Seminar Presentation

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The Wireless Plant of the Future by Graeme Lane
USA Sales - ELPRO Technologies www.elprotech
.com
THE WIRELESS ALTERNATIVE TO EXPENSIVE CABLING
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Instrumentation control where
is it heading?
No. of tags Information
1950 1970 1990 2010
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Instrumentation control where
is it heading?
Proliferation of information systems 4-20mA ?
Hart Marshalling cables ? FF, Ethernet Automation
? DeviceNet, Profibus et al Alarm systems ?
Pagers, SMS, email
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Instrumentation control
? Information
The largest constraint to collecting information
cost of wiring ?
wireless The largest constraint to sharing
information data incompatibility
? cleverer wireless
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Instrumentation control where does wireless
fit in now?
FT
FI
Signal Cable
Transducer
Indicator
FI
FT
Indicator
Wireless I/O
Transducer
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Factory automation where does wireless fit in
now?
Data Cable
PLC
PLC
PLC
Radio Modem
PLC
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Wireless I/O Radio modems

• Typical industrial plant or factory
• 1995 no wireless
• 2002 1 - 2 wireless applications
• 2010 100 - 200 wireless applications
• Can the radio spectrum handle this?

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Current Wireless Developments
Embedded wireless Bluetooth, Zigbee - low
power, limited range, good radio duty
factor Wireless I/O data bus interface -
900MHz, longer range, good radio duty factor,
proprietry systems 802.11 high data rates -
limited range, limited data compatibility, high
radio duty factor
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Re-cap
Instrumentation control
? Information
The largest constraint to collecting information
cost of wiring ?
wireless The largest constraint to sharing
information data incompatibility
? cleverer wireless
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Introducing . The WIB Concept Wireless
Instrumentation Backbone
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The WIB Wireless Instrumentation Backbone

• Plant-wide wireless instrumentation
• Factory-wide wireless automation
• Signal level - measured variables
• Connectivity - I/O, serial, field bus

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The WIB Structure
WIRELESS J-BOX
Field devices - Profibus, Devicenet, HART,
Bluetooth

WIRELESS J-BOX
DCS - Ethernet, Modbus, 802.11
WIRELESS NODE
WIRELESS J-BOX
Direct transducer connection
I/O - discrete, analog, pulse, t/c, RTD
WIRELESS J-BOX
Outside world - Ethernet, Internet
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Wireless J-box
WIRELESS J-BOX

• Connections for direct I/O and/or serial devices
  / field bus
• Wireless connectivity to all other J-boxes
• Converts data into neutral
• radio-friendly protocol

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Wireless I/O
WIRELESS J-BOX
I/O - discrete, analog, pulse, t/c, RTD

WIRELESS J-BOX
I/O - discrete, analog, pulse, t/c, RTD
WIRELESS J-BOX
I/O - discrete, analog, pulse, t/c, RTD
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Wireless I/O plus field interface
WIRELESS J-BOX
I/O - discrete, analog, pulse, t/c, RTD

WIRELESS J-BOX
I/O HART, Bluetooth, Zigbee
WIRELESS J-BOX
I/O - discrete, analog, pulse, t/c, RTD
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Wireless I/O plus system interface
WIRELESS J-BOX
I/O - discrete, analog, pulse, t/c, RTD

WIRELESS J-BOX
DCS Modbus Ethernet 802.11
WIRELESS J-BOX
I/O - discrete, analog, pulse, t/c, RTD
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PLC connectivity
WIRELESS J-BOX
PLC Devicenet

WIRELESS J-BOX
PLC Devicenet
WIRELESS J-BOX
PLC Devicenet
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Data bus connectivity
WIRELESS J-BOX
PLC Profibus
WIRELESS J-BOX
HMI Ethernet

WIRELESS J-BOX
PLC Devicenet
WIRELESS J-BOX
I/O HART
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Connectivity to outside world
WIRELESS J-BOX
PLC Profibus
WIRELESS J-BOX
HMI Ethernet

WIRELESS J-BOX
PLC Devicenet
WIRELESS J-BOX
Internet CDMA / GSM Email
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Put it all together WIB
WIRELESS J-BOX
INTERNET Ethernet
WIRELESS J-BOX
PLC Profibus

WIRELESS J-BOX
I/O - discrete, analog, pulse, t/c, RTD
WIRELESS J-BOX
PLC Devicenet
WIB
WIRELESS J-BOX
WIRELESS J-BOX
I/O HART
I/O - discrete, analog, pulse, t/c, RTD
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Wireless J-box Design Features
WIRELESS J-BOX

• Efficient radio communications - low density
  communications, powerful networking
• Expandability - station level, network level,
  world level
• Security - reliability hackers

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Efficient Radio Comms
ISM bands - 900MHz, 2.4GHz, 5.6GHz Compromise
- data rate vs distance in a plant/factory
environment MHz MB/sec Distance
(feet) 900 0.1 3000 2400 0.5 - 10 300
5600 1 - 100 30
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Efficient Radio Comms
A low data rate which works is better than a high
data rate which doesnt ? 900MHz Wireless
instrumentation does not require a high data
rate, but does require RF strength
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Low density communications

• Wired systems - 95 of info transfer is useless
  - polling, timed transfers
• ? Exception reporting
• Transmit on change - min. comms
• Transmit immediately on change - fastest
  response

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Communications Control

• Need extra controls to minimize traffic and
  maximize reliability
• Contention control - Listen-before-transmit,
  priorities, error-correction
• Self checking - Integrity Poll
• Adaptive messaging
• Learn from cell-phone systems

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Powerful Networking

• Peer-to-Peer Comms
• Each node can talk to any other node
• If any node fails, other nodes continue to
  operate
• Multiple comms sessions - e.g. comms A and
  comms B

A
B
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Powerful Networking Private Cellular system
Auto-routing Roaming Self-healing
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Station Level Expandability

• I/O expansion
• Seamless routing of messages for other stations
• Connectivity to high speed data buses

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Network Level Expandability

• Expandable Communications - able to communicate
  to more stations

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Is wireless safe?
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Security

• Protection against failure
• - spread spectrum band
• - unit addressing and error-checking, re-try
  features, failure alarms
• Protection against mal-operation - cross-talk
• - system addressing, data encryption
• Failure alarms - self checking system fail to
  send, fail to receive

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Security

• Protection against malicious operation
• Data encryption
• Frequency encryption
• PIN protection on configuration files

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The WIB Structure
WIRELESS J-BOX
Field devices - Profibus, Devicenet, HART

WIRELESS J-BOX
DCS - Ethernet, Modbus, ControlNet
WIRELESS NODE
WIRELESS J-BOX
Direct transducer connection
I/O - discrete, analog, pulse, t/c, RTD
Re-cap
WIRELESS J-BOX
Outside world - Ethernet, Internet
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Wireless J-box Design Features
WIRELESS J-BOX

• Efficient radio communications - low density
  communications, powerful networking
• Expandability - station level, network level,
  world level
• Security - reliability hackers

Re-cap
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Thank you for attending
www.elprotech.com