair itself and the PI booth.  Later posts will provide specific news of PROFIBUS and PROFINET. 

Hanover Fair was not as well-attended as past years, but everyone I spoke with felt that attendance was better than they expected.  The mid-day crowds on Tuesday, Wednesday, and Thursday were encouraging.  There are really many sub-fairs combined under the heading of Hanover Fair (Hannover Messe, locally).  I only had time to see the Industrial fair.

The hit of the fair was the autonomous flying penguins in (or rather over) the Festo booth: Flying Penguins Video
These have nothing to do with PROFIBUS or PROFINET.  In fact, they were really there just to attract young people to the profession I was told.  It worked, or at least it got their attention.

Now on to the PI booth (the PI stand, in European trade show parlance).  Here’s an overview (and yes, the booth is downsized from past years): Hanover 2009 Booth Overview Video
The major displays were PROFIsafe, PROFIBUS PA, IO-Link, PROFIdrive, PROFIenergy, and the PROFINET wall.  The PICCs were featured in a section devoted to easy addition of PROFINET to products.  (PICCs, PI Competence Centers, are certified centers located around the globe that provide assistance to product developers and users.  One of the 37 or so PICCs is North America’s PROFI Interface Center.)  There was also an Automation Lounge for meetings and refreshments.  When Bill Lydon and Rick Zabel of Automation.com visited, they felt right at home there.  (Although I think Rick yearned to add “.com” between Automation and Lounge.)

One of our new staff members in the PI Support Center, Kathrin Holzer, provides you with some of the facts about the booth: Hanover 2009 Introduction Video

The forum was always full when presentations were in progress.  Here PROFINET Marketing Working Group chair Xaver Schmidt presents PROFINET diagnostic capabilities.

The Fair also provides the opportunity to network… in the personal sense, not just the industrial communications sense.  The PI staff and the attending RPA chairmen had dinner together on Tuesday evening.  (RPA stands for Regional PI Association; PTO is the North American RPA.)  Many of the chairmen were unable to attend this year, but the registration for our annual PI meeting should make it our largest yet.  We are looking forward to adding another one or two RPAs shortly.

We also had the chance to celebrate the 20th anniversary of PI, albeit in a low-key way.  Here, Professor Klaus Bender cuts the cake:

Actually, a lot about the fair was low-key.  Our booth was smaller.  Many vendor booths were smaller, simpler and more focused.  There were fewer entertainment attractions in the booths.  There were not many Americans there.  I ran into Dave Greenfield of Control Engineering magazine.  Katherine Voss and Adrienne Meyer of ODVA were there; Katherine attended our 20th anniversary cake cutting.  PTO member Molex had two people from the US there, but only because they were making other customer visits.  I was the only attendee from PTO this year as we also are more conservative these days.

For other news from the Fair, visit Control Engineering.  Phoenix Contact had a daily video from their booth.   You’ll find the occasional mention of PROFINET since Phoenix Contact is one of the major companies behind the technology.  I’ll show you some other products in a future post.

Manny and Mike were in Pittsburgh for the PROFIBUS one-day training class.  Here’s Manny’s report:

Last Wednesday’s PROFIBUS Training Class in Pittsburgh marked our largest PROFIBUS class of 2009.  Over one hundred people packed the room at the Hilton to learn about the latest developments in PROFIBUS technology.  Even though we did not quite have the great weather that Austin did.

Everyone in the audience was very engaged throughout the day and was extremely interactive with the vendors.  I came across several people during the breaks who were taking what they had just learned to the next level by getting more hands-on information from the vendors.  In my opinion, that is exactly how this training is supposed to work. 

There was a great deal of vendor participation at this seminar and it really added to the event.  It was fantastic to see attendees taking advantage of all the knowledge in the room.  I have always found that to be the key to these sessions.  Getting the real-time feedback and materials from the vendors gives attendees the full package.  Not only do they receive the information from the presentations, but they can go back to their respective companies with options and solutions. 

As I was thumbing through the feedback forms two comments in particular really struck me as summing up the day:
“I came with very little knowledge of PROFIBUS, and left with a much greater understanding.  Good combination of basic and advanced information.  Thank you!”
“Very informative.  I have never used a bus system before – now I know some of the capabilities and options that are available using this type of technology.”

There were also many comments and questions about PROFINET.  I am thinking that we need to set up a PROFINET class for the Pittsburgh area in early 2010. 

I had many attendees asking about referring their colleagues to attend this training.  As promised, here is the training schedule for May:
May 6, PROFINET, Jacksonville
May 14, Process, Newark
May 21, PROFIBUS, Salt Lake City
The full Training Class schedule can be viewed here.

There were 45 of us in Austin for the PROFINET one-day training class.  Not many compared to the previous day’s PROFIBUS class in Pittsburgh with 102, but still a very engaged group posing lots of questions for us. So many questions that we did not finish until 5:00 pm!  Despite the late finish, most thought the length just right (3 too long, 1 too short).

It’s always interesting to see the attendees’ reactions on the Course Evaluation forms:

A few folks wanted more on wireless.  I’ll refer them to the Wireless webinar.

Some wanted more on IRT – Isochronous Real Time, typically used for motion control and occasionally for very high speed IO.  In fact there many questions related to IRT during the course.  I think this was because we had a lot of device manufacturers in attendance.  In fact we were asked about a course specific to PROFINET Developers.  We had one n Detroit earlier in the year, but don’t have more scheduled in 2009.  We are considering a webinar or two to cover that ground though.  And we’re always willing to help one-on-one.

We were asked to provide more on security, but the time is just not there.  We do provide an extensive list of outside resources though.

One person asked us to talk about advantages of other standards.  It’s interesting that he thought that the other standards had any advantages.  [There’s that weird sense of humor that gets me in trouble.]  Actually we did cover them – we just did not dwell on them.

We had mixed reviews on the demos.  Some thought them too long.  One said “Demo explanation/preamble could be improved.”  But we also had some very positive comments: “On programming side configuring master controller devices was great.”

In the category of constructive criticism:
“Some acronyms were not defined.”  [I wish I knew where; we try hard to define them all.  Hopefully another review of the material will reveal them.]
“Some sections were too detailed.”  [I wish I knew where to trim.]
“Too much left at end of day.”  [I think the only topic that got shorted was Security and that not by much.]

The good stuff:
“Course material: the best I’ve seen.”
“Liked quizzes – keeps us thinking and awake.”
“Well presented.”
“Great information.”
“Great course.”
“Perfect intro training on this technology.”
“Slides and manual are great.”
“Good food/snacks, nice room, like the quizzes and raffles.”

Serendipitous discovery at the class: Phoenix Contact has a PROFIBUS proxy with built-in 4-port Ethernet switch.  Is this the beginning of a trend toward more devices with switches – with more switch ports built in?

I’m finishing this on the train from Frankfurt to Hanover for Hanover Fair.  The train is running 45 minutes late due to signal problems.  This is the first time I’ve experienced a late German train.  My late flight from DFW to Frankfurt, on the other hand, is not a first (only 3 hours late leaving).  Sigh, the joys of traveling. 

Will this be the year I finally blog more contemporaneously about the fair?  Will I have time after the fair, dinner meetings (and sleeping)?  Stay tuned.