Lecture 12 Fieldbus

Lecture 12 Fieldbus 1

FAB 30203 INDUSTRIAL

NETWORKINGMuhamad Fahezal Bin Ismail

Lecturer

Industrial Automation Section

Universiti Kuala Lumpur Malaysia France Institute

[email protected]

Office location : Block A Room A 009

H/P No: 019-619 0439

Office Tel: 03-8926 2022 ext 1203/4


Network Comparison

VISIONLINE SCANBAR CODE

FLOW SENSOR

LIMIT SWPE

PROX SW

MOTIONCONTROL

DRIVES

DISPLAYSVALVESMETERS

RELAYCONTACTRPILOT LITECIR BRKR

MULTIBIT NETWORKS MULTIBYTE NETWORKS

MESSAGING NETWORKS

DEVI

CENE

T

PRO

FIBU

S DP

ETHERN

ET

LOOPCONTROL

ASI SERIPLEX

INTE

RBUS

-S CONT

ROLN

ET

LONW

ORK

S

BACNET

MO

DBUS

SERIAL I/O NETWORKS


Multibit Networks

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


AS-I Minimum Components

S lave S lave S lave

S lave S lave

P ow er S upplyM A S TE R


AS-I Topologies

star line branch lines tree

controller

M aster

contro ller

M as te r M as te r M aster

S la ve

S la ve

S la ve

S lave

S lave

S lave

S la ve

S la ve

S lave

S lave

S la ve

S lave

S lave

S lave

S la ve

S la ve

S la ve

S la ve

S laveS la ve

controller contro ller


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)• 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


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


Serial Network Applications

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


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


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


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


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


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???


Mutli-byte Networks

• Primarily Byte Oriented • Some Determinism• Pseudo Real-Time Operation• Significant Diagnostics• Low cost - Support for small Sensors • Analog Data• Simple low volume messaging• Generally No peer capabilities• Improved Src/Dst or Prod/Cons Model


DeviceNet Overview

• CAN Application Layer• DeviceNet Transports

– I/O Data– Non-Control Data

• Using– Master/Slave Communications

• Between– Devices represented by Objects


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


Other CAN Protocols

• J1939– SAE Sponsored standard– Communication between vehicle components– Peer–Peer Messaging

• CANOpen– European Community Standard– Can In Automation (CiA) specification– Wide acceptance in consumer to medical and

industrial applications


ProfiBus

• German Initiative in 1989• RS-485 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


Ethernet Application Layers

• Modbus/TCP (www.modbus.org)

• Ethernet/IP (www.odva.org)

• ProfiNet (www.profibus.com)


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


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


Ethernet/IP

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


CIP Layer Integration

C IP A pp lica tion Layer E xp lic it, I/O , R outing

A pplication O bect L ibrary

SemiDevices

PneuValve

ACDrives

PositionContro llers

O therProfilers

D E V IC E N E T C O N T R O LN E T F uture ?E ncapsulation

U P D T C PIP

F uture ?E TH E R N E TC O N T R O LN E TD E V IC E N E T

C IP

P hysica lLayer

T ransport &D ata L ink

A pplicationLayer

A pplicationLayer


Network Comparison

VISIONLINE SCANBAR CODE

FLOW SENSOR

LIMIT SWPE

PROX SW

MOTIONCONTROL

DRIVES

DISPLAYSVALVESMETERS

RELAYCONTACTRPILOT LITECIR BRKR

MULTIBIT NETWORKS MULTIBYTE NETWORKS

MESSAGING NETWORKS

DEVI

CENE

T

PRO

FIBU

S DP

ETHERN

ET

LOOPCONTROL

ASI SERIPLEX

INTE

RBUS

-S CONT

ROLN

ET

LONW

ORK

S

BACNET

MO

DBUS

SERIAL I/O NETWORKS


The Future Is Clear

ETHERNET


Ethernet Is The Future

• Industrial Automation– Discrete– Process– Sensor Bus Networking

• Building Automation• Product Categories

– Home Control & Automation– Factory Floor I/O– B2B Communications


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


Why Ethernet?NEW REQUIREMENTS

• Higher & Higher Levels of Integration• More Monitoring• More Archiving• Predictive Failures


Why Ethernet?CUSTOMERS LOVE IT

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


FIVE INFLECTION POINTS

Technology That Is Revolutionary Enough To Cause Significant Growth


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


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


IP3: Complex Adaptive Systems

• Self Organizing Peer-Peer Networks• Intelligence in Sensors & Actuators• Non-PLC Centric• Advantages:

– More Robust– More Adaptable

• Real Time Objects


IP4: WIRELESS TECHNOLOGIES

• 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

ULTRAWIDEBAND


IP5: M2M COMMUNICATIONS

BY 2010 THE INTERNET WILL HAVE TRILLIONS OF USERS

ONLY A FRACTION OF THEM WILL BE HUMAN



• 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

APPLICATIONS



• 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

MOTES



• 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

SUMMARY


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


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


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 don’t know they have

– Create Services they don’t know they need


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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Lecture 12 Fieldbus