Exchange of engineering data for communication
systems based on AutomationML using an
EtherNet/IPTM example
Dipl.-Wirtsch.-Ing. Falko Bendik
Otto-von-Guericke-University Magdeburg
October 14, 2015

Overview● Motivation● Requirement Analysis● Overview of AutomationML● General communication system modeling methodology
in combination with EtherNet/IPTM example

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Motivation
Requirements on the engineering of production systems● complexity of the systems● amount of data to be handled● high development costs● different applicable efficient engineering processes● different sets of software tools in the development process● exploiting different engineering artifacts● modular control structures / distributed control systems

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3Motivation
Involved engineering
activities exchanging
engineering artefacts

Simulation
Test / VirtualCommissioning

Bus Configuration

Commissioning /Device
Configuration

Plant Planning*.aml

MechanicalEngineering

Electrical Planning

Documentation

PLC Programming

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Robot Programmingwww.odva.org

4Motivation
General semantic for communication systems with AutomationML● A significant cost factor of industrial plants is the engineering process.
● To reduce this factor new methods and description tools are needed!
Project management (3%)
Pre-commissioning (2%)
Assembly (11%)
Bought-in parts (28%)
Geometry simulation (1%)
Robot programming offline/online(5%)
Engineering [incl. Commissioning](50%)

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5Motivation
Do redundancies exist in the engineering process?

Where are the avoidable costs exactly?
Yes (41%)● A survey reveals:□ That 82% of the respondents cannot
exclude non-redundancy of planning steps.
□ That the pdf/paper interface is the mostwidespread interface with 31%.
□ That only 12% of the respondents
use standardized interfaces.

Depending on application (41%)
No (18%)Which interfaces are currently used ?
Paper/PDF (31%)
Proprietary interfaces (26%)
Generic exchange formats(12%)
Consistent project database(20%)
Other (11%)

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6Motivation
Solutions for an efficient engineering of production systems● highly sophisticated engineering tools● fault free creation of engineering artifacts● consistent exchange of engineering data
● planning of communication systems, addressing and communication packagestructure● device configuration data and structures describing the communication network● contain topological information● information on communication links and their quality● basic semantic libraries and process models of communication models

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7Motivation

InternalLink

Physical Device

Logical modeling
PhysicalEndPoint

Physical modeling

Physical Device

PhysicalEndPoint
InternalLink
InternalLink

Logical Device● physical communication links

PhysicalConnection

InternalLink

and the expected transmission
rate of information between
application parts

InternalLink● addressing of applications

InternalLink

Logical and physical topology
of communication systems

LogicalConnection
Communication
Package

LogicalEndPoint

Logical Device

LogicalEndPoint

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Communication
Package
DataObject

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InternalLink

VariableInterface

InternalLink

between devices
VariableInterface

8Requirement Analysis
What is needed?
● identify types of information characterizing a communication system● which information should be covered by a method for a neutral exchange of communication
system engineering information● data in the engineering process of a production system□ mechanical and electrical engineering data
□ control programming “PLC Code”□ virtual commissioning□ commissioning● definition of involved automation devices and their wiring● control programming, runtime information (represented by control variables)● identify additional technical details such as data types, transmission rates etc.

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9Requirement Analysis
What is used?
● electrical engineering: specifying wiring diagrams, wiring● control programming: specify device configurations, variable lists, link descriptions● virtual commissioning: used to test the physical realization of the intended data exchange● commissioning: used variable declaration and linking descriptions for monitoring and diagnosismechanicaland electricalengineering

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controlprogramming

virtualcommissioning

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commissioning

10

Requirement Analysis
What information is needed to describe the modeling method?
● control application□ components are linked with each other by exchanging variables□ need to establish logical connections by logical interfaces (namely the corresponding
exchanged variables or sets of them)□ identify the requirements in terms of communication properties on the exchange of data
within the logical connections□ create properties of the control application components, e.g. processing times,
characteristics of logical interfaces, or a port number

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11Requirement Analysis
What information is needed to describe the modeling method?
● control devices□ control application components are running on different physical devices□ the logical connections must be realized by the physical data exchange□ physical device has interfaces for physical connections (necessary cables forcommunication system realization)□ describe the active and passive infrastructure components such as switches, interface
converters, plug, or cable types□ analogy to the control application parts, the logical connections, and the logicalinterfaces□ represent the properties of the physical devices, the physical interfaces and the physicallinks

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12Requirement Analysis
What information is needed to describe the modeling method?
● general modeling requirements□ represent the relations between logical and physical connections□ map the corresponding structures at least at the used interfaces to each other□ communication system information is transmitted by data packages□ represent the mapping of variables within the data package sender to variables within
the data package receiverTechnical Track© 2015 ODVA, Inc.

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Overview of AutomationML● AutomationML is a XML based data format.
● It is an international standard (IEC 62714)
and free of charge● AutomationML allows a consistent dataexchange within different tool chains● It allows the integration of the world of toolsinto the digital factory of the future

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Overview of AutomationML
Which data contents are covered by AutomationML?
Plant structure

Plant components• Components hierarchy• Topology• Components relations• Mechatronic structures• Attributes of components• Economic data

Geometry andkinematics

Network• Mechanic construction• Locomotion planning• Electric construction

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Plantdescription• Electric construction• Communication systems

ConductSemantics• Conduct of the components• Control design• Robotic process• Clear meaning of the objects
about classification systems

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Overview of AutomationML
AutomationML is …
● Data format, that allows a data exchange of engineering data of production systems
independent of the manufacturer.
● Storage format for information.
● Connection between different discipline-specific engineering tools with that it is usable in thewhole engineering process.
● Object orientated and allows the modeling of plant components as data objects summarizing
different aspects.
● Combination and adaptation of already existing industry formats that were developed forexchange and storage of different engineering aspects.
● consistent, distributed document architecture, that enables the handling of large
amounts of data and the outsourcing of libraries to external documents.

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Overview of AutomationML
AutomationML is NOT…
● Tool functionality● Review of conditions, attribute values, relations, references, or semantic correctness of several
data objects● Review and matching of the consistence resp. version of data objects● Automatic standardization of user specific information● Automatic creation of libraries● Automatic management of versions and variants● Project management tool
● Project management database► But it allows the storage of all data required for thatTechnical Track© 2015 ODVA, Inc.

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Overview of AutomationML
The AutomationML – architecture
Plant Planning

IEC 62714● Based on the use of existing
XML data formats□ CAEX - structure/relation of the plant objects□ COLLADA - geometry and kinematics□ PLCopen XML - behavior

Functional
engineering

Top level format
CAEX IEC 62424

Plant
Topology
Information

Commissioning

GeometryandKinematic
formatCOLLADA

Logic
formatPLCopenXML

Mechatronics
Networks
Devices

Semanticreferencing

Attributes

Further aspects
in other XML
formatTechnical Track© 2015 ODVA, Inc.

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D1

D2

1
Dn18

Overview of AutomationML
The AutomationML – architecture

COLLADACAEXCOLLADA

PLCopen XML

PLCopen XML

PLCopen XML

COLLADA

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Overview of AutomationML
Development of roleclasses for theapplication process

Application
process

Development ofinterface classes forthe application
process
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Development ofSystemUnitClasses
for the application
process

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System modeling20

Overview of AutomationML
Topology description with CAEX
● Definition of the meaningof objects by roles● Definition of reusable
objects for the engineering□ Components□ Interfaces□ Roles● Representation of project
data as project tree
● Integration of object descriptionsas attributes● Relations between objects
and references to external documents
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InstanceHierarchy

System Unit Library

Description of project data

Definition of reusable components

IH

IE

Instantiation ofobjects

SUC
LIB

IE

IE

Linking ofobjects

SUC

Reference toexternal data

SUC

IE

SUC

*.dae

IE

*.xml

Role Class Library

Interface Class Library

Definition of object semantics

Definition of interfaces

Role
LIB

NutzenUse ofvon
Bedeutungensemantics

Role

LIB

NutzenUse ofvon
Bedeutungeninterfaces

RoleRole

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Overview of AutomationML
Topology description
with CAEX
Source: www.arburg.com

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Description ofplanning data

Definition
reusablesystem parts

Attributes of thewhole project

Definition ofobject sematics

Definition ofinterfaces

Attributes of single
project elements

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Overview of AutomationML
Topology example

ProjectComponent
library

CAEX

CAEX
Quelle: www.arburg.com

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Overview of AutomationML
Geometry and kinematic description with COLLADA● COLLADA is standardized as ISO/PAS 17506□ KHRONOS● Originally developed for the gaming industry□ Main driver: SonyAutomationML

AutomationML

InternalElement

COLLADA data
GeometryCAEX

COLLADA
Kinematics

Robot

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Overview of AutomationML
Behavior description with PLCopen XML● PLCopen XML based on IEC 61131-3● Derived from the SPS world● Allows the description of conduct about different types of models like Gantt Charts, PERT
Charts, Impuls diagram, State Charts, …
AutomationML
InternalElement

CAEX

AutomationML
PLCopen XMLBehaviour
State 1

Event 4 / [Guard 5]
Event 4 / [Guard 4]

H

State 2

State 1.1
State 1.3

Event 2

[Guard 6.1]

Event 2

Event 1 / [Guard 1]

Event 5

Event 3 / [Guard 3]

State 1.2
C

Guard 2 / Activity 1
State 1.3

[Guard 6.2]

PLCopen XML

State 3

Event 6

Entrance Activity 2
Activity 3
Exit Activity 4[Guard 6]

Sequencing
Sequence 2
IdRobot

Name Prede- Start Dura- Endcessor time tion time

1Handover to HTR002
2
Move to Lift Position
3Lift skid
4Lower skid
5Move to end of 110HTR002
6
Initialise Robot 1
7 Execute Manufacturing Robot 1
8Postprocess Robot 1
9Initialise Robot 2
10 Execute Manufacturing Robot 2
11
Postprocess Robot 2

1
2743, 6
767, 91004
723270918618
23Interlocking Var1
Var2

43
2
4
76
94
4
5
305

1015

20

30

35

40

45

50

55

60

65

70

75

8085>=1&
Var3

254
7
927
34
61822
102326

Var5>=1

Var4Technical Track© 2015 ODVA, Inc.

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General communication
system modeling methodology
Networks are the integral part of modern communication systems● Combination of used elements
PLC● Requirement: Illustration ofMain control

AutomationML
Communication

IO Device

Physicaldevice

IO function

application
Logical Connection A□ Logical network structures
at application level□ Physical network structures for thetechnical realization of interactions□ Relationship between both views□ Descriptive attributes of both views

Physicalconnection
with endpoint
Wire 1PDUDatagram
objectActive infrastructure device

Mapping of
Variable /Signalinterface todatagram
objectWire 2

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Physicalend pointof device

PDU 1

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Variable /Signalinterface

Logical device
Logicalend pointof device
Logicalconnection
with endpoints

Mapping oflogical tophysicalinterfaces

26

General communication
system modeling methodology
Example network with EtherNet/IPTM
0. Application of predefined basic libraries

VAR Real NumberOfRevolutions ENDVAR
Controlapplication

EthernetIP
ControllerrolesEthernetCable1

ConcoderProfileEncoderinterfaces

VAR Real Rotation ENDVARTechnical Track© 2015 ODVA, Inc.

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General communication
system modeling methodology
Example network with EtherNet/IPTM
1. Definition of the role classes for the corresponding use case
► RoleClassLib

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General communication
system modeling methodology
Example network with EtherNet/IPTM
2. Definition of the interfaces for the corresponding use case
► InterfaceClassLib

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General communication
system modeling methodology
Example network with EtherNet/IPTM (Part 1&Part 2)
3. Modeling of the used devices and connections►SystemUnitClassLib

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General communication
system modeling methodology
Example network with EtherNet/IPTM (Part 3)
3. Modeling of the used devices and connections►SystemUnitClassLib

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31General communication
system modeling methodology
Example network with EtherNet/IPTM
4. Modeling of the system► InstanceHierarchy

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General communication
system modeling methodology
PLC
Main control
application

Application to communication
network

AutomationML
Communication

IO Device

Physicaldevice

IO function
Logical Connection A

Physicalend pointof device

PDU 1

Physicalconnection
with endpoint
Wire 1
PDU

Datagram
objectActive infrastructure device

Mapping ofVariable /Signal
interface todatagram
objectVariable /Signal
interface

Wire 2

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Logical device
Logicalend pointof device
Logicalconnection
with end
points

Mapping oflogical tophysicalinterfaces

33

General communication
system modeling methodology
Attributes
RefBaseSystemUnit
Path

Determination of the semantics for several attributes…
……

RefSemantic
InternalElement

Attribute…

SupportedRoleClass…

RoleRequirements…
……

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SummarySummary● neutral data format● system models / engineering of automation technology● fault free creation of engineering artifacts● modelling industrial communications● basic semantic libraries● decrease of planning costs

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