Industrial Automation Networking 2004

1
Industrial Automation Networking 2004 Beyond

• John S. Rinaldi
• Real Time Automation
• June 9, 2004
• www.rtaautomation.com

2
Housekeeping

• Turn off all Cell Phones, Pagers
• Questions are welcomed at any time
• Todays Slides See www.rtaautomation.com
• See Sensors Expo People about Environmental
  Issues
• This session doesnt require a lot of networking
  knowledge

3
Todays Presentation

• Where We Are Today
• Where Are We Going?
• Five Critical Inflection Points
• What All This Means to Organizations, Business
  Models Products/Services That We Deliver

4
Some Very Good Company!

• "I'm just glad it'll be Clark Gable who's falling
  on his face and not Gary Cooper."
• -- Gary Cooper
• "Heavier-than-air flying machines are
  impossible." -- Lord Kelvin, president, Royal
  Society, 1895.
• "I think there is a world market for maybe five
  computers."
• -- Thomas Watson, 1943.

5

• "Computers in the future may weigh no more than
  1.5 tons."
• -- Popular Mechanics, 1949
• "There is no reason anyone would want a computer
  in their home."
• -- Ken Olson, founder of DEC, 1977
• "640K ought to be enough for anybody."
• -- Bill Gates, 1981

6
Network Comparison
MOTION CONTROL
VISION LINE SCAN BAR CODE
DRIVES
LOOP CONTROL
DISPLAYS VALVES METERS
FLOW SENSOR
RELAY CONTACTR PILOT LITE CIR BRKR
LIMIT SW PE PROX SW
MULTIBIT NETWORKS
MULTIBYTE NETWORKS
SERIAL I/O NETWORKS
MESSAGING NETWORKS
ASI
SERIPLEX
7
Multibit Networks

• Direct hardwire replacements
• High Speed
• Low data capacity
• Discrete oriented No Analog
• No Diagnostic Data

8
AS-I Minimum Components
9
AS-I Topologies
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AS-Interface

• Best for binary devices like limit switches,
  photoeyes and prox switches
• 15-40 Cost Reductions possible
• AS-I ASIC provides network access
• 1 Master, 31 Slaves (62 in V2.1)
• 4DI, 4DO per Node (248 I/O Max)
• 100M Length total (Yellow Cable)

11
AS-Interface (continued)

• Tree, Line, Star and other topologies
• 100M Length total (Yellow Cable)
• Integrated Data and Power
• 5ms Cycle time with all 31 slaves
• Nodes commissioned offline or by Master
• Flat Round Cabling

12
Serial I/O Networks

• Uart oriented - 232/422/485
• Low Cost Implementation
• Usually Efficient for Messaging
• Low Speed - Not Real Time
• Source/Destination Network Model
• Proprietary or Open Standard

13
Serial Network Applications

• Chart Recorders
• Scales
• Drives
• Barcode Readers
• RF Readers
• Tank Farms
• Waste Water Plants

14
MODBUS

• 1960s Technology
• Simple, Concise Communication strings
• RS232/422/485 Physical Layers
• Devices modeled as Registers Coils
• Well-defined instruction set
• 1 Master, 254 Slaves
• Low Cost implementation

15
MODBUS (Continued)

• Coil/Register Network Representation
• Asynchronous Comms 232/422/485
• Low Speed - Not Real Time
• 247 Nodes Max GT 10 is problematic
• You can roll your own
• No formal certification
• Promoted by Groupe Schneider

16
MODBUS (Continued)

• Advantages
• Open Widely Distributed
• Clear/Concise Command Set
• Large Installed Base
• Low Cost Implementation
• Disadvantages
• Source/Destination Network Model
• Very difficult to Troubleshoot

17
MODBUS Summary

• All devices should support Modbus
• Handy tool for configuration
• Most customers can use it
• Easy access to gateways for other networks
• Free Tools on the web
• Increase Market penetration

18
Serial Network Limitations

• Insufficient Electrical Standards
• Most Proprietary Protocols
• Susceptible to Noise problems
• Grounding issues

• Termination problems
• Configuration Issues
• Performance Limitations
• Very difficult to troubleshoot
• Future Support???

19
Mutli-byte Networks

• Primarily Byte Oriented
• Some Determinism
• Pseudo Real-Time Operation
• Significant Diagnostics
• Low cost - Support for small Sensors

20
Mutli-byte Networks (Cont.)

• Analog Data
• Simple low volume messaging
• Generally No peer capabilities
• Improved Src/Dst or Prod/Cons Model

21
DeviceNet Overview

• CAN Application Layer
• DeviceNet Transports
• I/O Data
• Non-Control Data
• Using
• Master/Slave Communications
• Between
• Devices represented by Objects

22
DeviceNet Characteristics

• Trunkline with Drops
• 64 Nodes
• Multiple Masters
• Node Removal/Insertion under power
• Cable includes Power and Data
• 125K, 250K and 500K Baud Rate
• Future Direction ESTOPs/Redundancy

23
Other CAN Protocols

• J1939
• SAE Sponsored standard
• Communication between vehicle components
• PeerPeer Messaging
• CANOpen
• European Community Standard
• Can In Automation (CiA) specification
• Wide acceptance in consumer to medical and
  industrial applications

24
ProfiBus

• German Initiative in 1989
• RS485 based communications
• Profibus ASIC contains stack, MAC
• Multiple versions DP, FMS, PA
• 127 Nodes, 1000M
• 244 Bytes/Message, 12Mbaud
• Master/Slave Polling type Network
• Supported by Profibus Trade Organization

25
Ethernet Application Layers

• Modbus/TCP (www.modbus.org)
• Ethernet/IP (www.odva.org)
• ProfiNet (www.profibus.com)

26
Modbus/TCP

• Base message structure is Modbus
• Identical Register/Coil Network Architecture
• Simple to implement
• Off-the-shelf tools available
• Supported by many HMIs, PLCs
• Simplicity is greatest weakness strength

27
Modbus/TCP (Cont.)

• Strengths
• Application Layer on TCP/IP
• Easily implemented
• Concise Messaging
• Modbus widely used and understood
• Weaknesses
• Little/No interchangeability
• Limited data types
• Data transfer size limitations

28
Ethernet/IP

• CIP (DeviceNet Object Model) on Ethernet
• Significant Vendor Support
• Vendor Driven Architecture
• Sponsored by ODVA
• Compatible with DeviceNet ControlNet

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CIP Layer Integration
30
CSIRO Mining
31
Network Comparison
MOTION CONTROL
VISION LINE SCAN BAR CODE
DRIVES
LOOP CONTROL
DISPLAYS VALVES METERS
FLOW SENSOR
RELAY CONTACTR PILOT LITE CIR BRKR
LIMIT SW PE PROX SW
MULTIBIT NETWORKS
MULTIBYTE NETWORKS
SERIAL I/O NETWORKS
MESSAGING NETWORKS
ASI
SERIPLEX
32
The Future Is Clear

• ETHERNET

33
Ethernet Is The Future

• Industrial Automation
• Discrete
• Process
• Sensor Bus Networking
• Building Automation
• Product Categories
• Home Control Automation
• Factory Floor I/O
• B2B Communications

34
Why Ethernet?

• TRENDS IN SILICON
• ARM Controllers Prices Continuing to Fall
• Increased Functionality
• On board MACs
• On board Phys, RAM ROM
• Smaller Footprints
• ARM Controllers are the new 8051 Workhorses

35
Why Ethernet?

• NEW REQUIREMENTS
• Higher Higher Levels of Integration
• More Monitoring
• More Archiving
• Predictive Failures

36
Why Ethernet?

• CUSTOMERS LOVE IT
• Comfort Level
• Readily available components
• Less Training
• Believe it is low cost
• Standard Tools
• Standard Methodologies Networking

37
Questions???

• How Fast Will This Happen?
• Will It Really Replace Profibus DeviceNet?
• What Ethernet Application Layers will dominate?
• What Do We Do In The Short Term?

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FIVE INFLECTION POINTS

• Technology That Is Revolutionary Enough To Cause
  Significant Growth

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IP1 WEB SERVICES

• Standard Technology for transferring information
  and data between business systems
• Complexity of data and any protocols are hidden
• Systems share data No Custom Programming
• Request-Response Model with published interfaces
• Applications describe them selves to the network
• Firewall Friendly
• Based on XML, SOAP and HTTP

40
IP1 WEB SERVICES

• XML eXtensible Markup Language
• Describes Data Using Tags
• Tags are user-defined
• Designed to be self descriptive

lt?xml version"1.0" encoding"ISO-8859-1" ?gt
lt!-- Edited with XML Spy v4.2   --gt - ltnotegt  
lttogtTovelt/togt   ltfromgtJanilt/fromgt  
ltheadinggtReminderlt/headinggt   ltbodygtDon't forget
me this weekend!lt/bodygt   lt/notegt
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IP1 WEB SERVICES

• SOAP Simple Object Access Protocol
• Platform Language Independent
• Protocol based on XML
• Replaces RPC

lt?xml version"1.0"?gt ltsoapEnvelope
xmlnssoap"http//www.w3.org/2001/12/soap-envelop
e" soapencodingStyle"http//www.w3.
org/2001/12/soap-encoding"gt ltsoapHeadergt
... ... lt/soapHeadergt
ltsoapBodygt ... ... ltsoapFaultgt
... ... lt/soapFaultgt lt/soapBodygt
lt/soapEnvelopegt
42
IP1 WEB SERVICES
APPLICATIONS

• Amazon
• Retrieve Product Data
• Process a User Style Sheet
• Google
• Semiconductor Tooling

43
IP2 MEMS NEMS

• MEMS
• Miniature Turbines, Motors, Gears, Mirrors
• Sensors Actuators Integrated on Silicon
• Extremely small footprint and low cost
• NEMS
• Ability to build products at the atomic level
• No bending, shaping and grinding

44
MEMS APPLICATIONS
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DIVING HEADS UP DISPLAY

• Silicon Microstructures
• Diving Mask
• Pressure
• Depth
• Time Underwater
• Tire Pressure System

46
IP3 Complex Adaptive Systems

• Self Organizing Peer-Peer Networks
• Intelligence in Sensors Actuators
• Non-PLC Centric
• Advantages
• More Robust
• More Adaptable
• Real Time Objects

47
PROFInet

• PROFInet CBA
• IMAP Component Modeling Tool
• Supports PROFInet, Profibus, Interbus-S Devices
• No PLC Required
• PROFInet RT
• 10msec Response
• Eliminates TCP, IP Layers
• PROFInet IRT
• lt250msec Response

48
IP4 WIRELESS TECHNOLOGIES
ULTRAWIDEBAND

• Hundreds of Megabits per sec within 10 meters
• Every device with a micro may be UWB-enabled
• Applications
• Automatic/continuous logging of patient data
• Self-Correcting Clocks
• Microwaves with downloadable recipes
• Other Techs Zigbee/Mesh Networking

49
IP5 M2M COMMUNICATIONS

• BY 2010 THE INTERNET WILL HAVE TRILLIONS OF USERS

ONLY A FRACTION OF THEM WILL BE HUMAN
50
IP5 M2M COMMUNICATIONS
APPLICATIONS

• Monitor Every Orange Tree In Florida
• Identify Problem Pumps by Vibration Data on 4K
  Pumps per Facility at Intel
• Study Humidity Temp of Redwood Trees
• Monitor 18,000 Petrel Nests off Maine
• Security Systems for Ship/Air Containers
• Monitor Movements of Golden Gate Bridge

51
IP5 M2M COMMUNICATIONS
MOTES

• Integrated Sensors Radio Transceivers
• Tiny, Slow Microprocessors
• Small, Custom OS called TinyOS
• 99 Off Time Only A Few Millionths of Watt
• Battery or Solar Powered
• Mesh Networking
• EXTREMELY INEXPENSIVE

52
IP5 M2M COMMUNICATIONS
SUMMARY

• Automatic Communications Between Devices over the
  Internet without Human Intervention
• Opportunity for much more business control over
  machine operation to get financial benefits
• 5Billion to 200Billion
• Huge New Opportunities in Business, Environment,
  Security, Consumer Markets

53
IP5 M2M COMMUNICATIONS

• Revenue is not in the technology or the
  applications
• but the services provided

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WHERE DO WE GO FROM HERE?

• TRENDS
• Increasing Product Complexity, More Innovation
• Faster Time-to-Market
• Vastly More Data Archiving
• More Automatic Continuous Monitoring
• Global and Decentralized Operations
• Virtual Enterprises

55
RECOMMENDATIONS

• Make Ethernet-enabled Products NOW
• Support EtherNet/IP, MB/TCP and PROFInet
• Use IDEs, Operating Systems and full integrated
  Ethernet networking as base platform
• Expect Security to become much more of an issue
• Avoid NIH Syndrome now more than ever

56
RECOMMENDATIONS

• More, Better Training
• Multi-disciplinary, Cross Functional Teams
  (combine IT and Controls)
• Prepare for high levels of integration with
  suppliers customers using Web Services
• Innovate
• Solve Problems your customers dont know they
  have
• Create Services they dont know they need

57
REAL TIME AUTOMATION

• M2M Monitoring Products
• Sensor Bus Networking
• DeviceNet
• Profibus
• Ethernet Networking
• Software
• Board Level Gateways
• Add On Daughter Cards

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