wireless applications at machine level in industrial automation bruno forgue – emea marketing...
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Wireless Applications at Machine Level in Industrial AutomationBruno FORGUE – EMEA Marketing Manager
ETSI #67 - The Wireless Factory13 June 2008
June 13 2008 - ETSI - 2
The Wireless FactoryWireless at Machine Level
Introduction• Typical factory data communication model• Devices and protocols• Wireless for industrial automation
Who is ProSoft Technology?• Communication solutions for industrial automation• Application and support oriented company
Why do customers ask for wireless?
Application examples
Conclusion
June 13 2008 - ETSI - 3
Introduction: Typical Factory Data Communication Model
Information Technology Dept.
Control room
PLC ControllersSensors
ActuatorsOperator interfaces
PCsHMI software
IT SystemsERP software
Plant floorMachinesIndust. Automation
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 4
Introduction:Devices and Protocols
Equipments to be connected are:• Programmable controller: the CPU which controls the machine• Operator interface: for interaction between human and machine• PC: configuration, programming , maintenance…• Sensors: convert a physical variable to current or voltage (detect /
measure process information to bring to the CPU)• Actuators: convert a command to power (motors, valves, heater…
controlled by the CPU)• …
Equipment 1 Equipment 2Communication
Industrial Communication
Protocols Profibus… EtherNet/IP… Modbus… DF1… ControlNet…
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 5
Introduction: Wireless for Industrial Automation
…to wirelessly connect business system to the control system
…to wirelessly connect business system to the control system
… to wirelessly access remote plants or stations
… to wirelessly access remote plants or stations
…to wirelesly connect remote racks of I/O …to wirelesly connect remote racks of I/O
…to wirelessly link PLCs for messaging…to wirelessly link PLCs for messaging
… to wirelessly program, configure, &
monitor the system
… to wirelessly program, configure, &
monitor the system
Diagram courtesy of Rockwell Automation© 2005 Rockwell Automation
… to wirelessly connect HMI to
controllers and devices
… to wirelessly connect HMI to
controllers and devices
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
… to wirelessly connect I/O devices, sensors and actuators.
… to wirelessly connect I/O devices, sensors and actuators.
June 13 2008 - ETSI - 6
Who is ProSoft Technology?Communication Solutions
Modbus Plus
Profibus DP
…
…
ASCII/Serial
IEC 60870-5-101
IEC 60870-5-103
DNP 3.0
HART
DE
ASCII/Ethernet
Modbus TCP/IP
IEC 60870-5-104
DNPSNET
……
…
Modbus
Integrate to non-native protocols into the architecture
Wireless
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 7
Communication Solutions for industrial automation“Where Automation Connects”
More than 20 years of experience• Industrial Automation• Industrial Protocols• Industrial Wireless
In partnership with • Rockwell Automation, • Schneider Electric • and other automation and process control leaders
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 8
Who is ProSoft Technology?Application Oriented Company
Bringing innovation• Industrial wireless
Unique family of high performance solutions
• Interface gateways High-speed gateways
• In-rack modules PLC processor has direct access to memory via backplane
Benefits for Customer• High performances!• Ease of implementation!• Unequaled Technical Support
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 9
Who is ProSoft Technology?Support Oriented Company
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 10
Why do customers ask for wireless?
Installation
Maintenance
Operation cost reduction
Flexibility
Moving & Rotating equipments
Distance
Reliability
…
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 11
WarehouseIntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 12
Logistic – Material handling
Moving parts
Remove data cables from flexible cable runways
A lot of metal frames
Metal moving parts (cabinets between rows of the warehouse)
Reliability, availability (moving cabinet must not loose connection when at stop points).
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 13
ManufacturingIntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 14
OVEN 1
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OVEN 8
ManufacturingIntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 15
Steel foundryIntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 16
CokingIntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 17
CokingIntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 18
Wood Ladder
A1
B1
a1
b1
660 m
Heavy loads handlingIntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 19
Heavy load handling
Anti-collisions system for heavy load handling With two cranes – application fail-safe in event one crane
Loses power
Allow two portal cranes to work independently and simultaneously while sharing a common rail track
Monitoring and control of Ethernet drivesLarge number of multicast producer consumer packets per drive
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 20
Material handling
No more collisions• Protects mechanical installation
against potential damages• Avoid collisions
and repair costs
Increase availability• Reduce amount of disturbances
and faulty situations
Replace slip-ring• Improve network availability
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 21
Remote SCADA
Tight time frame Private line needed 2 roads crossings No existing path for cables
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 22
And more…
Wireless in Industrial Automation
Extended network over Widespread area
Obstacles• Rail way• River• Highway
Leverage maintenance (Slip ring)
Telecontrol Harsh environment
Ethernet Serial FHSS IEEE802.11abg Field Devices Protocols…
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
Moving partsDistance
June 13 2008 - ETSI - 23
ConclusionWireless at Machine Level
Industrial environment constraints for the electronics• Temperature, vibration, humidity, EMC…
Protocols and application specificities• Automation specific protocols• Functionalities
RF reflections / multi-paths (indoor) and obstacles (outdoor)
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion
June 13 2008 - ETSI - 24
One word about standardization processes
Safety Class 0: Emergency action (always critical)
Control
Class 1: Closed loop regulatory control (often critical)
Class 2: Closed loop supervisory control (usually non-critical)
Class 3: Open loop control (human in the loop)
NOTE: Batch levels* 3 & 4 could be class 2, class 1 or even class 0, depending on function
*Batch levels as defined by ISA S88; where L3 = "unit" and L4 = "process cell"
Monitoring
Class 4: FlaggingShort-term operational consequence (e.g., event-based maintenance)
Class 5: Logging & downloading/uploadingNo immediate operational consequence (e.g., history collection, SOE, preventive maintenance)
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June 13 2008 - ETSI - 25
Before leaving…
Questions?
Thanks
Bruno [email protected]
IntroductionProSoft TechnologyWhy Wireless?ApplicationsConclusion