Exchange of engineering data for communication … step towards lossless data exchange within...

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2015 ODVA Industry Conference 1 ©2015 ODVA, Inc. Exchange of engineering data for communication systems based on AutomationML using an EtherNet/IP TM example Development of a vendor-neutral data exchange format for the application in existing tool chains Concept development for the realization of various relevant structural, behavioral and device configuration data and the possibility of horizontal data integration Dipl.-Wirtsch.-Ing. Falko Bendik; apl. Prof. Dr.-Ing. habil. Arndt Lüder; Dipl.-Ing. Nicole Schmidt; Research Assistant; Head of CVS, Research Assistant; Research Assistant; Otto-von-Guericke-University Magdeburg Faculty of Mechanical Engineering Institute of Ergonomics, Manufacturing Systems and Automation (IAF) / Chair for Factory Operation and Manufacturing Systems Presented at the ODVA 2015 Industry Conference & 17th Annual Meeting October 13-15, 2015 Frisco, Texas, USA Executive Summary Communication systems are an important part of modern control systems used within industrial production systems. They enable the interaction of control systems with the used equipment to satisfy the different requirements related to the controlled behavior of the production system. During the engineering process of production systems and its embedded control systems communications systems need to be considered in detail. At early stages of the engineering process relevant data for the communication system design is created and the results of the communication system engineering are needed in later phases. However, this data exchange is still a technical challenge as there is no suitable data exchange format available which enables a consistent and lossless transfer of information between engineering tools covering all relevant communication system engineering information.

Transcript of Exchange of engineering data for communication … step towards lossless data exchange within...

2015 ODVA Industry Conference 1 ©2015 ODVA, Inc.

Exchange of engineering data for communication systems based on AutomationML using an EtherNet/IPTM example

Development of a vendor-neutral data exchange format for the application in existing tool chains

Concept development for the realization of various relevant structural, behavioral and device configuration data and the

possibility of horizontal data integration

Dipl.-Wirtsch.-Ing. Falko Bendik; apl. Prof. Dr.-Ing. habil. Arndt Lüder;

Dipl.-Ing. Nicole Schmidt;

Research Assistant; Head of CVS, Research Assistant;

Research Assistant;

Otto-von-Guericke-University Magdeburg Faculty of Mechanical Engineering

Institute of Ergonomics, Manufacturing Systems and Automation (IAF) / Chair for Factory Operation and Manufacturing Systems

Presented at the ODVA

2015 Industry Conference & 17th Annual Meeting October 13-15, 2015 Frisco, Texas, USA

Executive Summary Communication systems are an important part of modern control systems used within industrial

production systems. They enable the interaction of control systems with the used equipment to satisfy the

different requirements related to the controlled behavior of the production system.

During the engineering process of production systems and its embedded control systems

communications systems need to be considered in detail. At early stages of the engineering process

relevant data for the communication system design is created and the results of the communication

system engineering are needed in later phases. However, this data exchange is still a technical challenge

as there is no suitable data exchange format available which enables a consistent and lossless transfer of

information between engineering tools covering all relevant communication system engineering

information.

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To solve this problem, a methodology for modeling the communications systems was developed by the

AutomationML association using the basis of the data exchange format AutomationML, which will be

presented in this paper. Finally, this methodology is applied on an EtherNet/IPTM example.

Motivation The requirements on the engineering of production systems respectively automation systems have been

growing continuously in the last years. This effects the duration of the engineering project, the complexity

of the systems to be created, as well as the amount of data to be treated [1, 2]. To cope with these

challenges engineers have developed highly sophisticated engineering tools assisting the engineers with

their work. Thus, within the different applicable engineering process different sets if software tools are

involved exploiting different engineering artifacts [3, 7]. To make the engineering processes efficient and

fault free the created engineering artifacts or parts of them have to be exchanged between the

engineering tools within the established engineering tool networks.

Today, an important part of the automation of production systems is the industrial communication system.

That connects the various automation components and, thus, makes modular control structures and

distributed control systems possible. As for all engineering artifacts, for the engineering of those

communication systems it is necessary to enable a consistent exchange of engineering data [4].

Here, different use cases of data exchange may be relevant. A first intuitive example is the transfer of

configuration information for communication modules of automation devices, which describes device

addressing and communication package structuring. Thus, information must be transmitted from PLC

programming tools to the corresponding configuration tools to automation devices.

Another example is the transfer of device configuration data and data structures describing the

communication network from PLC programming tools or configuration tools of automation devices to

documentation tools for representing the overall structure of a communication system for maintenance or

diagnostics purposes (see Figure 1).

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Figure 1: Considered application cases

So far, various user organizations and companies have developed and supported different description

formats (like FDCML [8], EDDL [6]) FDT-DTM [14], which primarily focus on the exchange of device

configuration data [5]. This is, however, not sufficient regarding the applications mentioned above, as they

describe only data of a device and, for example, do not contain topological information or information on

communication links and their quality.

For this reason, the AutomationML association has developed a method based on AutomationML [9] to

represent engineering data for communication systems. This method reflects the distinction between a

logical and a physical topology of a communication system as illustrated in Figure 2.

Electrical Planning

Mechanical Engineering

Bus Configuration

PLC Programming

Test / Virtual Commissioning

Commissioning /Device

Configuration

Monitoring, Maintenance

Plant Planning

Documentation

Robot Programming

Simulation

*.aml

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Figure 2: Logical and physical topology of communication systems

A logical topology comprises control applications and their components exchanging information on a

logical level. Here, the addressing of applications and the expected transmission rate of information

between application parts might be of interest for modeling. A physical topology maps the communication

devices and the built up physical communication links between them. Again, addresses and transmission

rates are relevant, but on a different abstraction level representing the system capabilities. Both

topologies are interlinked; the physical topology must implement the logic one.

AutomationML has developed and documented basic semantic libraries and process models in the

AutomationML Whitepaper Part 5 – “Communication” to enable the representation of different

communication technologies and different communication protocols. This paper will sketch the

developments accomplished so far by means of an EtherNet/IPTM example.

To make the above named problem of information exchange more intensive, companies, (especially

system integrators of different industries) have to face the challenge of increasing technological

divergence. Especially Small and Medium-sized Enterprises (SMEs) are intended to be enabled to meet

high individualization of kind and characteristics of communication technologies within the use cases of

their customers. They require support for protocol- and architecture independent design, configuration

and documentation of arbitrary industrial communications networks. They need appropriate procedures

and data models for these processes.

Here, the AutomationML based communication system modeling can provide a first assistance to face

this challenge. This paper will show preliminary results of an ongoing research project at the Otto-von-

Physical Device

Logical Device

LogicalEndPoint

PhysicalEndPoint

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Logical Device

LogicalEndPoint

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Guericke-University Magdeburg related to modeling and planning of communication systems including

protocol details using AutomationML as modeling language. This project focuses on the application field

of factory automation and energy generation and distribution systems and strives to reduce the duration

of installation and commissioning of the communications systems by 20%, to limit the error rate, and to

improve communication system documentation. The project focuses on the development and use of

communications system models within a neutral format, which are qualified for project parts and, beyond

that, for the universal use within arbitrary applications. The project focuses on the application field of

photovoltaic. Specifically, this paper will show the application of an Ethernet-Network and EtherNet/IPTM

as an example.

What is needed - a requirement analysis First step towards lossless data exchange within engineering of communication systems is to identify the

types of information characterizing a communication system. Communication systems are necessary for a

variety of applications in practice. Some of the most relevant applications will be described below. With

these it is shown, which information should be covered by a method for a neutral exchange of

communication system engineering information.

Starting point of the investigations is the engineering process of a production system [10, 11, 12]. In this

process mainly, the mechanical and electrical engineering, control programming, virtual commissioning,

and commissioning are executed. The first two activities are executed partly in parallel resulting in a

definition of involved automation devices and their wiring. In the subsequent the control programming, the

runtime information (represented by control variables) to be exchanged between automation devices by

use of communication systems are defined. This information (variables) must be transmitted through a

communication system. In addition technical details such as data types, transmission rates, etc. are

specified.

This information is used in the electrical engineering, for example, for specifying wiring diagrams, cable

lines and to specify device configurations. This is used to setup the physical realization of the intended

data exchange. The device configurations, variable lists, and link descriptions which are created in the

control programming as well as in the mechanical and electrical construction are needed afterwards to

create the appropriate system models in the virtual commissioning.

During the commissioning the device configuration data is required, for executing the device configuration

and the variable declaration and linking description for monitoring and diagnosis.

The mentioned application describes only a small part of the relevant applications. However, it could be

seen, which information are needed to describe the modeling method:

Control applications usually consist of a set of application components. These components are

linked with each other by exchanging variable. Therefore, they need to establish logical

connections by logical interfaces (namely the corresponding exchanged variables). It is important

to identify the requirements in terms of communication properties on the exchange of data within

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the logical connections. Similarly, properties of the control application components could be

interesting such as processing times, characteristics of logical interfaces or a port number.

The individual control application components are running on different physical devices. Between

these physical devices the logical connections must be realized by the physical data exchange.

Accordingly, a physical device has interfaces for physical connections (necessary cables for

communication system realization). Additionally, it must be possible to describe the active and

passive infrastructure components such as switches, interface converters, plug, or cable types

based on the selected communication technology. In analogy to the control application parts, the

logical connections, and the logical interfaces, it must be possible to represent the properties of

the physical devices, the physical interfaces and the physical links.

In order to represent the relations between logical and physical connections, it is necessary to

map the corresponding structures at least at the used interfaces to each other.

Within the communication system information is transmitted via data packages. They represent

the mapping of variables within the data package sender to variables within the data package

receiver. Thus they shall be assigned to logical connections. Nevertheless, they are

implementation technology dependent as their header represents the physical implementation of

the communication system.

The resulting structure is shown in Figure 3.

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Figure 3: Example of the objects to be imaged

Brief overview of AutomationML AutomationML (AML) [10] is a neutral, free, open, XML based, and standardized data exchange format,

which allows a lossless data exchange within the engineering process of production systems. For that

purpose, it was not developed as a completely new format but consists of three pre-existing formats,

which were extended, adapted, and combined appropriately. By doing so, it is possible to model

production system data starting at the plant structure, over geometry and kinematics information up to

sequences and logical dependencies (see Figure 4).

PLC IO Device

Physicaldevice

Active infra-structure device

Main controlapplication

IO function

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Logical device

Logical end pointof device

Physicalconnection

with end point

Logical connection

with end points

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Wire 1

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interface

Mapping ofVariable /

Signal

interface todatagram

object

Datagramobject

PDU

PDU 1

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Figure 4: AutomationML Architecture

AutomationML stores engineering information following the object-oriented paradigm and allows the

modeling of physical and logical plant components as data objects encapsulating different aspects. An

object may consist of other sub-objects, and may itself be a part of a larger composition or aggregation.

Typical objects in plant automation comprise i) information on the plant structure (including device

hierarchy and communication structures) expressed as a hierarchy of AutomationML objects and

described by means of CAEX following IEC62424 [11], ii) geometry and kinematics represented by

means of COLLADA 1.4.1 and 1.5.0 (ISO/PAS 17506:2012) [12], iii) control related logic data by means

of PLCopen XML 2.0 and 2.0.1 [13], and iv) relations among AutomationML objects and references to

information that is stored in documents outside of the top level format.

The foundation of AutomationML is the application of CAEX as top level format. Here semantics of

system objects can be specified using role classes (RC) defined and collected in role class libraries

(RClib), interfaces between system objects can be specified using interfaces classes (IC) defined and

collected in interface class libraries (IClib), classes of system objects can be specified using system unit

classes (SUC) defined and collected in system unit class libraries (SUClib), and the individual objects are

modeled in an instance hierarchy (IH) which, in turn, may contain internal elements (IE). IEs reference

both SUCs they are derived from, RC defining their semantics, and IC used to interlink objects among

each other or with externally stored information (e.g. COLLADA or PLCopen XML files). For details on this

structure the authors refer to the different AutomationML whitepapers available at [10].

1

Top level format

CAEX IEC 62424

Plant Topology Information

Mechatronics

Networks

Devices

Attributes

Geometry

andKinematic format

COLLADA

Logic

formatPLCopenXML

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referencing

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in other XMLformat

D1 D2

Dn

IEC 62714Plant Planning

Functional engineering

Commissioning

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AutomationML is standardized within the International Electrotechnical Commission (IEC), where at IEC

62714-1 “Part 1: Architecture and General Requirements” and IEC 62714-2 “Part 2: Role class libraries”

are international standards (IS) already. The entire standard series is specified and maintained in

cooperation with the expert group “Engineering” of the Deutsche Kommission Elektrotechnik Elektronik

Informationstechnik (DKE) and the working group 9 of International Electrotechnical Commission (IEC)

sub-committee SC 65 E. The Figure 5 gives an overview about the AutomationML datasets.

Figure 5: AutomationML datasets

General communication system modeling methodology AutomationML addresses basic semantic definition based on role classes and interface classes and an

approach to derive special semantics from these roles by role inheritance, and use of roles in system unit

classes and internal elements. Therefore, the developed method for communication system modelling is

characterized by the usage of specific predefined role classes and interface classes. As indicated above,

the method has to reflect the logical and the physical topology (and its dependencies) indicated above.

Interface Class LibraryDefinition of interfaces

System Unit LibraryDefinition of reusable components

InstanceHierarchyDescription of project data

Role Class LibraryDefinition of object semantics

IH

IE

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*.dae

*.xml

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Reference toexternal data

Linking ofobjects

Instantiation ofobjects

Nutzen von Bedeutungen

Use ofsemantics

Nutzen von Bedeutungen

Use ofinterfaces

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As a first step, a <CommunicationRoleClassLib> was specified by AutomationML that contains all the

necessary semantic objects for the description of communication systems. It contains role classes that

provide the corresponding semantics for physical networks, physical devices, and physical links as well

as logical networks, logical devices, and logical connections which are derived in accordance with the

rules of AutomationML from the base role class <AutomationMLBaseRole>. In addition to this role class

library an interface class library was defined, which provides the necessary interface classes for the

modeling used to set the different objects in relation to each other. Thus, the interface classes contained

therein are intended to be used for the description of the physical and logical interfaces. The resulting

libraries are shown in Figure 6.

Figure 6: Role classes and Interface classes for communication modeling

For the practical presentation of a communication system a procedure of five steps divided into two parts

should be followed on the basis of the specific role and interface classes. The first three steps are

executed only once for an application case and the amount of communications technologies and control

applications used in it. The next two steps have to be performed for every communication system

modeled.

For a better explanation of the procedure, an example shall be used at this point. At the Application

Center Industrial Automation (INA) of the Fraunhofer IOSB in Lemgo, Germany, a learning factory is

located (see http://www.iosb.fraunhofer.de/servlet/is/22756/) which consists of different modules. The

figure 7 show one part of IOSB Application, a control is connected with two I/O devices over an Ethernet

based communication system. The I/O devices are used to connect the sensors and actuators to the

control system. The Figure 7 shows the modeled communication system.

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Figure 7: Communication System Example

At first role classes are defined that are used for the current application and communication technologies

and control example are identified that are relevant in this application. In the example, this would be the

role classes <CommunicationTechnologyXY> and <ApplicationXY>. For these the corresponding roles

are derived from each role for physical networks, physical devices and physical links as well as logical

networks, logical devices and logical connections as shown in Figure 8 below. Generally this procedure is

applicable for all conventional communication technologies such as EtherNet/IPTM, DeviceNetTM, CIP

SafetyTM, Sercos, Interbus, PROFINET®, or and for common applications such as the control of sensors

and actuators or the web-based configuration [5].

Figure 8: Roles and interface classes for the application example

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In the subsequent second step the interface classes have to be defined in the same way. Again, from the

interface classes appropriate technological and application-specific classes are derived that shall be used

later, see Figure 8 above.

Based on these role and interface classes, the physical devices, physical connections and the

corresponding logical devices and connections are modeled in appropriate system unit classes libraries

as system unit classes in the third step. To define the meaning of each component (each system unit

class) the role classes defined in the first step are used and for the connections among them the modeled

interface classes are used.

By doing so, in the example system named above three physical devices for the three control devices

each one with a physical interface, a physical device with six interfaces for the switch, and three logical

devices are the result. Similar classes result for connections which represent cables or radio links in case

of physical links. For the assignment of specific characteristics to the individual physical and logical

devices and connections as well as the interfaces located in the corresponding attributes are used.

Finally, for the communication data packages the relevant system unit classes shall be modeled

representing the exchanged sets of information on the logical connections.

The resulting system unit class libraries for the example are shown in Figure 9.

Figure 9: <SystemUnitClassLib> s for the application example

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After all the preparations for individual network modeling are met, in the fourth and fifth step, the

individual network model can be created. In doing so, at first the modeling of individual devices (network

components) takes place in the fourth step. For this purpose the various necessary physical and logical

devices are instantiated as internal elements in an appropriate topology in a corresponding instance

hierarchy. Then, all relevant parameters are assigned to describe the specific characteristics of the

devices.

In the subsequenly final steps, the devices are connected. At first internal elements are generated in the

instance hierarchy that have role classes assigned to them derived from the role classes <Physical

Network> and <Logical Network>. They serve as a container for all physical and logical connections. As a

next step, internal elements for all logical and physical connections are created by instantiating the

corresponding system unit classes and are filled with appropriate parameters. To detail the relation

between devices and connections the corresponding interfaces of both are linked by internal link objects

as a last step. The modeling results of the example are shown in Figure 10.

Figure 10: Network Description of the application example

If the connections are modeled, the exchanged communication packages are modeled by internal

elements with a communication data package role. Their interfaces will be linked to the representation of

exchanged variables within the communication devices.

The described method is a gradual approach of system design. Logical and physical networks do not

have to occur at the same time or be linked, but they can.

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EtherNet/IPTM example As mentioned in the introduction the described modeling methodology for communication systems is

applied in a research and development project at Magdeburg University to support the technology

independent engineering of communication systems. Thereby, the project will cover communication

technologies ranging from simple protocols like ModbusTM on serial line up to powerful communication

technologies like EtherNet/IPTM. The intention is to cover the complete range of technologies applicable in

factory automation as well as energy generation and distribution.

EtherNet/IPTM has been selected deliberately as the involved engineers at Magdeburg University work

within the ODVA TestLab for Europe and the protocol is on the high end of sophistication within

communication technologies. It is expected that, if the EtherNet/IPTM Protocol can be modeled then the

modeling capabilities are proven to be sufficient for all other communication technologies.

The modeling of EtherNet/IPTM networks using AutomationML is considered in the following section. It will

be shown how the object architecture of EtherNet/IPTM is translated to relevant AutomationML modeling

entities, how communication data packages are represented, and how all modeling objects are used for

individual network modeling.

To make the following representation not too complex, a simple example is selected for further

consideration in this paper. It is based on a controller and a rotary encoder device connected within one

application (see Figure 11). Both devices are running a part of a control application using the rotation

information measured by the rotary encoder. Hence, they are connected by a logical connection (orange

in Figure 11) representing the information exchange and a physical connection (blue in Figure 11)

representing the physical wire among them.

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Figure 11: Example for an EtherNet/IP Network

Starting point of the modeling of EtherNet/IPTM networks is the creation of an EtherNet/IPTM role class

library. This library is derived from the basic communication library by inheriting the roles of the

AutomationML <CommunicationRoleClassLib> as depicted in Figure 12. These roles are enriched by

classic attributes for the different entities. Thereby, for example, the physical EtherNet/IPTM device will

have attributes for the MAC address as well as the IP address.

Figure 12 <RoleClassLib> of example Network

EthernetIP

Controller

Encoder

VAR Real NumberOfRevolutions ENDVAR

EthernetCable1

VAR Real Rotation ENDVAR

Control

application

Concoder

Profile

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Similar to the role classes, Interface classes are derived for EtherNet/IPTM. As visible in Figure 13, the

different interface types can be detailed in the interface class library. For example, there are plugs and

sockets for physical wiring and request and response interfaces for logical connections. In addition the

EtherNet/IPTM datagram objects can be detailed as given with the <DeviceTypeAttribute> object to be

transmitted as part of a communication package.

Figure 13 <InterfaceClassLib> of example Network

Using the developed role and interface classes the system unit class libraries can be developed. Here it is

essential to reflect the internal structure of the EtherNet/IPTM devices given by the physical realization as

well as the internal software structure and to build up the models structure in a bottom up way.

Therefore, starting point is the development of system unit classes for device profiles representing logical

applications and associated data packages transmitted by them. Figure 14 depicts some of the developed

system unit classes and their inheritance structure. There are, for example, the basic objects within an

EtherNet/IPTM device like the identity object and the message router as well as communication packages

for single attribute request and response.

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Figure 14 <SystemUnitClassLib> of example network (Part 1)

Using these system unit classes more complex classes are developed using the defined objects as

internal structure. Figure 15 contains the developed EtherNet/IPTM explicit messaging encoder profile for

velocity information. It contains on the one hand interfaces enabling the assignment of logical connections

for client request and server response as well as the related communication packages.

Figure 15 <SystemUnitClassLib> of example network (Part 2)

As next step the physical devices are modeled. Here the modular device structure of control devices is

reflected. The EtherNet/IPTM controller, as example, contains a rack, a CPU component, IO components,

etc. and a component reflecting the logical device (in this case the control application). Figure 16 reflects

the developed system unit classes.

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Figure 16: <SystemUnitClassLib> of example network (Part 3)

Exploiting all developed system unit classes, the individual communication systems are modeled as an

instance hierarchy. Thus, in the example case the network consisting of a rotary encoder, a control

device, an Ethernet wire, and all its integrated logical components is modeled and connected. In Figure

17 the resulting hierarchy of internal elements is presented. Here the controller placed in an enclosure

and the encoder are visible. In addition there are the logical and the physical networks each containing

one connection. In the logical connection the transmitted data packages are modeled.

All of the elements are equipped with related attributes covering the special properties of the modeled

objects. Figure 18 gives the example of the EPath attribute required for address modeling within the

transmitted data packages.

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Figure 17: <InstanceHierarchy> of example network

Figure 18: Attribute representing an EPath information

Summary and Outlook

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An important part in the engineering process of control systems is related to information representing

communication systems. In order to enable a lossless exchange of engineering data between different

engineering tools the AutomationML association has developed an AutomationML based method for

communication technology independent communication system representation.

This paper has presented this modeling methodology and has shown an example of its application based

on EtherNet/IPTM communication. It has been demonstrated that the described method is applicable in

principle.

Since the initial development of the modeling methodology by the AutomationML association different

pilot applications have been considered. Main lessons learned within these application cases are the

need of a detailed modeling of the involved communication devices in their physical and logical structure

including the representation of all related data to be exchanged and all related device properties, the

increasing complexity of resulting models, and the applicability of the created models for engineering and

installation assistance by automatic generation or artifacts out of the created models.

In sum all of the application cases have shown, that the developed modeling methodology is rich enough

to model all relevant engineering information.

Keywords engineering of automation technology, industrial communications, system models, AutomationML,

EtherNet/IPTM, neutral data format,

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[7] Diedrich, Ch., Suchold, N.: Mechatronisches Anlagenmodell und die hybride Inbetriebnahme im

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****************************************************************************************************************************************************** The ideas, opinions, and recommendations expressed herein are intended to describe concepts of the author(s) for the possible use of ODVA technologies and do not reflect the ideas, opinions, and recommendation of ODVA per se. Because ODVA technologies may be applied in many diverse situations and in conjunction with products and systems from multiple vendors, the reader and those responsible for specifying ODVA networks must determine for themselves the suitability and the suitability of ideas, opinions, and recommendations expressed herein for intended use. Copyright ©2015 ODVA, Inc. All rights reserved. For permission to reproduce excerpts of this material, with appropriate attribution to the author(s), please contact ODVA on: TEL +1 734-975-8840 FAX +1 734-922-0027 EMAIL [email protected] WEB www.odva.org. CIP, Common Industrial Protocol, CIP Energy, CIP Motion, CIP Safety, CIP Sync, CompoNet, ControlNet, DeviceNet, and EtherNet/IP are trademarks of ODVA, Inc. All other trademarks are property of their respective owners.