3. arc v2-wireless in process automation 2

8/8/2019 3. ARC v2-Wireless in Process Automation 2

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1 ARC Advisory Group

Wireless in Process AutomationTrends and Outlook

ETSI Board #67

13 June 2008

Wireless in Process AutomationTrends and Outlook

ETSI Board #67

13 June 2008

Harry ForbesSenior Analyst, North America

ARC Advisory [email protected]

David HumphreySenior Analyst, EuropeARC Advisory [email protected]


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ARC Advisory Group

Who Is ARC Advisory Group?Who Is ARC Advisory Group?

Strategic Advisory and Management Consulting Firm: The leader in manufacturing and logistics

Supply Chain: Sourcing to Fulfillment

Plant Systems: Production Management to Controls

Product Lifecycle Management: Design to Service

First-hand industry and application experience

Technology trends and business forecasts

Formed in 1986 22 years of growing knowledge

Enterprise to Plant Floor


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3

ARC Advisory Group

Industrial Wireless Segmentation

Which are the critical parameters?

Process Industries Wireless Market Forecast

Wireless Applications in Manufacturing

Wireless Standards organizations and efforts

AgendaAgenda


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ARC Advisory Group

Device Power Model

Replaceable battery (low-power)

Rechargeable battery

Mains power

Manufacturing Process Type

Continuous Process Manufacturing

Discrete Manufacturing

Wireless Network levelSensor level network

WLAN level network

Industrial Wireless SegmentationIndustrial Wireless Segmentation


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ARC Advisory Group

Manufacturing Process TypeManufacturing Process Type

Process AttributeContinuous Process

Manufacturing UnitDiscrete

Manufacturing Unit

Sensor types Predominately Analog Predominantly Discrete

Sensor count per unit 1000 100

Unit Physical Size 1000 Meter 10 Meter

Units per Plant 10s 100sProduction Cycle Length 100 Days 1 Day

Unit Startup Time Hours Minutes

Control Loop Time .1-1000 Sec .001-.5 Sec

Field Device Cost $1000 $100

Installation Cost/device cost 10 X 4 X

Automation Technology DCS PAC/PLC

Commonly Used DeviceNetworks

HART,Foundation Fieldbus,Profibus-PA,Ethernet

Profibus-DP,DeviceNet,Interbus,AS-i,Ethernet


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ARC Advisory Group

Process ManufacturingWireless Market ForecastProcess ManufacturingWireless Market Forecast

Size and Growth

Wireless penetration into Process Field DeviceMarket


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ARC Advisory Group

Wireless Market Growth in Process IndustriesWireless Market Growth in Process Industries

0

2 0 0

4 0 0

6 0 0

8 0 0

1,000

1,200

2 0 0 7 2 0 0 8 2009 2 0 1 0 2 0 1 1 2 0 1 2Worldwide Market for Wireless Devices in Process Manufacturing

($Millions) 2008 ARC Advisory Group


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ARC Advisory Group

Wireless Impact on Field Device Markets?Wireless Impact on Field Device Markets?


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Wireless Field Device PenetrationWireless Field Device Penetration


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Current and EmergingProcess Wireless ApplicationsCurrent and EmergingProcess Wireless Applications

Bridging

Field Process Sensing

Equipment Condition Monitoring

Advanced Metering Infrastructure (AMI)


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Wireless Cable Replacement (Bridging)Wireless Cable Replacement (Bridging)

Many commercial products

E.g. Cooper (MTL/Elpro),Phoenix Contact, ProSoft, others

Proprietary and Wi-Fi radio Optimized for longer range

Not glamorous, but veryuseful and economical


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Wireless Process SensingWireless Process Sensing

Commercial productssince 2003

Longer life now possible

More reliablecommunication

Better security

Becoming standards-based

IEEE8

02

.15

.4

HART V.7 (WirelessHART)

ISA 100


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Equipment Condition Monitoring - PresentEquipment Condition Monitoring - Present

These address assets that are NOT beingmonitored now, whichis most plant assets

ECM Application Components

Specialized Mobile Computers

Vibration Sensors

Analytical Software

Historical Data Repository

Current suppliers include:

ABB

Emerson GE/Bentley

Honeywell

SKF


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PowerGeneration

GenerationSwitchyard

TransmissionSubstation

DistributionSubstation

EndUser

Common Information Infrastructure

Advanced Metering +Demand Response

Advanced Metering:Integrates Devices at the Edge of the GridAdvanced Metering:Integrates Devices at the Edge of the Grid


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WLAN ApplicationsWLAN Applications

Mobile Operator Support

Process Operations

Maintenance, Safety, Environmental operations

Visibility During Planned Shutdowns

(turnarounds)


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Mobile Operator SupportMobile Operator Support

Initially networked via cradles

Applications

Rounds and readings

Data CaptureWork Order Generation

Condition Monitoring

Process Operations

Turnaround visibility Combines with AutoID,

and sensing

Converged with voice


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WLAN Infrastructure Trend:Discrete ManufacturingWLAN Infrastructure Trend:Discrete Manufacturing

Wi-Fi coverage becomes dense Multiple Wireless Applications

Automation

Data

Voice

Location services

Manufacturers are moving to aunified WLAN network model

Common services

Wider coverage

RF Spectrum management willbecome a part of networkmanagement practices


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WLAN Infrastructure Trend:Process ManufacturingWLAN Infrastructure Trend:Process Manufacturing

Layer 2

WLAN

Segment

Layer 2

WLAN

Segment

Bridge

or Router

.11s Mesh #1 .11s Mesh #2

Mesh

Portal


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Discrete Manufacturing Sensor Applications:ABB WISADiscrete Manufacturing Sensor Applications:ABB WISA

Commercial Product

Uses Bluetooth radio Radio only, not stack

Unique sensor power solution No batteries

Rotating magnetic field induced around machine

Well thought-out requirements for discrete manufacturingsensor use-cases Number of sensors, range, latency, reliability, etc.

FESTO has done related work using IEEE 802.15.4


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Location TrackingLocation Tracking

Technology Decision Variables

Technology

Radio type

RSSI vs. TDOA

Required Precision ofLocation

Cost ( installed cost, Total Cost of Ownership)

Possible Radios for Location Technologies

Wi-Fi (Aeroscout, Ekahau, Cisco, others)

802.15.4 (Innerwireless, others)

UWB (Zebra/Multispectral Solutions, Nanotron)


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ARC Advisory Group

Location System ArchitectureLocation System Architecture

Passive RFID Tags

Passive

Readers

Enterprise

Applications

Location Engine Appliance

Wi-Fi Tags, clients,

integrated sensors

Dual-mode

Wi-Fi /UWB Tags

UWB

Readers

ExcitersWi-Fi

Network


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ARC Advisory Group

Wireless Standards Organizationsand InitiativesWireless Standards Organizationsand Initiatives


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ARC Advisory Group

WSN Standards and TechnologiesWSN Standards and Technologies

IEEE 802

ZigBee Alliance

HART Communication Foundation

IETF

ISA

TinyOS Alliance

Bluetooth SIG

Proprietary technologies (ANT, Z-Wave, others)


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ARC Advisory Group

IEEE 802IEEE 802

802.15.4e MAC amendment to the existing standard 802.15.4-2006

to

better support the industrial markets

permit compatibility with Chinese WPAN

Suppliers do not use standard 1

5.4

MACs 15.4 TDMA (called GTS) network operation

not completely specified

802.11n

Next enhancement to Wi-Fi

802.11s

Multi-vendor Wi-Fi mesh networking

Ballots have failed so far


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ARC Advisory Group

ZigBee AllianceZigBee Alliance

Built over IEEE 802.15.4 standard ZigBee Scope

Network layer, Security, Mgmt, Profiles

Network formation

RF Channel choice

Scope equivalent to TCP/IP Suite

Too broad

Largely unsuccessful Solved the low-power

problem with:

Reduced function devices, RFDs

Mains-powered routers

Not a good fitfor manufacturingapplications

ZigBee Application focus Began with building lighting (2003)

Challenging performance requirements

Few commercial products

Now has shifted to Advanced Metering/Home Automation Networks

AMI needs wireless access to home energy controls

Utilities will want secure end-end IP connections


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ARC Advisory Group

HART Communication FoundationHART Communication Foundation

WirelessHART Part of HART Field Communication Specification, Revision

7.0

Ratified September 2007

Allows for wireless transmission of HART protocol

Based on IEEE 802.15.4 PHY with modified MAC Layer

Full mesh network topology

Adaptive frequency hopping

Time-division multiple access (TDMA)


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ARC Advisory Group

HART Communication FoundationHART Communication Foundation

Network Manager

Critical Makes all decisions

Devices can be dumb

Presently a sole-sourced technology

Dust Networks SoC and module products

2nd source of WirelessHART technology is possible

Client Device portion only, not network manager

Talk but no investment yet


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ARC Advisory Group

ISA 100ISA 100

Instrumentation, Systems, and AutomationSociety (ISA)

ISA develops standards for ANSI

ISA 100 scope includes all types of manufacturing

ISA 100.11a is first standard. Due 2009 ISA Compliance Institute

ISA began compliance function only in 2007

Compliance work for 3 important ISA standards

Wireless (ISA 100) Cyber-security (ISA 99)

Enterprise Interoperability (ISA 95)

ISA ability to execute is unproven


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IETFIETF

RFC 4944 (6LowPAN)

IPV6 over 802.15.4

ROLL Working Group

Began May 2007

Routing over low-power lossy nets

Application areas:

Industrial

Home

Buildings

Sensor Network

(Mesh, Star, or Tree)

Sensor Network Data Link Layer

IPV6 Services Layer

IPV4-IPV6 Routing

Sensor Network Gateway

IP V4

Network

IPV6

Network


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TinyOS AllianceTinyOS Alliance

TinyOS is an open-source OS for WSNs

Used for most academic WSN research

Global collaboration among academics

Not used in commercial WSN applications

RFM

Radio byte SensorSensor

MessagingLayer

clocksbit

byte

packet Radio Packet

RoutingLayer

sensing applicationapplication

HW

SW

ADC

messaging

routing

UART Packet

UART ADC


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ARC Advisory Group

Bluetooth SIGBluetooth SIG

Low Power Bluetooth (formerly Wibree)

Compatible with Bluetooth7-device PANs

ANT (Garmin) for non-Bluetooth applications


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ARC Advisory Group

Summary: Things To RememberSummary: Things To Remember

Critical Industrial Wireless Segmentations

Power use model (replaceable, rechargeable, mains)

Process vs. discrete applications

Wireless Sensor Networks vs. WLAN

Industrial Wireless Market Will Grow Rapidly

But adoption cycles and service lives are long Current wireless applications in process manufacturing:

Cable replacement

Process Sensing

Equipment condition monitoring

Mobile operator support Location tracking attractive, but far less mature

Industrial Wireless Standards

Many, many organizations are participating now


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ARC Advisory Group

Thank You.Thank You.For more information, contact the authors at

[email protected]@ARCweb.com

or visit www.arcweb.com

3. arc v2-wireless in process automation 2

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