PROFINET in action at a major plant of AUDI The paper describes the successful deployment of a diagnostic and monitoring solution for the provision of network perfomance status based on PROFINET diagnostics. The implementation took place in a major plant of AUDI, one of Germany’s leading car manufacturers. AUDI’s decision to standardize on PROFINET as communication protocol within its plants was in accordance with the recommendation of the German AIDA organisation (an initiative of the leading German car manufacturers Audi, BMW, Daimler, Volkswagen and Porsche) to introduce PROFINET for automation projects in the German Automotive Industry in 2004. AUDI’s specific requirements for the implementation of the PROFINET communication protocol went beyond the scope of typical network diagnostics and included the following: Provision of network and error statistics as well as diagnostic information read from devices Access to topology and asset information such as current firmware versions in real-time Detection of added or failed devices and the creation of a reference measurement Availability of the communication metrics for subsequent comparison Graphical display of possible changes Secure access from the overall network – managed by the IT department – to the automation network

1. PROFINET Network Diagnostics at Audi Neckarsulm, Germany
Bernd Kremer, Softing Industrial Automation
PI UK Conference 23/24 June 2015
The Stratford Manor Hotel
Photo:  Audi AG

2. © Softing 2014 / Page 2 of 20
PROFINET and German Automobile Industry
About Audi
PROFINET at Audi Neckarsulm
Network Diagnostics Requirements at Audi
About the Solution
Résumé

3. © Softing 2014 / Page 3 of 20
PROFINET and German Automobile Industry
AIDA - Automation Initiative of
German Car Manufacturers
► Founded 2003
► Development of mutual positions on automation topics
(e.g. harmonization / standardization of technologies)
► 2004 decision for using PROFINET
► Setting requirements for every PROFINET component
being used in Automotive production
– Integrated safety (PROFIsafe)
– CC B (RT) or CC C (IRT)
– Fast Start-Up (FSU)
– Media redundancy
– PI-Certification
 Support of network management services
 PROFINET and standard Ethernet through
common port
 Connectivity via copper as well as fiber optics
 Integrated switch for line and ring topologies
Photo:  Shutterstock

4. © Softing 2014 / Page 4 of 20
About Audi
Facts and Figures
► Member of Volkswagen (VW) Group
► More then 73,000 employees
► Over 1,5 million cars sold (49 models)
► #1 sales position with Premium Cars
in Europe and China
► 2 digit growth in main export markets
USA, China and Great Britain
► 11 Production Sites
► Ingolstadt and Neckarsulm responsible for installation of production
lines at other sites
► „one name, one standard, everywhere“
Photo:  Audi AG

5. © Softing 2014 / Page 5 of 20
About Audi
Neckarsulm Plant
► More then 15,000 employees
► Over 275,000 built
► 1st place J.D. Power Award for best assembly quality
in Europe and Africa
► Site with broadest product variety
(19 models)
► 10.8 Million ft2 production floor space
 New pressing plant
 One aluminum-steel frame and body construction facility
 Two pure aluminum frame and body construction facilities
 One paint spray line
 Multiple assembly lines
► Lead for production sites
 Changchun and Foshan, China
 Aurangabad, India
 Lamborghini, Italy
Photos:  Audi AG

6. © Softing 2014 / Page 6 of 20
PROFINET at Audi Neckarsulm
Network Composition
► First PROFINET installations proving high speed
communication capabilities and robustness in 2006
(A8 Project)
► 1 GBit/s Uplink from Network Cabinet to Access Switch
► Network structure laid-out for up to 8 cells
► Cells based on PROFINET with some Ethernet
components
► Cu-wiring of Facility and Cell networks with PROFINET
Type B cables only
► Field installations of cells (CC-C / IRT) as redundant
POF-rings
– Max. 40ea subscribers plus max. 10ea on branches
– Exceeding subscribers as extra ring on additional
IRT-switch
► Each cell as own Class C network (256 IP-Addresses)
► One network diagnostics interface TH LINK PROFINET
per cell (own IP-address)
Graphics:  Audi AG

7. © Softing 2014 / Page 7 of 20
Network Diagnostics Requirements at Audi
Body Shop Production Planning
► Tool for effective and efficient support of
 installation quality assurance,
 plant asset management ,
 and maintenance across
 entire lifecycle of the facility
► Automation network diagnostics must:
 cover all subscribers (PROFINET and standard Ethernet)
– summarize from entire network all information about:
– diagnostics,
– system, and
– devices including
– their individual diagnostics history
 be suitable to support through facility lifecycle at:
– installation,
– commissioning,
– acceptance, and
– maintenance
 offer report functionality incl. comparison with previous status
 provide continuous monitoring capabilities
 support SNMP (IT acceptance) Photos:  Audi AG

8. © Softing 2014 / Page 8 of 20
Network Diagnostics Requirements at Audi
Final Assembly
► Tool for effective and efficient support of
 network management,
 maintenance, and trouble shooting
► PROFINET diagnostics and monitoring tool must:
 fit in flow of work
 relieve maintenance resources
 work independent from brand of network components
 offer hot plug-in without PLC project modification
 provide little hardware footprint for cabinet installation
 not require any additional components, e.g. data base PC
 provide functionality offering:
– topology discovery,
– different breakup views,
– inventory information about components
– detection of sporadic failures
Photos:  Audi AG

9. © Softing 2014 / Page 9 of 20
About the Solution
Three interlocking Components
► Network monitoring and analyzing software (TH SCOPE)
– Consolidation of data from all TH Links
– Network overview and topology information in different views
– Network statistics and history of network quality
– Status and bandwidth information for network infrastructure
– Inventory list with related network and device details, such as device type,
firmware version and, IP configuration
– Detailed information about communication failures
– Generation of reports respectively acceptance protocols
– Comparison with filed reference measurements (previous status)
– Data export functionality (e.g. Reference Measuring, Inventory List)
– Web Server
– SNMP agent for handing over diagnostics information from automation networks to IT
with central network monitoring
► Network diagnostic hardware interface (TH LINK PROFINET)
– Network access
– Monitoring communication and device status
– Passive “listening” and active communication (PROFINET, Ethernet)
– Data collection for processing through specific diagnostics algorithm
► Training
– 1 day, regularly performed at customer´s site
– Content (Ethernet, PROFINET) and methodology (hands-on) defined jointly with customer

10. © Softing 2014 / Page 10 of 20
About the Solution
Protocols and Services used for the
Diagnostics Algorithm
Device Detection
&
Device Identification
Device Diagnostics
&
Network Statistics
Configuration
&
Communication
Failures
Network
Topology
PROFINET
(Communication & Services)
X X X X
PROFINET Diagnostics Services X X
ARP (Address Resolution Protocol) X X
Ping X X
SNMP X X X
DCP / DHCP X X
LLDP X X

11. © Softing 2014 / Page 11 of 20
About the Solution
Outcome
► All network diagnostics requirements of customer met
► Solution specified for all future body-shop facility projects
managed / coached by Audi Neckarsulm
► Step by step integration into existing assembly lines
► Solution provides:
– Maximized availability of all facilities
– High use efficiency through consistent user interface
( one solution / tool for multiple maintenance tasks)
– Assurance of consistently high communication quality
– Hot plug-in capability
– Independence from availability of IT department capacities
Photo:  Audi AG

12. © Softing 2014 / Page 12 of 20
About the Solution
Course of Project
► 2012 initial contact with Softing / Trebing + Himstedt IC
(at first “Body Shop Production Planning” only)
► Test phase for target-performance comparison bringing up
differing and additional mandatory requirements, e.g.:
– Acceptance Report
– Usability (e.g. sequence of work)
– Topology views at different detail levels
► Realization of enhancements and changes with standard products
► 2013 Acceptance
► 2014 first deliveries
► 2015 Equipment of assembly lines for three models and new
body shop facilities
► …
Photo:  iStock

13. © Softing 2014 / Page 13 of 20
Roundup
Conclusions
► Ethernet-based industrial communication offers the opportunity for
realizing networks utilizing multiple technologies in parallel
► Existing requirement for dedicated network diagnostics tools
► PROFINET leveraging numerous standard Ethernet technologies
and protocols hence provides the prerequisite condition for a
consistent hence beneficial network diagnostics of real life industrial
Ethernet installations
► PROFINET is providing the functionality for highly effective and
efficient network management and maintenance meeting the
challenging demands of a leading premium car manufacturer
OSI-Layer PROFINET
7a
Application
IO Services & Protocols
7b RPC
6 Presentation
--
5 Session
4 Transport UDP
3 Network IP, ARP, SNMP, DHCP
2 Data Link CSMA/CD, VLAN, DCP, MRP, MRRT, LLDP
1 Physical 100BASE-TX, 100BASE-FX
Photos:  Audi AG

14. © Softing 2014 / Page 14 of 20
About Softing Industrial
Competence in Industrial Communication
► 35 years of experience in industrial communication between
devices, controllers and host systems based on international
standards
► Integration of fieldbus technologies, industrial Ethernet and OPC
for Factory and Process Automation
► Ready to use hardware and software products for data integration,
network diagnostics and Plant Asset Management
► Effective May 1st, 2014 Softing Industrial took over the Industrial
Communication business of Trebing + Himstedt including the
solution presented
Photos:  Shutterstock

15. © Softing 2014 / Page 15 of 20
Thank you very much!
Bernd Kremer
Head of Channel Sales International
Softing Industrial Automation GmbH
+49 172 93 99 808
bernd.kremer@softing.com
http://industrial.softing.com/en/