Ethernet-Based Industrial Communication

Protocols Connect LabVIEW to PLCs

Agenda
Why Ethernet-Based Protocols?
Overview of Ethernet-Based Industrial Protocols
Adding Deterministic I/O to NI PACs
Connecting NI Devices to Industrial Protocols
Modbus TCP/IP
Plug-In PXI/PCI Devices, PROFIBUS
Ethernet/IP
Agenda
Why Ethernet-Based Protocols?
Overview of Ethernet-Based Industrial Protocols
Adding Deterministic I/O to NI PACs
Connecting NI Devices to Industrial Protocols
Modbus TCP/IP
Plug-In PXI/PCI Devices, PROFIBUS
Ethernet/IP
Why Ethernet-Based Protocols?
Modbus Modbus TCP/IP

DeviceNet Ethernet/IP

CANopen EtherCAT

PROFIBUS PROFINET

Traditional Industrial Ethernet Physical

Protocols Layer
Industrial Ethernet Adoption
Total market $630 M
Expected Trends in Type of Wireline Infrastructure Networks
Ethernet really means: being used in Industrial Facilities

Ethernet/IP
PROFINET
Modbus TCP/IP

Source: VDC 2006

Agenda
Why Ethernet-Based Protocols?
Overview of Ethernet-Based Industrial Protocols
Adding Deterministic I/O to NI PACs
Connecting NI Devices to Industrial Protocols
Modbus TCP/IP
Plug-In PXI/PCI Devices, PROFIBUS
Ethernet/IP
Industrial Ethernet and OSI Model
7. Application
Modbus TCP/IP,
6. Presentation Ethernet/IP,
PROFINET, and
5. Session EtherCAT,

4. Transport
TCP and UDP
3. Network IP

2. Data Link
Ethernet
1. Physical
Industrial Ethernet protocols are not all just
Ethernet. They add features for reliability and
determinism and the trade-off is compatibility
with standard Ethernet.
Ethernet-Based Industrial Protocols
Modbus TCP/IP
EtherCAT
Ethernet/IP
PROFINET
Similarities
Reuse OSI model layers 1 and 2
What about the other 5 layers?
Define master (scanner) and slave (adapter)
devices
Address 1 or more target applications
Non Real Time
Real Time
Hard Real Time
Application Targets
Non Real Time
Uses standard TCP/IP or UDP/IP
Application: PLC to HMI or PLC to SCADA
Real Time
Provides added determinism with COTS hardware
Application: Control data
Hard Real Time
Adds specific hardware to deliver determinism
Application: Distributed motion
Where Protocols Fit?

EtherCAT PROFINET (IRT)** Ethernet/IP CIP

Sync

PROFINET (RT)** Ethernet/IP

Modbus TCP/IP PROFINET (NRT)* Ethernet/IP

**Also PROFINET I/O

*Also PROFINET CBA
Ethernet-Based Industrial Protocols
Modbus TCP/IP
EtherCAT
Ethernet/IP
PROFINET
Modbus TCP/IP Overview
First industrial protocol on Ethernet (introduced 1999)
Based on Modbus developed by Modicon in 1979
Widely adopted and opened Ethernet standard
Advantages
Uses standard Ethernet (hardware and TCP/IP transport layer)
Open and relatively simple
Disadvantages
Not a hard real-time protocol
Does not deliver determinism
 Modbus Data Items
Modbus Modbus Slave
Data Item Data Type Description Example
Read Write Read Write
000001065535 Boolean value Yes Yes Yes Yes Accesses single-bit coils. 000001 = {000001}

100001165535 Boolean value Yes No Yes Yes Accesses single-bit discrete inputs. 100002 = {100002}

Accesses individual input register bits and interprets

300001.1 = {the first
300001.1365535.16 Boolean value Yes No Yes Yes them as logical TRUE or FALSE values. The least
bit of 300001}
significant bit is 1. The most significant bit is 16.

16-bit
Accesses 16-bit input registers as unsigned integers
300001365535 unsigned Yes No Yes Yes ranging from 0 to 65,535.
300001 = {300001}
integer

Accesses individual bits of holding registers and

400002.16 = {the
400001.1465535.16 Boolean value Yes Yes Yes Yes interprets them as logical TRUE or FALSE values. The
16th bit of 400002}
least significant bit is 1. The most significant bit is 16.

16-bit
Accesses 16-bit holding registers as unsigned integers
400001465535 unsigned Yes Yes Yes Yes ranging from 0 to 65,535.
400002 = {400002}
integer
Ethernet-Based Industrial Protocols
Modbus TCP/IP
EtherCAT
Ethernet/IP
PROFINET
EtherCAT Overview
EtherCAT Ethernet Control Automation Technology
Managed EtherCAT Technology Group (ETG)
Open and based on standards such as IEC 61158
Advantages
Hard real-time industrial protocol
Extremely efficient and straightforward communication
Disadvantages
Addresses only hard real time (?)
Not designed for standard TCP/IP packets and EtherCAT packets
Functional Principle: Ethernet On-the-Fly
Fast Train Analogy
Train (Ethernet frame) does not stop
Even when watching the train through a narrow window one sees the entire train
Car (subtelegram) has variable length
One can extract or insert single person (bits) or entire groups even multiple
groups per train

Master
Slave Slave Slave Slave
Ethernet Frames
EtherCAT commands are transported in the Ethernet frame data area
and coded via a special EtherType
EtherType is limited to an Ethernet subnet (not relayed by routers)
Ethernet-Based Industrial Protocols
Modbus TCP/IP
EtherCAT
Ethernet/IP
PROFINET
EtherNet/IP Overview
Dominant bus for Rockwell Automation
Managed by Open Device Vendors Association (ODVA)
Extends DeviceNET concepts to Ethernet
Advantages
Uses Ethernet transport layer (TCP and UDP)
Disadvantages
Can overload networks with UDP messages if note correctly
configured, recommend managed switches with IGMP snooping
Device Classes
Master
Scanner Class Initiate implicit and explicit communications

Slave
Adapter Class Only sends data if requested by a scanner
Supports explicit and implicit messaging

Used for setup or on-demand data transfer

Messaging Class Initiates data transfer by either device
EtherNet/IP Add-Ons
CIP Sync
Based on IEEE 1588
Provide shared clock to devices

CIP Motion
Builds on CIP Sync to perform distributed control for motion
Uses clock sharing not QoS

CIP Safety
Builds on DeviceNet safety
Intelligent devices with time-out parameters
Ethernet/IP Terminology
TCP/IP
Used to set parameters and initiate
Explicit Messages implicit communication

UPD/IP multicast
Used to communicate I/O data
Implicit Messages
Normally set up for cyclical updates
 Communication from NI LabVIEW to
ControlLogix PLCs
EtherNet/IP

Available for download from NI Labs at ni.com/labs

EtherNet/IP VIs for LabVIEW
Provides VIs for communication to Logix PLC tags
Directly read and write tags on Allen-Bradley
ControlLogix and CompactLogix PLCs
Runs on LabVIEW for Windows and LabVIEW
Real-Time OSs (Phar Lap and VxWorks)
Explicit messaging
Good for low numbers of tags
Use on Real-Time Controllers
Need to install the communications drivers onto the
real-time target from NI Measurement & Automation
Explorer
EtherNet/IP VIs for LabVIEW
Advantages
Simple method to communicate to Rockwell PLCs
LabVIEW initiated communication (no need to change PLC code)
Good for communicating low number of tags
Uses TCP/IP and does not require IGMP snooping to prevent
network flooding
Disadvantages
Not recommended for high tag counts
Inefficient packing of data into Ethernet (slower communication)
Increased processor burden on PLC
Can only communicate to Rockwell Logix PLCs
No SLC support, no third-party EtherNet/IP device support
Ethernet-Based Industrial Protocols
Modbus TCP/IP
EtherCAT
Ethernet/IP
PROFINET
PROFINET Overview
Dominate bus for Siemens
Application protocol that extends PROFIBUS to Ethernet
Managed by PROFIBUS & PROFINET International (PI)
Advantages
Supports both standard and deterministic Ethernet traffic
Uses IEEE 1588 and QoS to add determinism
Disadvantages
For RT/IRT managed switch with QoS is recommended
Switch with ERTEC ASIC for most challenging applications
Three Levels
Non Real Time (NRT)
PROFINET CBA
For plant commissioning
100 m/s range

RT (Real Time)
PROFINET CBA and PROFINET I/O
I/O applications
Up to 10 m/s cycle times

IRT (Isochronous Real Time)

PROFINET I/O
Applications in drive systems Source:
Less than 1 m/s cycles time Wikipedia
PROFINET Network cycle
No start period message
Clock synchronization via IEEE 1588 and asynchronous
Red portion of the cycle (isochronous)
Green portion of the cycle (asynchronous) minimum 125 s
IEEE 1588 Technology
Technology to synchronize distributed clocks
Accuracy based on clock jitter
IEEE 1588 Technology
HRT: Determinism and Performance

Organization Response Time Jitter Data Rate

(ms) (us) (Mb/s)
EtherCAT ~ 0.1 < 0.1 100
Sercos III < 0.5 < 0.1 100
PROFINET IRT <1 <1 100
Ethernet Powerlink <1 <1 100
Ethernet/IP ~1 <1 100
Table 1. Real-Time Comparison of the Various Real-Time Methods
Standards-Based Real-Time Ethernet Now Off-the-Shelf by Klaus Zwerina
Agenda
Why Ethernet-Based Protocols?
Overview of Ethernet-Based Industrial Protocols
Adding Deterministic I/O to NI PACs
Connecting NI Devices to Industrial Protocols
Modbus TCP/IP
Plug-In PXI/PCI Devices, PROFIBUS
Ethernet/IP
NI System with Deterministic Distributed I/O

Host Computer

(TCP/IP)
(TCP/IP) NI PXI System
NI PXI System
with Ethernet Interface
with Ethernet Interface

NI cRIO-9074
NI cRIO-9074
(EtherCAT)
(EtherCAT)

NI 9144
NI 9144
NI Master Controllers
Requirements
NI CompactRIO or PXI real-time system with two
Ethernet ports
NI-Industrial Communications for EtherCAT
NI 9144 Expansion Chassis
Two ports for
daisy chaining

Rugged Chassis
-40 to 70C Eight slots
9 to 30 V input for
HazLoc NI C Series
Shock/vibe
LabVIEW Experience

CompactRIO
Chassis

{
NI 9144
Expansion {
Chassis
Deterministic
Distributed I/O
Demo
C Series I/O
Supports more than 30 analog and digital modules
All single-point measurements
No waveform support (NI 9233 and NI 9234)
Module-to-module and chassis-to-chassis
synchronization
Compatibility with different NI chassis

EASY POWERFUL OPEN

Agenda
Why Ethernet-Based Protocols?
Overview of Ethernet-Based Industrial Protocols
Adding Deterministic I/O to NI PACs
Connecting NI Devices to Industrial Protocols
Modbus TCP/IP
Plug-In PXI/PCI Devices, PROFIBUS
Ethernet/IP
LabVIEW Modbus Options
NI Modbus VIs Modbus I/O Server
Modbus: Connect to Third-Party Gateways
Wide variety of communication protocols
Supported by all LabVIEW Real-Time PACs
Not for deterministic applications

PROFIBUS
DeviceNet
EthernetIP
ControlNet
Modbus TCP
PXI/PCI with Real-Time Support
PROFIBUS
CAN
CANopen
DeviceNet
FOUNDATION fieldbus
PROFIBUS
Compatible with Windows XP/2000, LabVIEW Real-Time OSs
Graphical networking configuration software
LabVIEW Express API for simplified programming
Supported services include DPV0 Master class 1/2, DPV0 Slave, and
DPV1 Master class 2
Ethernet/IP VIs for LabVIEW
VIs for Ethernet/IP message and scanner modes
Available on NI Labs
Installer that provides VIs for communication to
Ethernet/IP adapters
Demo: Ethernet/IP VIs
Questions?