The solution? A close and unpretentious collaboration where we put our heads together. By developing and implementing a tailored integration layer for PROFIsafe support directly into existing embedded device platform, we managed to solve the equation.
The solution was built on PROFINET, where PROFIsafe uses the underlying communication as a black-channel. By integrating the PROFIsafe safety stack on top of the RT-Labs P-Net communication stack, we could add Functional Safety without redesigning the system architecture.
In this month’s article, we share the story of this journey, from the deep technical challenges in the lab to how the solution is now approaching its final stages.
The challenge: Cracking the code in a complex stack
KK Group had purchased a standardized PROFIsafe stack from their system supplier. The methodology looked solid on paper, but the path to practical implementation turned out to be far more tangled than expected. The issue wasn’t the technology itself, but the need for deep specialist knowledge in PROFINET and the PROFIsafe stack, and how the software layers interact beneath the surface.
Testing and verification became particularly challenging, largely due to sparse documentation and limited external configuration tools.
The KK Group engineering team had already invested significant effort in understanding and addressing the integration challenges. It was clear early on that the team had a deep understanding of the system and a strong commitment to finding the right solution.
Why we succeeded together
KK Group had a clear understanding of what the system needed to achieve at the application level and played a key role in defining the practical requirements. It became the perfect combination where domain knowledge met protocol expertise.
We were facing a complex integration task where it was important to preserve the existing architecture. Working with RT-Labs gave us access to the specialized expertise needed to implement PROFIsafe without requiring an extensive redesign process.
Behind the scenes: The deep technical craftsmanship
Transforming the challenge into a stable, long-term solution required methodical, in-depth work. We divided the project into four key phases to ensure we built the right solution from the ground up without compromising system integrity :
1. A clean test environment (Sample Device)
Before touching a single line of code, we created a fully isolated and dedicated test environment from scratch. We worked through the supplier’s stack documentation, analyzed the customer’s existing integration, and set up physical lab environments with the relevant hardware tools and PLC systems. This gave us the solid foundation needed for the next step.
2. The bridge between the stacks (Integration Layer)
The heart of the solution was a smart architectural bridge. Instead of making risky changes to the existing software stacks, we extended and restructured a tailored integration layer, a robust wrapper supporting the complete PROFIsafe API. This bridge acts as a clean and well-defined interface between our P-Net stack and the external software stack. The result is a system that remains stable, isolated and easy to maintain over time.
3. Verification on two levels
Safety-critical communication leaves no room for assumptions. We therefore carried out extensive validation on two separate fronts.
Standardized testing (ETS): The official PROFINET test suite, which includes a limited set of PROFIsafe checks. This ensured full compliance with the PROFINET communication requirements.
Layer Test: A dedicated PROFIsafe test suite used by accredited labs. It provides a deeper, more PROFIsafe-focused verification of the communication layers and ensures that the integration behaves correctly even under demanding conditions.
4. Continuous quality assurance
To secure the future, we didn’t settle for manual checks. We reviewed all code in the integration layer thoroughly and established automated tests. This means the customer now has continuous quality control that flags even the smallest deviation before the software reaches the production environment.
The collaboration: Engineer meets engineer
What made this journey successful was not only our technical expertise. It was above all the quality of the practical collaboration. The work required a shared understanding of both PROFINET communication and Functional Safety.
KK Group provided the specific hardware needed, and we worked side by side in the lab to break down the tough problems and challenges that arose during testing. It became a close engineering collaboration where both teams combined application knowledge, protocol expertise, and hands-on problem-solving to address complex technical challenges. An open and constructive enabled both teams to work efficiently together towards a shared goal.
For Mathias Hedberg Hartmann, Team Lead – Customer Solutions Engineering at KK Group, the value of the collaboration was clear:
“We were facing a complex integration task where it was important to preserve the existing architecture. Working with RT-Labs gave us access to the specialized expertise needed to implement PROFIsafe without requiring an extensive redesign process.”
The collaboration between KK Group and RT-Labs was a central part of the success. Combining system knowledge, application expertise, and protocol specialization enabled the teams to deliver a robust solution.
Collaboration is the key to success
The project’s success was built on strong collaboration, openness, and a shared commitment to solving complex challenges together.
It is easy to get lost in lines of code and certificates, but in the end, collaboration is what makes the difference. The right partner, the right attitude and the willingness to solve complex problems together is what separates a challenging project from a success in production.
For KK Group, the solution made it possible to introduce PROFIsafe functionality while preserving the existing architecture. By avoiding a complete redesign, the team reduced implementation risk and established a maintainable foundation for future development.
In the end, this project showed that PROFIsafe can be retrofitted without rebuilding the entire system, if the right expertise and a strong collaborative mindset are in place.
Do you have a project that requires deep technical expertise in industrial communication?
Get in touch and tell us what you are working on, and let’s take the next step together.
