IOLink Safety Digitalization down to smallest functional safe

IO-Link Safety Digitalization down to smallest functional safe Sensors/Actuators/Mechatronics "Event" "Presenter's name"

Overview • • • Status of IO-Link and Basics What is OSSDe all about? Fieldbuses and Functional Safety Communication Profiles (FSCPs) Requirements of Customers and Manufacturers Why a new safe communication profile? What did we achieve? Integration into FSCPs Test & assessment Development support © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 2

IO-Link CURRENT STATUS © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 3

11, 4 million IO-Link nodes by end of 2018 © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 4

The IO-Link Story("V 1. 1. 3") PLC/FS-PLC/OPC-UA Internet, IT, Browser Fieldbus integration IEC 61131 -9 Fieldbus controller Webserver OPC-UA Gateway Application Fieldbus interface UDP Gateway Application GA Master Tool (IODD; Firmware Update) Standardized Master Interface (SMI) Master / FS-Master / W-Master Port Air interface "Port" Data storage IO-Link Device Application IODD Engineering Tool Ethernet e. g. XML, JSON Embedded controller: e. g. Drive Parameter server FS-Device Application IODD © 2019 Copyright IO-Link Community IODD Air interface Dedicated Tool W-Device Application IODD Pairing button IO-Link Safety Technology @ "Event", "Date" "Presenter's name" IODD Finder 5

IO-Link BASICS © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 6

IO-Link Topology (Point-to-Point) Master Unshielded cable L+ (24 V) Port 1 (Class A) C/Q (Signal) Device L- (0 V) L+ (24 V) Upper level system Port 2 (Class A) C/Q (Signal) Device L- (0 V) . . . Maximum 20 m © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 7

Port Class A and B Class A (Device) 2 1 3 4 I/Q Master Power 1 power supply C/Q 3 4 5 M 12 -4 Isolated from Power 1 Class B (Device) 2 P 24 (Actuator) Master 1 2 1 3 4 C/Q 3 5 4 M 12 -5 © 2019 Copyright IO-Link Community Power 1 power supply Power 2 extra power supply 5 N 24 (Actuator) IO-Link Safety Technology @ "Event", "Date" Class B Ports shall be marked unambiguously "Presenter's name" 8

Class A Power Supply (Master and FS-Master) ISM ISIRM min ISM min 1000 m. A (current limit for IO-Link Safety) 400 m. A 200 m. A Unspecified behavior Master can provide higher currents Minimum current of the Master port 50 ms © 2019 Copyright IO-Link Community t IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 9

SIO (Standard Input/output) to IO-Link communication L+ Switching signal ("SIO") 1 2 I/Q 4 C/Q 3 SIO COMx 4, 8 / 38, 4 / 230, 4 kbit/s IO-Link communication L- "Coded Switching" © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 10

SIO to OSSDe and Functional Safety Communication IOL-OSSDe OFF state Testpulses L+ IOL-OSSDe: Equivalent signals OFF state 1 2 I/Q 4 C/Q 3 IOL-OSSDe COMx 4, 8 / 38, 4 / 230, 4 kbit/s IO-Link Safety communication L- AIDA compatible! © 2019 Copyright IO-Link Community OSSD: Output Switching Sensing Devices (Solid state outputs) OSSDe: = OSSD with equivalent switching signals; type C, class 1 according to Position Paper CB 24 I (ZVEI) IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 11

Basic Start-up Procedure of IO-Link Communication, Identification Power-on OPERATE STARTUP Standard Input/Output (SIO/OSSD) Cyclic Process Data exchange © 2019 Copyright IO-Link Community Configure, Parameterize IO-Link Safety Technology @ "Event", "Date" PREOPERATE "Presenter's name" 12

IO-Link Safety UPPER LEVEL SYSTEMS (FIELDBUS & FSCPS) © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 13

Functional Safety Communication Profiles (FSCP) FSCP 3 FSCP 1 FSCP 2 FSCP 6 FSCP 18 Non-IEC "A" Non-IEC "C" FSCP 12 FSCP 13 FSCP 14 FSCP 17 FSCP 8 IEC 61784 -3 -x: Collection of FSCPs © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 14

"Black Channel" Architecture of FSCPs Application FSCP Fieldbus Application FSCP RIO-Gateway Fieldbus Application FSCP Fieldbus "Black Channel" © 2019 Copyright IO-Link Community Application FSCP Fieldbus "Safety Technology" "Safety Layer" FSCP Message IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 15

Safety Function (Example) FS-PLC Light Curtain Drive & Remote I/O FS-DI Channel User Program E-Stop © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 16

IO-Link Safety CURRENT SITUATION WITH FSCPS © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 17

Manufacturer's Situation FS-PLC Safety controller (FS-PLC) Fieldbus / FSCP Remote I/O with FS modules FS-DI FS = functional safety PLC = programmable logic controller © 2019 Copyright IO-Link Community Redundant signal lines e. g. Emergency Stop IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 18

Customer's Situation • Machine builder decides on type of fieldbus to be used depending on deployment case • Thus, specific devices for each fieldbus with separate spares inventory, version maintenance and service are required • Thus, high degree of persistence to stay with "classic" interfaces such as OSSD, 4 to 20 m. A, and etc. on "remote IO" field devices, since they are independent from fieldbus • However: no connection to Internet-of-Things (Io. T) and Industry 4. 0 • Numerous new applications: (see "Smart Manufacturing") - New sensor technologies, e. g. strain, torque, pressure, multi-sensing, and etc. - More measuring sensors, e. g. object types, distance - Mechatronics, e. g. combinations sensors/actuators • Progressive miniaturization © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 19

IO-Link Safety as a Solution Fieldbus with one of the FSCPs (IEC 61784 -3) Remote I/O AI AO DI FS-Master DO 0 0 0 0 7 7 7 7 e. g. 0 to 10 V Analog measurements OSSD Switches © 2019 Copyright IO-Link Community IO-Link Safety PM switching Relays Digitized measurements IO-Link Safety Technology @ "Event", "Date" OSSDe or COM "Presenter's name" Intelligent drives 20

Automation "hierarchy" with IO-Link Safety PLC Level (Functional Safety) Higher-Level Systems Fieldbus Level with IO-Link FS-Master (mapping and/or local processing) Enabling New Markets safety SIO Mode OSSDe Mode Devices © 2019 Copyright IO-Link Community Sensor / Actuator / Mechatronic Level with IO-Link Safety FS-Devices safety IO-Link Devices a Worldwide Standard Valves | Locking Units | Light Curtains IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 21

"Off-Site" Parameterization and Test (OSSDe) Off-site configuration & parameterization Fieldbus Remote IO F-DI Modul FS-Master 0 0 7 7 "USB Master" Tool software with safety IODD USB OSSDe FS-Device "USB-Master" Parameter FS-Device Test History © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 22

Migration Strategy (example: PROFIsafe) Fieldbus (FSCP) PROFI safe 1999 IEC 61784 -3 -3 F-DI FS-Master Develop… Connect… FS-Master Remote IO F-Device Remote IO Connect… (Subset) and others… Connect… Develop… IO Level ("OSSD") IO-Link Safety 2018 F-Sensor OSSD © 2019 Copyright IO-Link Community ZVEI CB 24 I IO-Link Safety Technology @ "Event", "Date" FS-Device New: OSSD + communication "Presenter's name" 23

IO-Link Safety COMMUNICATION © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 24

Specifications and Assessment Reports © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 25

"Black Channel" Principle also with IO-Link Safety application Gateway FSCP (e. g. PROFIsafe) Standard application, e. g. Diagnosis Standard Safety application, e. g. Diagnosis IO-Link Safety Device (Stack) Master (Stack) Safety Communication Layer (SCL) IO-Link ("Black Channel") Point-to-point communication © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 26

Messages with IO-Link Safety CRC Signature Non-safety Process Data Out 32 to 0 octets From FS-Device: Safety Process Data In 2/4 octets From FS-Master: Control & M-Counter Port number Safety Process Data Out 1 octet 3/25 octets Port Number Status & D-Counter CRC Signature Non-safety Process Data In 1 octet 2/4 octets 32 to 0 octets 3/25 octets © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 27

Start-up and Securing Measures Communication, Identification SIO / OSSDe Cyclic Process Data exchange Configure, Parameterize Parameter verified? Start safety communication (SCL) © 2019 Copyright IO-Link Community • • • Safety parameter verification (Verify. Record) Misconnection? (Authenticity/Port check) Replacement? (Data Storage if "out-of-the-box") IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 28

IO-Link Safety INTEGRATION INTO FSCPS © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 29

Integration Objectives of IO-Link Safety FSCP 3 RIO FS-DI FSCP 2 Ethernet-based "Classic fieldbus" FS-Master 3 Switches, OSSDe FS-Device RIO FS-DI FS-Master 2 "One" safety device with OSSDe and IO-Link Safety communication RIO = Remote I/O RIO FS-DI FS-Master 12 RIO FS-DI "Classic fieldbus" Ethernet-based FSCP 12 © 2019 Copyright IO-Link Community FS-Master 8 FSCP 8 IO-Link Safety Technology @ "Event", "Date" Ethernet-based "Presenter's name" 30

Prospects FSCP A RIO FS-DI FSCP B Ethernet-based "Classic" IOL-S RIO IOL-S FS-DI Local signal processing Dual mode FS-Device (OSSDe) FS-Device Largest commonality for sensors, actuators, and mechatronics Port Class B RIO FS-DI IOL-S "Classic" Ethernet-based FSCP C © 2019 Copyright IO-Link Community Ethernet-based FSCP D IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 31

Integration In progress: PROFINET / PROFIsafe PROFINET Integration White Paper Role model for Fieldbus / FSCP White Paper Available on: www. io-link. com © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 32

System Overview (PROFINET / IO-Link) Engineering System IO controller IO supervisor PROFINET domain PNIO PROFINET/PROFIsafe GSD (IO device) IO-Link PDCT IO device Linking Module (B) "safety" IOLink IODD (Device, FS-Device) FS-Master IOLink Port 1 Port 2 Port 4 Port 3 Off-site commissioning © 2019 Copyright IO-Link Community FS-Devices/Devices IO-Link Safety Technology @ "Event", "Date" "Presenter's name" IO-Link domain 33

Safety is Linear Extension of Fieldbus Integration (Example PN) PROFIsafe development kit PROFIsafe services + Protocol state machine PROFINET PROFIsafe Gateway: PROFINET IO-Link Integration ("Linking Modules") FS-IO mapping IO-Link Safety (COM) FS-DI (OSSDe) IO-Link Safety services + Protocol state machine Standardized Master Interface (SMI) Configuration Manager (Parameter) Data Storage Acyclic Data Exchange PROFIsafe ‒ IO-Link Safety Gateway Splitter/Composer Diagnosis Unit IO-Link Safety Cyclic Process Data Exchange Master layers FS-Device © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 34

IO-Link Safety TEST & CERTIFICATION © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 35

Test & Assessment • Step 1 is achieved: Draft V 1. 0 with SCL + OSSDe • Step 2 Draft V 1. 1 comprises the complete tests Content: • OSSDe • FS-Device functions • FS-Master functions • SCL tests (automated test script generation) • FS-Master Tool tests • Assessment & certification SCL = Safety Communication Layer © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 36

Automated Test Case Generation Sequence charts © 2019 Copyright IO-Link Community IO-Link Tester IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 37

FS-Master Tester Fieldbus Initialize FS-Master, and Activate test mode, and Power. OFF/ON e. g. USB SMI FS-Master (EUT) Mapper FSCP UT © 2019 Copyright IO-Link Community FS-Master. Tester-HW SPDU IOL-Safety Fieldbus. Interface Non safety part used as "test control channel" to "UT" SPDU IO-Link Test. FW Message IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 38

FS-Master Tester (without fieldbus dependency) Fieldbus layers / Ethernet FS-Master FSCP FS mapping Gateway IO-Link/PROFINET IO-Link Safety Standardized Master Interface (SMI) FSCP Test Temporary test signal channel (part of the safety implementation) Master layers SPDU Test signal data IO-Link safety Test FS-Master Tester © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 39

FS-Device Tester e. g. USB FS-Device (EUT) FS-Device. Tester IO-Link © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 40

Assessment & Certification (FS-Device or stand-alone FS-Master) IO-Link partner starts developing an FS-Device or stand-alone FS-Master Availability, immunity and electrical safety (IO-Link) Immunity (EMC) + E-safety • EMC test • Electrical safety check Functional Safety Conformance (IEC 61508) Interoperability (IO-Link) • IO-Link Vendor. ID • Basic IO-Link Device test ("black channel") Test of FS-Device (SCL + opt. OSSDe) "Test standard" Test Center (fulfills Testlab instructions): Test of FS-Device (SCL + optionally OSSDe) "Reference standard" • Safety assessment by Assessment Body • Optionally: Role of the Test Center Corrections not passed Test and check successfully passed + Assessment successfully passed IO-Link manufacturer declaration Including certificate number © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" Certificate from Assessment Body "Presenter's name" 41

Assessment & Certification (FS-Master on Fieldbus/FSCP) IO-Link partner starts developing an FS-Master Availability, immunity and electrical safety (Fieldbus and IO-Link) Immunity (EMC) + E-safety • EMC test • Electrical safety check Functional Safety Conformance (IEC 61508) Interoperability (Fieldbus and IO-Link) • Prove Fieldbus and FSCP conformity • IO-Link Vendor. ID • Basic IO-Link Master test ("black channel") Test of FS-Master (SCL + opt. OSSDe) "Test standard" Test Center (fulfills Testlab instructions): Test of FS-Master (SCL + optionally OSSDe) "Reference standard" • Safety assessment by Assessment Body • Optionally: Role of the Test Center Corrections not passed Test and check successfully passed + Assessment successfully passed IO-Link manufacturer declaration Including certificate number © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" Certificate from Assessment Body "Presenter's name" 42

IO-Link Safety DEVELOPMENT SUPPORT © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 43

Technology Provider • "Development Support" • "Functional" versions for FS-Device and FS-Masters are already available (no SIL). • Developers can implement without waiting on an "official" counterpart of the market FS-Master FS-Device Dev. FS-Device FS-Master Dev. • "Starterkits" • "Functional safety" versions will show up FS-Master + Tool • Safety development with support from assessment bodies • Pre-certified "SCL-driver" software for up to SIL 3/PLe, assessed on one HW, Cert. Driver • Architecture, design, and testing according IEC 61508/ISO 13849, • Implementation µC independent (ANSI-C? ) and according MISRA (2012) standard, • Product and marketing strategy depending on technology provider © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 44

What's next? • Finalization of the Test Specification in fall 2019 (Draft for WG-Review; dependancy on V 1. 1. 3 test • FS-Master and FS-Device-Tester in 3 rd quarter of 2019 • "White Paper" to be incorporated in Integration Specification PROFINET/PROFIsafe Ed. 2 • Encourage and enable other FSCP integrations (FSo. E, CIP-Safety, and etc. ) • IO-Link Safety workshop on 9 th and 10 th of October 2019 • Certified designer training classes starting in spring 2020 • Investigations on IO-Link Safety protocol extensions for IO-Link wireless (HS University, Hamburg) © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 45

Working Group Members © 2019 Copyright IO-Link Community IO-Link Safety Technology @ "Event", "Date" "Presenter's name" 46

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