Make CIP Safety Your
Safety Protocol
Lechler, Schlechtendahl, Leurs, Verl

Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW)
University StuttgartandBosch Rexroth

Technical Trackwww.odva.org

General Problem Description

FIELDBUS X
SAFETY PROTOCOLUsing CIP Safety as Safety Protocol for a fieldbus

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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Content Introduction into sercos III
 Specification enhancement
 Concept validation
 Conformance testing Summary + Conclusion
Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
All rights reserved.

page 3www.odva.org

basics – sercos III
FSPDrive

FSP
IO

FSP
…

Function Specific Profiles

Safety Profile

GDP
Generic Device
ProfileFSP
Encoder

Condition Monitoring
Diag

Identification

State machine

SCP

S/IP
SMP

sercoscommunication
profileStandard
IP
Applications

Energy Profile

SVC

Connection
UDP/TCP

Hot-Plug

Redundancy

SYNC

IP

Ethernet

Hardware
100 Mbit/s

SERCON100 Master or
SERCON100 Slave
Ethernet Dual PHY

Technical Track© 2012 ODVA, Inc.

or

netX with core ofsercos Master orsercos Slave

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sercos III – important facts
sercos III:

Master – Slave design
Connection orientatedUnified Communication ChannelRing or Line Topology
Support of different Profiles (e.g. I/O, Drive,Energy, Safety)

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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Content Introduction into sercos III
 Specification enhancement
 Concept validation
 Conformance testing Summary + Conclusion
Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
All rights reserved.

page 6www.odva.org

Overview Specification

CIP Safety General
Profile update
CIP Safety fieldbus
specific update
CIP Safetyadaption
Data transportenhancement
Data transmission
layerTechnical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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page 7www.odva.org

sercos communication
MasterConnectionin ATConnection
in MDTCP

Application

Slave
Technical Track© 2012 ODVA, Inc.

PApp

P = Producer
C = Consumer
red = Connection
green = transmitted data

Application

Application

PPCConnectionin ATCCommunication

CCPAppApplication

Slave

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sercos – general problems
sercos is designed to…


really hard real-time,high precision synchronization with minimal jitterand high band width.

lack of following features

Fully application-controlled transmission in a time
pattern uncoupled from the transmission layer
Flexible multiplexing and fragmenting of data for
optimum utilization of the specified band width
Transmission of non-cyclical messages of variable
length.

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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page 9www.odva.org

Overview Specification

CIP Safety General
Profile update
CIP Safety fieldbus
specific update
CIP Safetyadaption
Data transportenhancement
Data transmissionlayer

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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page 10www.odva.org

sercos messaging protocol (SMP)
Applications layer
SERCOS session layer−−

Point-to-point connections
Management of logical connections between
two endpoints

SERCOS transport layer−−−

Definition of transport containers
Decoupling from SERCOS timingFragmentation

SERCOS
Messaging Protocol(SMP)(CIP Safety, …)

SERCOS data link layer−−−

Service channel services
Hotplug services
Real time services

SERCOS II physical layer
Technical Track© 2012 ODVA, Inc.

SERCOS III physical layer

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SMP Tasks
Manage Session (ID + Priority), New Data
Toggle (NDT), Last and First of Sequence Bit,
Session Counter
Split and rebuild message

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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Overview Specification

CIP Safety General
Profile update
CIP Safety fieldbus
specific update
CIP Safety
adaption
Data transportenhancement
Data transport
layerTechnical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
All rights reserved.

page 13www.odva.org

CIP Safety adaption
Motivation
sercos does not support the Common Industrial
Protocol (CIP)
adoption of CIP Safety as a safety layer forsercos devices raises the need for an adaptation
layer that implements a basic set of CIP services
and objects

Note:
CIP Safety Adaption layer is not part of the safety
protocol itself  black channel
Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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CIP Safety Adaption Layer
Services and Objects

Identity Object (Get Attribute Single)
Connection Manage Object (Forward Open andClose)
Connection Configuration Object (Get/Set
Attributes All, Create & Delete, Get/Set AttributeSingle, Open/Close Connection, Stop Connection,
Get Status)
Message Route Object (no service, task todistribute incoming explicit messages)

Technical Track© 2012 ODVA, Inc.

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CIP Safety Adaption Layer
VCEE
Validator Connection
Establishment EngineID

CMIdentity
ObjectConnection Manager
ObjectSSOSVAI

Safety Supervisor
ObjectSafety Validator
ObjectApplication
Interfaceacyclic
data

I/0
Connection
InterfaceMR
Message Router Object

CSAL
CIP Safety
Adaptation Layer

CSAL Main Loop

SMP

SMP

SessionSessionSMP Container

SMP Container

Technical Track© 2012 ODVA, Inc.

SMP
Channel2012 ODVA Industry Conference & 15th Annual Meeting
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SMP
SERCOSMessaging Protocol
page 16www.odva.org

cyclicdataobjectrelation

Overview Specification

CIP Safety General
Profile update
CIP Safety fieldbus
specific update
CIP Safety
adaption
Data transportenhancement
Data transport
layerTechnical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
All rights reserved.

page 17www.odva.org

Adaption of CIP Safety
Add Requirements to Volume 5:Transport layer information ( Sercos MessagingProtocol)
Adaption layer description ( CIP Safety on
sercos Adaption Layer)
CIP Safety and sercos device model
Mechanism for Unique Node ID (UNID)
assignment

 In total 12 pages

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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Overview Specification

Fieldbus Safety
ProfileCIP Safety fieldbus
specific update
CIP Safety
adaption
Data transportenhancement
Data transport
layerTechnical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
All rights reserved.

page 19
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Fieldbus Safety Profile
Additional Safety Profiles

Possibility to add additional Safety Profiles tofieldbus specification
Profiles are located on top of CIP Safety

Preferred way:Specify a common profile with ODVA (e.g. safemotion profile)
Advantage is the common usability of profile overfieldbus boundaries

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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Content Introduction into sercos III
 Specification enhancement
 Concept validation
 Conformance testing Summary + Conclusion
Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
All rights reserved.

page 21www.odva.org

Concept Validation
Validation by TÜVNo need to recertify Safety Protocol
Only sercos specific extension have to beapproved  done through cyclic review of new
Volume 5 by TÜV & BGIATÜV does not care about black channel (CIP
Safety Adaption Layer, sercos Messaging
Protocol, sercos Communication)

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
All rights reserved.

page 22www.odva.org

Content Introduction into sercos III
 Specification enhancement
 Concept validation
 Conformance testing Summary + Conclusion
Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
All rights reserved.

page 23www.odva.org

General Architecture
CIP safety
Certification
SoftwareDevice
CIP safety
on sercos

User Programwith GUIPython
Tests
Gatewaysercos III
GUI Interface

Script Interface

CIP safety adaption(sercos III Conformizer)
DPR
HardwareTechnical Track© 2012 ODVA, Inc.

sercos III
Hardware DPR Dual Ported RAM
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Topology Considerations
Topology sercos:


MasterSlave

Topology CIP Safety

Originator
Target In total 4 combinations

Technical Track© 2012 ODVA, Inc.

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Hardware Architecturesercos slave solution:
Using active sercos master PCI card
Certification of Originator and Target located onsercos Slave
Windows XP mit PCI PortCIP safety
Certification
Softwaresercos Slave &CIP Safety Target /CIP Safety Originator
Sercos III

DPR
sercosMasterTechnical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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Hardware Architecturesercos master solution:
Using passive sercos slave PCI cardCertification of Originator and Target located onsercos Master

Windows XP
CIP safety
Certification
SoftwareLinux RT Preempt
mit PCI PortCIP Safetysercos Master &CIP Safety Originator
CIP Safety Target

DPR
passiveslave
Technical Track© 2012 ODVA, Inc.

Sercos III

2012 ODVA Industry Conference & 15th Annual Meeting
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Only Adaptions

Originator /TargetConsumer /Producer

Software Architecture Python
IO channel(cyclic)
In SID 1

In SID 1

Testcase No.

ServerFramework

Configuration(Conform.py)

Input
ServerInput

In SID 2

In SID 2…
In SID 95

In SID 95

DeviceDevice 1

Out SID 17

Out SID 17
OutputServerOutput

ServerOut SID 18

Out SID 18…
Out SID 103

Out SID 103
1 Out- and 1
In-Server per
DeviceTechnical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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1 Out and 1 In
per Fwd_Openpage 28
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sercos III

Device 2

Interface Description
Conformance Software Interface:Use of 4 simple functions encapsulated in DLL:• Explicit: sendExplicitMessage & receiveExplicitMessage• I/O:
sendIOMessage & receiveIOMessage



Attributes for send functions: Instance (sercosconnection number), SMP Session ID, length andmessage pointerAttributes for receive functions: Instance (sercosconnection number), SMP Session ID, length andmessage pointerFor diagnostic purpose: readSercosPhase

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
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Content Introduction into sercos III
 Specification enhancement
 Concept validation
 Conformance testing Summary + Conclusion
Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
All rights reserved.

page 30
www.odva.org

Summary + Conclusion
Points to do:

Develop a concept to connect CIP Safety to yourfieldbus
Show concept to the TÜV and let it be approved
through review of Volume 5
Connect the certification solution to your network communicate SAFE

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
All rights reserved.

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Thank you very much
Any questions?

Technical Track© 2012 ODVA, Inc.

2012 ODVA Industry Conference & 15th Annual Meeting
All rights reserved.

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