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Reliable and highly available automation systems: PROFINET S2 system redundancy with Hilscher

What do I need system redundancy for?

Depending on the industry sector and specific application, industrial networks place very different demands on the reliability and availability of automation systems. The higher these requirements are, the more the keyword redundancy plays a decisive role: in other words, the additional availability of functionally identical or comparable resources that enable a technical system to continue to function without disruption if individual system components fail.

In the following blog post, you will learn everything you need to know about common redundancy mechanisms, S2 system redundancy in particular and how Hilscher can support you in implementing them in PROFINET networks.

Which redundancy mechanisms does PROFINET offer?
A PROFINET controller icon on top, a PROFINET device icon on the bottom. In the middle is a PROFINET icon.
S1 redundancy:

PROFINET S1 does not actually describe a special redundancy configuration, but rather the conventional PROFINET standard. This means that one IO device has a PROFINET interface that can establish a communication relationship with one controller.

Two PROFINET controller icons on top, a PROFINET device icon on the bottom. In the middle is a PROFINET icon.
S2 redundancy:

With S2 redundancy, an IO device also has exactly one PROFINET interface, which can however establish up to two communication relationships with two redundant IO controllers. Data is usually exchanged via the primary connection. However, if this connection is faulty, data is exchanged via the backup controller.

Two PROFINET controller icons on top, a PROFINET device icon on the bottom. In the middle is a PROFINET icon.
R1 redundancy:

In this configuration, an IO device has two PROFINET interfaces, each of which is connected to a controller. If the primary connection fails, the same interface does not switch to the second controller, but the IO device switches to the second interface.

Two PROFINET controller icons on top, a PROFINET device icon on the bottom. In the middle is a PROFINET icon.
R2 redundancy:

R2 system redundancy combines the approaches of S2 and R1. The IO device therefore has two PROFINET interfaces, each of which has two communication relationships to redundant controllers. Depending on the type of system error, the connection is always restored via the fastest possible communication relationship.

S2 system redundancy: the efficient all-rounder

S2 system redundancy describes a redundancy at the control level in which two redundant controllers are used to ensure the continuous operation of a system. If one of the controllers fails, the second controller automatically takes over control without any downtime. This is particularly important in industrial applications where smooth and uninterrupted operation is critical. These include:

  • Critical process automation: Industries such as oil and gas, chemicals and pharmaceuticals require high reliability and availability. PROFINET S2 redundancy ensures that in the event of a controller failure, the backup controller can take over immediately. This guarantees the continuity of critical processes without interruptions.
  • Production with high availability requirements: In the high-performance production facilities used in automotive manufacturing or semiconductor manufacturing, for example, any unplanned downtime can lead to significant losses. S2 redundancy helps to maintain a smooth production flow by seamlessly changing the controller in the event of a fault.
  • Utilities and energy sector: Power plants, water treatment plants and other utility services rely on continuous operation. S2 system redundancy ensures that even if a control unit fails, operations can continue without noticeable interruption.

Compared to the R redundancies, which enable completely separate network segments, a redundant system can be achieved using S2 system redundancy with relatively straightforward means. In this case, a device only requires one network interface, i.e. just one communication controller. This makes it possible to connect a compact field device to a high-availability system without additional hardware. This type of redundancy is already sufficient for most application scenarios in factory automation and even applies to large parts of process automation. S2 redundancy can therefore be described as the efficient all-rounder among redundancy mechanisms.

PROFINET S2 system redundancy with Hilscher

Hilscher offers a netX PROFINET firmware for device applications that require PROFINET S2 system redundancy. This means that devices that use the netX 51, netX 90 and netX 100 communication controllers and products based on them (e.g. PC cards from the cifX family or embedded modules such as netJACK or comX) as network interfaces can be integrated into redundant systems with minimal effort.

In relation to the low investment, companies benefit in many ways from upgrading their standard devices to redundant counterparts. The advantages include

  • Increased system availability: Redundancy minimizes downtime as the system automatically switches to the secondary controller if one controller fails.
  • Reduced maintenance costs: As the systems are still operational, maintenance work can be carried out without haste, reducing the cost and effort of emergency maintenance.
  • Fast recovery from faults: The automatic switchover to the secondary controller enables fast recovery from faults, which increases productivity and reduces downtime.
  • Increased safety and reliability: The use of system redundancy minimizes the risk of a complete system failure, which is particularly important in safety-critical applications.
  • Flexible adaptation to network requirements: S2 redundancy allows networks to be flexibly adapted to specific requirements and environments, providing a customized solution for various industrial applications.

By using PROFINET S2 system redundancy, companies can therefore significantly improve the availability and reliability of their production systems, leading to an increase in efficiency and a reduction in downtime costs.

 

 

 

A tray of embedded modules with a netX chip onboard in a production machine. A red gleam is seen in the background. A small golden needle for testing comes from the top pointing at the tray.
Our PROFINET controllers

Network controller for fieldbus slave and Real-Time Ethernet slave with memory controller

 

Smallest multiprotocol SoC

 

Network controller for fieldbus and Real-Time Ethernet (master and slave)

 

Our PROFINET PC cards

PC card PCI Express - Real-Time Ethernet

Communication for PC-based automation

PC card for extended temperature range PCI Express - Real-Time Ethernet

Communication for PC-based automation

PC card Mini PCI Express halfsize - Real-Time Ethernet

Communication for PC-based automation

Detached network interface Real-Time Ethernet

Communication for PC-based automation

Detached network interface Real-Time Ethernet

Communication for PC-based automation

PC card M.2 2230 Key A+E - Real-Time Ethernet

Communication for PC-based automation

PC card M.2 3042 Key B+M - Real-Time Ethernet

Communication for PC-based automation

Detached network interface Real-Time Ethernet

Communication for PC-based automation

Detached network interface Real-Time Ethernet with M12 connectors

Communication for PC-based automation

PC card M.2 2242 Key B+M - Real-Time Ethernet

Communication for PC-based automation

PC card low-profile PCI Express - Real-Time Ethernet

Communication for PC-based automation

PC card with NVRAM low-profile PCI Express - Real-Time Ethernet

Communication for PC-based automation

PC card with NVRAM Mini PCI Express - Real-Time Ethernet

Communication for PC-based automation

PC card Mini PCI Express - Real-Time Ethernet

Communication for PC-based automation

Detached network interface Real-Time Ethernet

Communication for PC-based automation

Detached network interface Real-Time Ethernet with M12 connectors

Communication for PC-based automation

PC card with NVRAM and extended temperature range Mini PCI Express - Real-Time Ethernet

Communication for PC-based automation

PC card without heat sink Mini PCI Express - Real-Time Ethernet

Communication for PC-based automation

PC card for extended temperature range Mini PCI Express - Real-Time Ethernet

Communication for PC-based automation

PC card PCI - Real-Time Ethernet

Communication for PC-based automation

PC card CompactPCI - Real-Time Ethernet

Communication for PC-based automation

PC card Mini PCI - Real-Time Ethernet

Communication for PC-based automation

Detached network interface Real-Time Ethernet

Communication for PC-based automation

Detached network interface Real-Time Ethernet with M12 connectors

Communication for PC-based automation

Our embedded modules for PROFINET

Communication module dual-port memory - Real-Time Ethernet

Flexible communication module for automation

Communication module SPI - Real-Time Ethernet Slave

Flexible communication module for automation

Communication module dual-port memory - Real-Time-Ethernet

Flexible communication module for automation

Communication module SPI - Real-Time Ethernet Slave

Flexible communication module for automation

comX Evaluation Board

Development platform for all comX types

netX 90 Chip Carrier - preloaded protocol stack

Ultracompact netX 90 design - tested and loaded completely

netX 90 Chip Carrier with an additional memory - preloaded protocol stack

Ultracompact netX 90 design - tested and preloaded completely

netRAPID H90 Evaluation Board - Real-Time Ethernet & Fieldbus

Equipped with an NRP H90-RE\F8D8

netX 51 Chip Carrier with an additional memory - Real-Time Ethernet slave

Ready-to-solder netX design in stamp format

netRAPID 51 Evaluation Board - Real-Time Ethernet

Equipped with an NRP 51-RE

netX 52 Chip Carrier incl. transformer - Real-Time Ethernet slave

Ready-to-solder netX design in stamp format

netRAPID 52 Evaluation Board - Real-Time Ethernet

 

Exchangeable Module PCI Express - Real-Time Ethernet

For mounting at any time in the delivery chain

Exchangeable module SPI - Real-Time Ethernet Slave

For mounting at any time in the delivery chain

Exchangeable module dual-port memory - Real-Time Ethernet

For mounting at any time in the delivery chain

netJACK Evaluation Board dual-port memory

For every netJACK with dual-port memory or SPI

netJACK Evaluation Board PCI Express

For every netJACK with PCI Express

DIL-32 communication IC for fiber optic cable - PROFINET IO-Device

Communication for simple slave devices with connection to fiber optic cable

DIL-32 communication IC without heat sink - Real-Time-Ethernet slave

Communication for simple slave devices without a host processor of their own

DIL-32 communication IC - Real-Time-Ethernet slave

Communication for simple slave devices without a host processor of their own

netIC Evaluation Board with fiber optic cable - PROFINET IO-Device

Evaluation platform netIC with fiber optic cable

DIL-32 communication IC for fiber optic cable - PROFINET IO-Device

Communication for simple slave devices with connection to fiber optic cable

netIC Evaluation Board - Real-Time-Ethernet slave

An evaluation platform for all Real-Time-Ethernet protocols

DIL-32 communication IC - Real-Time-Ethernet slave

Communication for simple slave devices without a host processor of their own

Our gateways for PROFINET

SPE Media Switch

Single Pair Ethernet conversion to Industrial Ethernet

Gateway CANopen to Ethernet

Cost-optimized entry level gateway for simple conversions

Gateway CC-Link IE Field Slave to PROFINET IO-Device

Data coupling between CC-Link IE Field and PROFINET

Gateway Real-Time Ethernet to DeviceNet

High-end gateway for demanding conversions

Gateway PROFIBUS DP to Ethernet

Cost-optimized entry level gateway for simple conversions

Gateway Real-Time Ethernet to Real-Time Ethernet

Data transmission between two Real-Time Ethernet networks

Gateway Real-Time Ethernet to Modbus RTU, 3964R, or Serial (ASCII / programmable)

High-end gateway for demanding conversions

Gateway DeviceNet to Ethernet

Cost-optimized entry level gateway for simple conversions

PROFINET / PROFIBUS Proxy connector

Upgrading a PROFIBUS Slave to PROFINET

Gateway Serial (ASCII) or Modbus RTU to Ethernet

Cost-optimized entry level gateway for simple conversions

Gateway Real-Time Ethernet to CC-Link Slave

High-end gateway for demanding conversions

Gateway CC-Link Slave to Ethernet

Cost-optimized entry level gateway for simple conversions

Gateway Real-Time Ethernet to Ethernet

High-end gateway for demanding conversions

Gateway Real-Time Ethernet to PROFIBUS DP

High-end gateway for demanding conversions

Gateway Real-Time Ethernet to CANopen

High-end gateway for demanding conversions

Ethernet LAN PROFINET IO-Controller

LAN-controlled PROFINET IO-Controller for the DIN rail

Ethernet LAN Real-Time Ethernet multiprotocol

LAN-controlled Real-Time Ethernet Master for the DIN rail

Gateway PROFINET IO-Device to SmartWire-DT

SmartWire-DT connectivity to Real-Time Ethernet PROFINET systems

Related links
A photo collage showcasing various Hilscher products

From turn-key products to highly integrated solutions and complementary software, Hilscher is your partner for industrial communication. Get an overview of how we can help you take the networking of your machines to a whole new level!

The inside of a factory with a conveyor belt and grey boxes. On the right side is the PROFINET logo.

PROFINET IRT not only requires short cycle times, but also deterministic behavior. Industrial networks must therefore meet certain requirements. Find out more about PROFINET IRT with netX from Hilscher here!

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Customer Center / Sales: Hilscher India Pvt. Ltd.

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